Standard Operating Procedure (SOP)
Erection of Equipment at 110kV
Substation
1. Objective
This SOP defines the detailed procedures for the installation of equipment in a 110kV
substation, ensuring safe, effective, and compliant erection processes from start to finish.
2. Scope
This SOP covers all activities involved in the erection of the following equipment at a 110kV
substation:
- Transformers (Power and Distribution)
- Circuit Breakers
- Switchgear
- Busbars
- Control and Protection Panels
- Earthing Systems
- Auxiliary Systems (Cooling, HVAC, etc.)
3. Responsibility Matrix
| **Role** | **Responsibility** |
|-------------------------|-----------------------------------------------------------------------------------|
| **Site Supervisor** | Overall supervision of the installation process, ensuring adherence
to standards. |
| **Safety Officer** | Monitor safety compliance and risk mitigation practices.
|
| **Electrical Engineer** | Provide technical guidance and supervision. |
| **Erection Crew** | Conduct physical erection of equipment as per design
specifications. |
| **Quality Control Officer** | Ensure that all installations meet quality and safety standards.
|
4. Pre-Erection Activities
4.1 Site Preparation
• Site Inspection:
- Ensure that the foundations are prepared as per design, leveled, and clear of debris.
Confirm foundation strength to accommodate the equipment’s weight.
• Power and Grounding Verification:
- Ensure electrical supply and grounding systems are complete and tested for reliability.
• Layout Verification:
- Confirm that the equipment layout aligns with the design schematic.
4.2 Material Inspection
• Equipment Delivery Check:
- Inspect all incoming equipment for any visible damages and ensure compliance with
specifications. Verify the availability of manufacturer certificates and manuals.
• Tool and Equipment Availability:
- Confirm that necessary tools, lifting equipment (cranes, forklifts), and PPE are available,
tested, and in good working condition.
4.3 Safety Preparation
• Risk Assessment:
- Conduct a site-specific risk assessment to identify potential hazards. Implement
necessary control measures.
• Safety Briefing:
- Conduct a safety briefing for all personnel, highlighting site-specific hazards and
emergency procedures.
• Lockout-Tagout (LOTO) Implementation:
- De-energize all equipment and ensure all electrical circuits are locked out before work
begins.
5. Erection Process
5.1 Lifting and Transporting Equipment
• Lifting Methodology:
- Use cranes to transport heavy equipment, ensuring that the rigging is performed
according to manufacturer specifications to avoid damage during the process.
• Positioning Equipment:
- Position the equipment accurately as per layout drawings. Verify that each unit has the
required clearance and alignment for safe operation and future maintenance.
5.2 Installation of Transformers
• Positioning and Mounting:
- Position the transformer on the foundation base, ensuring the anchor bolts are correctly
positioned. Align the equipment based on the specified design.
• Electrical Connections:
- Connect the high-voltage bushings and low-voltage bushings as per the circuit diagram,
ensuring secure and tight connections.
• Coolant Systems:
- Install the cooling system and verify that all associated pipes and valves are secure and
leak-free.
5.3 Switchgear and Circuit Breaker Installation
• Mounting and Alignment:
- Mount switchgear and circuit breakers, ensuring correct alignment with the support
structure and adequate space for ventilation.
• Connection to Busbars and Transformers:
- Connect each unit to the busbars and transformers per the schematic layout. Ensure tight
and secure connections to prevent overheating.
5.4 Busbar Installation
• Fabrication and Positioning:
- Fabricate and install busbars according to design specifications. Ensure the supports are
installed correctly to prevent movement or vibration.
• Connection Checks:
- Confirm that all busbar connections are properly aligned and securely fastened.
5.5 Control Panels Installation
• Panel Placement and Mounting:
- Install control panels in their designated locations, ensuring they are securely fastened
and accessible.
• Wiring and Testing:
- Connect control and protection wiring as per the wiring diagram. Verify that connections
are clean, properly insulated, and securely tightened.
5.6 Earthing System Installation
• Grid Layout and Assembly:
- Install the earthing system according to the design. Ensure that all earthing conductors
are correctly positioned and securely connected.
• Testing:
- Conduct earth resistance testing to ensure that all earthing systems comply with local
safety standards.
6. Post-Erection Activities
6.1 Inspection and Testing
• Mechanical Inspection:
- Conduct a thorough visual inspection to verify that all components are installed according
to specifications and that no visible damage exists.
• Electrical Tests:
- Perform insulation resistance tests on all equipment.
- Conduct continuity checks on grounding systems.
- Perform high-voltage dielectric tests where applicable.
6.2 Commissioning
• Pre-Commissioning Check:
- Verify that all mechanical and electrical systems are correctly installed. Check oil levels,
pressure, and temperature settings for transformers.
• Energization:
- Energize the equipment step-by-step, monitoring system performance, including
voltages, currents, and temperatures. Check protection relays and control circuits for
proper operation.
• System Integration:
- Test the synchronization and communication between all components (e.g., breakers,
transformers, control panels) and verify interlocking systems.
• Final Commissioning Report:
- Document all test results, highlighting any issues and the corrective actions taken.
Provide the necessary documentation for client or regulatory approval.
7. Safety Protocols
• Personal Protective Equipment (PPE):
- All personnel must wear the following PPE:
- Hard hats
- Safety gloves
- Insulated boots
- Face shields (when working with live equipment)
- High-visibility vests
• Emergency Procedures:
- All workers must be trained in emergency evacuation and first aid procedures,
particularly for electrical incidents. Ensure fire extinguishers and first aid kits are readily
available.
• Worksite Safety Barriers:
- Install barriers to restrict unauthorized access to high-voltage areas and prevent
accidents.
8. Quality Control and Documentation
• Quality Assurance Checks:
- Conduct in-progress checks for alignment, tightness of connections, cleanliness, and
general workmanship. All deviations from the standard should be documented and
corrected.
• Final Inspection:
- Perform a final inspection to ensure that all equipment is correctly installed, aligned, and
operational. Cross-check with design drawings and manufacturers’ guidelines.
• Documentation:
- Maintain a complete record of the installation process, including inspection reports, test
results, and commissioning data.
9. References
• IEC 61850 – Communication Networks and Systems for Power Utility Automation
• ANSI C37 – American National Standards for Switchgear
• IEEE Std 80 – Guide for Safety in AC Substation Grounding
• Local Electrical Safety Codes and Standards
