Content

Ⅰ 、 Reference Information ............................................................ 1

Ⅱ、 General Introduction & Characteristics .................................. 1

Ⅲ 、 Construction Organization and Implementation Schedule. .4

Ⅳ 、 Construction Preparation........................................................ 4

Ⅴ 、 Flow Process and Implementation Procedure...................... 5

Ⅵ 、 Quality Control................................................................... 14

Ⅶ 、 Safe /Civilized Construction................................................ 14

0
Ⅰ 、 Reference Information

1.1 150kV Outdoor Switchyard Construction Drawing (NEPDI, F324S-D0201B)

1.2 Erection/Operation Instructions supplied by the Manufacturer
1.3 High Voltage Apparatus Construction and Acceptance Code for Electric Facility
Installation Works (GB147-90)
1.4 Bus Bar Construction and Acceptance Code for Electric Facility Installation Works
(GB149-90)
1.5 Quality Inspection and Evaluation Specification for Electrical Facility
Installation Works, DL/T 5161.1~5161.17-2002;

Ⅱ.General Introduction and Characteristics

Considering 150kV Switchyard of Labuhan Angin Coal-fired Steam Power Plant

Project (hereinafter referred to as “LASPP” or “the Project”), manage to adopt the double
bus bar arrangement, which shall be divided into 8 bays: #1 Loading Feeder Line Bay,
#1 Outgoing Bay, #1 Regional Main Transformer Incoming Bay, #2 Outgoing Bay, Bus
bar Potential Transformer Bay, Bus Bar Duct Bay, #2 Regional Load Feeder Line Bay, #2
Main Transformer Incoming Bay As for the main connection, it shall go as follows:

1
 Item Specification/Model U Quantit
nit y
Sf6 circuit breaker GL313-F1 1250A 31.5kA se 4.00
t
Sf6 circuit breaker GL313-F1 2000A 31.5kA se 2.00
t
Sf6 circuit breaker GL313-F1 2500A 31.5kA se 1.00
t
Disconnect switch(no grounding) S2DA 1250A 31.5kA se 4.00
t
Disconnect switch(one end S2DAT 1250A 31.5kA se 4.00
grounding) t

2
 Item Specification/Model U Quantit
nit y
Disconnect switch(both end S2D2A2T 1250A 31.5kA se 2.00
grounding) t
Disconnect switch(one end S2DAT 2500A 31.5kA se 2.00
grounding) t
Disconnect switch(no grounding) S2DA 2000A 31.5kA se 2.00
t
Disconnect switch(one end S2DAT 2000A 31.5kA se 2.00
grounding) t
Disconnect switch(both end S2DA2T 2000A 31.5kA se 2.00
grounding) t
Current transformer CTH-170 600-1200/1A P 6.00
C
Current transformer CTH-170 2×800/1A P 6.00
C
Current transformer CTH-170 2500/1A P 6.00
C
Current transformer CTH-170 2000/1A P 6.00
C
Surge arrester Y10W1-144/146 P 12.00
C
Capacitor voltage transformer CCVT170 P 12.00
C
Line tray 　 P 4.00
C
Terminal box 　 P 9.00
C
Post insulation ZSW1.5-252/4 P 16.00
C
Tension insulation string&clamp 16 （ XWP2-70） se 36.00
t
Tension insulation string&clamp 14 （ XWP-70 ） se 72.00
t
Suspension insulation 15 （ XWP2-70） se 18.00

3
 Item Specification/Model U Quantit
nit y
string&clamp t

Suspension insulation 13 （ XWP-70 ） se 38.00

string&clamp t
Steel-cored aluminium strand LGJF-500/35 m 4650.0
wire 0
30° terminal clamps SY-500/35B P 24.00
a×h×b=80×100×16 C
30° terminal clamps SSY-500/35B-120 P 24.00
a×h×b=80×100×20 C
0° terminal clamps SY-500/35A P 50.00
a×h×b=80×100×16 C
0° terminal clamps SY-500/35A P 12.00
a×h×b=200×100×16 C
0° terminal clamps SSY-500/35A-120 P 78.00
a×h×b=80×100×20 C
0° terminal clamps SSY-500/35A-120 P 6.00
a×h×b=200×100×20 C
90° terminal clamps SY-500/35C P 16.00
a×h×b=80×100×16 C
90° terminal clamps SY-500/35C P 12.00
a×h×b=200×100×16 C
90° terminal clamps SSY-500/35C-120 P 9.00
a×h×b=80×100×20 C
90° terminal clamps SSY-500/35C-120 P 6.00
a×h×b=200×100×20 C
90° terminal clamps SSY-500/35C-120 P 8.00
a×h×b=153×110×20 C
45° terminal clamps SY-500/35-120 P 12.00
a×h×b=80×100×20 C
T- connectors for single TL － 500A P 6.00
conductors C
T- connectors (compression type) TY-500/35 P 30.00
C

4
 Item Specification/Model U Quantit
nit y
T- connectors for double-bundle TYS-500/120 P 36.00
conductors C
T- connectors for double-bundle TLS-500/120 P 30.00
conductors C
Insulation cluster clamp MDG-6 D=190mm se 10.00
t
Insulation cluster clamp MSG-6/120 D=190mm se 6.00
t
Fixed metal clamp 　 se 108.00
t
Bus separate club MRJ-6/120 se 950.00
t
Channel steel ［８ , L ＝ 400 mm P 68.00
C
I type steel I 10, L ＝ 6910mm P 36.00
C
Angle steel galvanized ∠50×50×5 , L ＝ 700 mm P 72.00
C
Angle steel galvanized ∠50×50×5 , L ＝ 400 mm P 72.00
C
Plat steel galvanized —10×3 m 18.00
Bolt with nut and gasket M18×55 se 280.00
t
Bolt with nut and gasket M1 ６ ×40 se 136.00
t
Bolt with nut and gasket M16×140 se 48.00
t
Bolt with nut and gasket M16×50 se 144.00
t
Earthing screw M12×55 P 132.00
C
Earthing screw M12×55 P 306.00
C

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Ⅲ 、 Construction Organization and Implementation

Schedule

3.1 Manpower Allocation: Construction Chief, One Person; Technician: One Person; Electric
Erectors: Six Persons (qualified with job implementation certificates); Riggers: Two Persons

3.2 As to Implementation Schedule, refer to the chart as follows:

Date(Sept 2 2 2 2 6 1 1 1 2 2 3 3 7 1 1 1 2 2 3
—Oct) 0 4 8 0 4 8 2 6 0 1 5 9 3 7 1
Scaffoldin
g Erection
Foundatio
n
Installatio
n
Equipmen
t Erection
Equipmen
t
Adjustmen
t
Overhead
Line
Erection
Acceptanc
e and
Defects
Remedy

Ⅳ 、 Construction Preparation

4.1 To get acquainted with site conditions and embedded parts arrangement, implement

6
 centerline and perpendicularity check again on the steel columns for all the
equipments foundations;
4.2 To acquire the basic information of all the construction drawings, steer knowledgeable of
all the specifications about the breakers, disconnect switches, so as to master the
installation workmanship;
4.3 Prior to construction, carry out relevant safety and workmanship publicization, so that all
the construction workers can get acquainted with construction scope, safety
implementation methods, quality standards etc herein concerned.
4.4 Tools and Devices Preparation
4.4.1 Autocrane: One Set(40T); Electric Welding Machine: One Set; Winch: Two Sets(2T);
4.4.2 Bamboo Ladder, Nylon lifting ropes, torque spanner, adjustable wrench, box
spanner, offset ring spanner, plastic tape, steel tape, feeler gauge.
4.5 Main materials and consumable materials manage to be in readiness;
4.6 Check the equipment installation implementation.

Ⅴ 、 Construction Flow Process and Implementation

Procedure
5.1 Construction Workmanship Flow Chart

Technical Unpacking & Checking

Preparation

SF6 Breaker Installation, Adjustment

Tools/devices Machining and
Preparation Fabricating

Foundation Acceptance
Material and Taking-over Disconnect Switch Installation,
Preparation Adjustment

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 Site Equipment Flexible Bus
Acceptance Prepa Bar Fabrication and
ration Connection Auxiliary Equipments (CT, PT, Lightning Arrester etc)
and Overhead Line Erection

5.2 Installation implementation process

5.2.1 Prior to construction, relevant preparation activities shall manage to be well
prepared, which shall tend to include the following activities such as drawing
evaluation and approval, embedded holes and apertures acceptance, tools,
materials preparation, scaffolding erection etc.
5.2.2 SF6 Breaker Installation
a. Take the anchor bolts onto the performed holes on the pedestals of the
breakers, each phase shall be furnished with 4 sets of anchor bolts, lift and
deploy the actuation mechanism, which shall be lifted and deployed onto the
pedestal in accordance with lifting and deployment sequence, with the
adjustment completed, tighten the anchor bolts, then pour the second concrete
on the anchor bolts;
b. In response to breaker support and proper, while lifting and erecting, take the
nylon(loading capacity:5t) to prepare relevant activities, when lifting, make sure
the procedure to be smooth, stable and reliable, after verification and
confirmation, then begin the lifting and erecting, meanwhile, despatch specified
personnel for command and coordination, no any collision between the
equipment and the building nearby permitted, if take the chain hoist to
implement applicable activities, pay more attention to avoid the hook from
damage the porcelain bushings or clawing the skirts of the bushing.
Breaker adjustment and SF6 gas filling shall comply with instructions by the
Manufacturer, and with the witness of the Manufacturer’s representative on the
site, perform the foregoing activities.
During the installation, pay attention to the following cautions:
⑴Fastening moment on all the connection bolts shall comply with the

8
Manufacturer’s specifications;
⑴Prior to SF6 gas filling, implement water content test on the SF6 gas;
⑴When the gas inside the SF6 flash tank has been filled until to reach the rated
pressure, then perform the leakage test;
⑴In case of failure to meet the rated SF6 gas pressure, no any operation on the
breaker shall be permitted.
5.2.3 Disconnect Switch Installation
As for this project, there shall be shown three types of disconnect switches, saying,
S2DA, S2DAT, S2DA2T, respectively,
a. During installation, take care to check the following aspects:
⑴ Terminal Block and Intercept Sections shall manage to steer clear of any debris,
and ensure the contact to be in good conditions, silver coated layer on the
contact shall aspire to be kept from falling-off and tend to be thoroughly
cleaned;
⑴ Ensure surface of the insulator to be clean, there shall exist no cracks, spoilages,
residual defects etc, cohesion between the porcelain and iron shall be
fastened;
⑴ Driving parts on the pedestal of disconnect switch shall be ensured swift, and
apply the lubricate grease;
⑴ Ensure the elements/parts on the traveling part to be complete, all the fastened
parts herein manage to be tightened, the rotating parts manage to be spread
applicable lubricate grease;
During the construction procedure, endeavor to prevent the equipment from
dump, collision etc; if mobilize the disconnect switch with help of homemade
gantry, endeavor to prevent the possibility of rotation, then the gravity tends to be
rather high, easy to dump. When operating the crane, take care to keep the
distance between the adjacent equipments or foundations, try to avoid the
collision, friction, spoilage on the equipments. With positioning and adjustment
completed, check and confirm the deviations on the following sections to be in
compliance with the Manufacturer’s requirements or not:

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 Inter-phase deviation between the disconnect switches
Centerline deviations on the porcelain column of the same bracket
Perpendicularity deviations on the porcelain column
Height deviation on the porcelain column of the same phase
b. Integrated adjustment:
⑴To adjust the open/close positions on the disconnect switch, making sure that the
net distance between the contactors in open condition, relative contactor location
after the switch has been opened, contact information etc shall comply with
manufactory product specifications, and the asynchronous deviations shall stay
lower than 20mm.
⑴To calibrate the tie rod, between the inboard diameter and diameter of the actuation
mechanism, the clearance shall stay lower then 1mm.
⑴Mechanic or electric interlock between the main isolator and local switches shall
manage to be reliable.
⑴Contact between the contactors shall be tightened, contact pressure on both sides
of the contactor shall comply with requirements as required in technical
specifications;
⑴Only after completion of manual operation, which manages to be correct, then can
implement the electric operation.
5.2.4 Current Transformer Installation
As for current transformer lifting and erection, take the nylon for relevant
implementation, during the procedure, take care to prevent the collision between the
equipment and buildings, lifting direction manages to be reasonable, commonly
speaking, end L1 functions as current input terminal, adjust the level while lifting and
erection, polarity direction on the transformer of the same group shall be ensured
consistently, when adjustment manages to be stable, relevant arrangement aspires to be
tidy and trim.
5.2.5 Potential Transformer Installation
As for potential transformers deployed on bus bar potential transformer bay, #1
Outgoing Line Bay, #2 Outgoing Bay, they can be fastened with 12 sets of bolts

10
(M16X50) on the baseplate of the column.
5.2.6 Lightning Arrester Installation
On #1 Main Transformer Incoming Line Bay, #2 Main Transformer Incoming Line
Bay, #1 Outgoing Line Bay, #2 Outgoing Line Bay there shall be installed Zinc Oxide
Lightning Arrester (Y10W1-144/146) respectively.
Consisting of two sections, concatenated, during concatenation, both the sections
shall comply with the symbols, numbers as shown in manufacture specification, on the
contact surface where the two sections connect each other, remove and dispose the
oxide film, paints, oil grease etc, then spread one layer of compound grease, when the
arrester has been lifted and fastened on the support/hangers, make the arrester flat and
vertical, all the three phases manage to deploy along the same line, deploy the
nameplate on the same side where observation can easily take place, adjust the level of
the equalizing ring on its top, no inclination.
5.2.7 Post Insulator Installation
As for this switchyard, there will be 16 ZSW1.5-252/4 Post Insulator in the bus bar
isolation bay, each post shall consist of two sections. There will be 8 pieces of
centerlines of I Bus Phase S and II Bus Phase S respectively. During folding of the post
insulators, all the centerlines shall be in the same direction, flatly fasten the centerlines.
After fastening, make sure the post insulators to be vertical and perpendicular.
5.2.8 Overhead Line Erection
5.2.8.1 Setting-out
When setting-out, in accordance with the actual conditions, apply the ropes to
survey the split phase cables in each span respectively; adopt the circular sag to
implement relevant survey. Considering the plumb, generally, prefer to adopting arc
plumb, commonly speaking, take the middle section of the rope for arc plumb
observation.
When taking the “Equal Length Method” to check the circular sag, first of all, in
accordance with the current ambient temperature, find out the sag values from the
circular sag curve, then fasten one sag scale on both sides of the straight line link in the
observation area, so that the distance between the scale and cable suspension points

11
manages to equal to the values found from the arc plumb curve. Then with help of visual
check, confirm the circular sag whether to comply with the requirements or not, informing
the operators to adjust the cable length. For the purpose of better observation of the
goals, spread distinctive colors on the scale.
Allowable deviation for the arc plumb during conductor installation, shall not stay
higher than -2.5%--+2.5% of the designed value, adjust the circular sag until fulfillment of
the relevant requirements, then mark applicable identifications on the ropes, then lay the
rope down onto the ground, meter the rope length L and insulator string length L 1 、 L2
on both sides of the plumb, and the length L 3 of those non-overlapped section when the
metal parts and conductors compress each other, figure out the conductor baiting length,
saying, △L=L-L1-L2-2L3
5.2.8.2 Conductor Check
Prior to line erection, check the specification on the conductor to comply with
technical requirements or not, there shall exist severe mechanical spoilage, breakdowns,
damages, twists or severe corrosions etc or not, in case of observation of one of the
following situations, no any employment of the conductor permitted:
1 On the conductor, twists, breakdowns and distinct slacks found;
2 On the same section, there exist the spoiled area covering more than 5% of
the total section to be energized.
5.2.8.3 Setting-out
As planned, pull the wires in order to implement relevant setting-out, saying, put
the wire coils onto the support for conductor pulling and spreading. Prior to spreading the
conductor, along the route, steer clear of any obstacles, in those gravel areas, block the
cushions(such as grass mat), for the purpose of avoidance from damage to the
conductors. Prior to setting out, select the appropriate location to lay down the support
and coil, ensuring them to be stable and fastened, so as to put an end to the potential
dump. While setting out, under the coil, spread the conductors.
During setting out, do not make the conductor rub with the ground, despatch
specified to watch the coils, who shall bear the responsibility to check the conductor
quality and avoid the support and coil from dumping. Ensure the setting out velocity to be

12
even, do not arbitrary accelerate the velocity, otherwise, will easily dump the coils;
Decelerate the setting-out and rotation velocity when the setting out tends to reach the
appropriate length, no sudden termination permitted, otherwise, there will easily incur the
casualties and spoilage on the conductors due to friction between the conductor and
ground.
5.2.8.4 Baiting
While conductor baiting, take any one phase conductor randomly for baiting,
initially pressurize and suspend, after initial suspension, recheck the circular sag on the
conductor, only fulfillment of the requirements as stated in the standard, saying,
deviations can be controlled within scope, can commence with baiting about the
conductors on all other phases one by one in accordance with the tested conductor
baiting length, as well, mark with identifications. On both ends of the identification, take
the lead wire or adhesive tape to bind, and then reasonably bait on the marked locations.
All the end surface shall manage to be flat and smooth, no any burrs, and vertical with
the axis on the conductor, prior to compression on the conductor, cut the aluminum
wires, do not damage the steel core, and mark with applicable identifications on those
areas where relevant suspension shall take place, so as to avoid the mistakes during
suspension.
5.2.8.5 Pressurization
⑴ With help of the metal brush, remove and dispose the oxide film on the contact
area between the conductor and clamps, clean the area with gasoline, the
length to be cleaned shall stay 1.2 folds of the connection length, then spread
one layer of compound resin on the contact area evenly.
⑴ Insert the conductor terminal into the expansion-resistance wire clip or
equipment clip, length to be inserted shall reach the rated one.
⑴ When performing the connection between the conductor and wire clip with help
of hydraulic pressurization, those folded steel modules shall match the
compressed ducts, same to hydraulic pliers and steel modules. After
pressurization, diagonal size on the hexagon shall be 0.866D (D herein refers
to outboard diameter on the wire clip dropper), for any one side, its size cant

13
 not stay excessive than 0.866+0.2mm. When implementing the press between
steel cored strand wires and expansion wire clip, first of all, press the steel
cores and select the applicable steel modules. While pressing, it’ll be of a must
to make the clip to be in accurate locations, no obliquity permitted, overlaps
between the two adjacent modules shall not stay lower than 5mm.
⑴ Polish the wire clips, steering clear of burrs. Spread anti-rust paints on the
pressed pipes.
5.2.8.6 Overhead Erection
Ground-to-phase creepage distance: 1.5m. phase-to-phase creepage distance :
1.8m, on
the contact area between double conductor and equipment, deploy the spacers,
distance
for spacers on the overhead line:2m, distance for down lead spacers: 0.8m,
distance
between the conductors of equipment room: 0.4m.
⑴ To check the overhead line direction to be in consistence, one end functions as
adjustable insulator strings, check the nuts on the adjustable ring to be
deployed in the middle of the section adjustable.
⑴ Reasonably fasten one block on the structural frames, take some special tools to
slowly lift one end of the conductor with help of the winch, the other end shall
manage to be dragged by rope in order to fasten the conductors, when
approaching the destination, decelerate the lifting velocity, instead of operation
by the winch, take inching method to lift the conductor until such U-type
Suspension Link can be fastened. Cautions: Do not shake the insulator, which
tends to easily clash with the structural frame, erect one end, then continue
erecting the other one.
⑴ Re-check the circular sag on the conductor whether to comply with the
requirements or not:
a)
Allowable circular sag deviations:±2.5%

14
 b)
Inter-phase circular sag stress shall be in consistence with each other.
⑴ To adjust the length of adjustable ring, so that the circular sag can cater to the
requirements as stipulated in the specifications, with the adjustment completed,
lock and tighten the adjustable nut on the adjustable rings.
5.2.8.7 Jumper, down lead, equipment connection wire installation
⑴ After completion of overhead line erection, implement the installation on the
jumper, down lead, as for equipment connection, only after all the equipments
resorted to be installed and commissioned, then commence the applicable
arrangement.
⑴ Baiting length on the bus bar, in accordance with the setting-out length between
the connection terminals, decide the length aforementioned.
⑴Connection between the equipments aspired to be completed, there shall exist
no unnecessary stress.
⑴ During the procedure of jumper installation, on the ground, take care to connect
with the suspension insulators, and bind with one layer of aluminum band, no
need tightening and fastening the bolts, fasten the suspension sag with the
gantry, fasten both ends of the jumper and overhead lines, adjust the
suspension insulator strings to be upright with the ground, then tighten and
fasten the bolts. While connecting the equipment clips, remove and dispose
the oxide film on the overlapped surfaces on the terminal, spread compound
resin, and tighten the bolts with help of torque spanners, torque moments
resort to indicate as follows:

Bolt Spec M8 M10 M12 M14 M16 M18 M20 M24

(mm)
Moment 8.8 ～ 17.7 31.4 51.0 78.5 98.0 156.9～ 274.6～
（ N•m ） 10.8 ～ ～ ～ ～ ～ 196.2 343.2
22.6 39.2 60.8 98.1 127.4

Ⅵ 、 Quality Control

15
6.1 Quality Control Standard
6.1.1 High Voltage Apparatus Construction and Acceptance Code for Electric Facility
Installation Works (GB147-90)
6.1.2 Bus Bar Construction and Acceptance Code for Electric Facility Installation Works
(GB149-90)
6.1.3 Power Transformer, Oil-immersed Reactor, Voltage and Current Transformer
Construction and Acceptance Code for Electric Facility Installation Works
6.1.4 Quality Inspection and Evaluation Specification for Electrical Facility
Installation Works, DL/T 5161.1~5161.17-2002;

Ⅶ 、 Safe/Civilized Construction

7.1 All the construction workers shall carefully study the implementation method,
fostering awareness of responsibility to an extent, commanding basic information
and knowledge of construction workmanship, quality control standard.
7.2 To gravely abide by Electricity Power Safe Construction Codes herein involved.
7.3 To earnestly comply with any regulations herein set forth by the project and the
Owner.
7.4 After unpacking of the equipment, without any hesitation, remove and dispose all the
debris out of construction area in order to keep the gallery to be in smooth access
and no any injuries by the nails
7.5 While performing welding activities, anti-shock, explosion-proof and metal splashes
etc shall be carried-out, as for the shell of the electric welding machine, it shall be
well grounded.
7.6 On the site, all the tools and devices shall be kept in satisfactory storage and
custodian, the temporary power supply shall be in good conditions while
overlapping, as well, rainwater-proof, leakage-resistance methods and actions
shall be implemented. No any arbitrary dismantle those installed and assembled
scaffoldings and bamboo-centered structures, prior to completion of each
construction sequence or regular shift termination, take care to check those
electric-driven tools and grounding cable rolls to be shut-down or not.

7.7 In those energized areas, all the activities and operations shall be presented with
16
 applicable “Job Implementation Permits”, if necessary to utilize flame, Flame-
centered “Job Implementation Permits” shall be issued.
7.8 During construction, if there exist those equipments in operation or electricity power
supply, relevant “Job Implementation Permits” shall be submitted and assign
specified personnel for applicable supervision and surveillance, and apply the safety
sealing line (in red and white) to keep those unauthorized personnel out of those
areas, any construction personnel can not touch those equipments without any
relation with job implementation herein involved.

7.9 Endeavor to keep the construction area to be in good conditions during the safe/civil
construction.

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