ais specification.pdf
TRANSCRIPT
Invitation to Bid
For
PACKAGE-C
AIS SUBSTATIONS
765 kV S/C MAINPURI-HAPUR & MAINPURI-GREATER NOIDA
LINE WITH 765 kV AIS AT HAPUR AND GREATER NOIDA AND
ASSOCIATED SCHEMES/WORK THROUGH TARIFF BASED
COMPETITIVE BIDDING PROCESS ON BUILD, OWN,
OPERATE & MAINTAIN AND TRANSFER
(Hapur, Greater Noida, Sikandrabad, Nehtaur)
Table of Contents
1. Volume-I A. General Technical Feature B. Technical Details
2. Volume-II
A. Circuit Breaker B. Isolator C. Instrument Transformer D. Surge Arrester E. Battery and Battery Charger F. LT Transformer G. LT Switchgear H. Power and Control Cable I. Relay And Protection Panel J. Substation Automation System K. PLCC and SDH L. Capacitor Bank M. Illumination System N. Switchyard Erection O. Structures P. Fire Protection System Q. Air Conditioning R. Diesel Generator S. Civil Works
3. Volume-III
A. Guaranteed Technical Particulars
B. Schedule of Deviations
C. Bill Of Quantity
D. Mandatory Spare
E. Standard Code
F. Diagnostic Tools
G. Appendix-I (Single Line Diagram)
H. Appendix-II ( Plot Layout)
VOLUME-I
VOLUME-I, Section-A (GTF) 1
SECTION-A General Technical Features of AIS Substations
1.0 Scope of Work
The scope includes design, engineering, manufacture, fabrication, testing at manufacturers
work/testing laboratories, delivery, unloading at site, storage, erection, testing and
commissioning at site of the complete 765/400/220/132 kV switchyard with circuit breakers,
isolators, current transformers, capacitor voltage transformers, surge arresters, Control &
protection, PLCC equipments and other electrical and mechanical auxiliary systems on
turnkey basis. However, equipment/ activities listed in clause 3.0 are excluded.
Substations Covered
a) 765/400/220 kV Substation at Hapur–One and half breaker with double main bus scheme for
765 & 400kV side and Double main and transfer scheme for 220kV side.
b) 765/400/220 kV Substation at Greater Noida –One and half breaker with double main bus
scheme for 765 & 400kV side and Double main and transfer scheme for 220kV side.
c) 400/220 kV Substation at Sikandrabad–One and half breaker with double main bus scheme
for 400kV side and Double main and transfer scheme for 220kV side.
d) 400/132 kV Substation at Nehtaur–One and half breaker with double main bus scheme for
400kV side and Single main and transfer scheme for 132kV side
The bidders are strongly advised to quote for alternative proposals also for various packages whereby enhanced reliability and ease of operation and maintenance should be the focal point. The offer should clearly bring out the salient features & cost implications of adaption of such alternatives.
2.0 Intent of Specification
2.1 It is the intent of this specification to describe primary features, materials, and design &
performance requirements and to establish minimum standards for the work.
2.2 The specification is not intended to specify the complete details of various practices of contractor,
but to specify the requirements with regard to performance, durability and satisfactory operation
under the specified site conditions.
2.3 The Contractor shall also be responsible for the overall co-ordination with internal/external
agencies, project management, training of Owner's manpower, loading, unloading, handling,
moving to final destination for successful erection, testing and commissioning of the
substation/switchyard.
Note: 1. Bidder: The person/party quoting for the package.
2. Contractor: The successful bidder on whom the package order is awarded.
3. Owner: The package awardee.
VOLUME-I, Section-A (GTF) 2
2.4 Design of the AIS substation and its associated electrical & mechanical auxiliaries systems includes
preparation of single line diagrams , electrical layouts, erection key diagrams, electrical and
physical clearance diagrams, design calculations for Earth mat, control & protection schematics,
wiring & termination schedules, civil designs (as applicable) & drawings, design of fire fighting
system, air conditioning system, indoor/outdoor lighting/illumination and other relevant drawings
& documents required for engineering of all facilities under the scope of this contract.
2.5 Civil Works:
Option-1: The scope entails complete civil work including labour, materials, plants, equipment,
temporary works, constructional plant, fuel supplies, transportation and all incidental items not
specified but reasonably implied, or necessary for the proper completion of the work.
Option-2: The actual works will be carried out by the Owner/its subsidiaries as a sub-contractor to
the main contractor according to his design and requirements.
In this eventually cement, steel (construction steel and AIS structures), earthing rod and AIS strip
will be supplied by Owner. However, detailed justified estimate for the same will have to be
provided by package supplier at the start of the project
Laying of earthing mat (below ground) will also be undertaken by the Owner under the supervision
of contractor.
DG set, EOT cranes can also be provided by the owner under this option.
The choice of opting for option-1 or 2 shall be at the discretion of the Owner.
2.6 Any other items not specifically mentioned in the specification but which are required for erection,
testing and commissioning and satisfactory operation of the substation are deemed to be included in
the scope of the specification unless specifically excluded.
3.0 Specific Exclusions
The following items of work are specifically excluded from the scope of the specifications for all
substations:
a) Transformer and Reactor: These shall be supplied under a separate package. However,
erection and commissioning of the same shall form part of this package.
b) Colony/Housing of substation.
VOLUME-I, Section-A (GTF) 3
c) Outgoing lines (beyond gantries in case of over-head feeders).
d) Approach road up to Substation/Switchyard entrance.
4.0 Single Line Diagram
For Air Insulated Substation at the 765 & 400 kV voltage levels one and half breaker with
double main bus scheme, for 220kV Double main and transfer scheme, and for 132kV single
main and transfer bus scheme shall be used. Single line diagram and arrangements are enclosed
and shall be further engineered by the contractor.
The exact direction of the entry of lines for different voltage rating is still not frozen.
There is a possibility that the direction of termination of lines may force the Project to
adopt D type arrangement instead of I type for the one and half breaker scheme/s.
There is also a school of thought that whenever there are two transformers in one and half
breaker scheme, one should normally be connected to the first bus and other to the
second bus, otherwise effectiveness of scheme is reduced. Please comment on this
especially from protection point of view.
The following single line diagrams shall be adhered to: (See Appendix-1)
a) 765/400/220 kV Substation at Hapur – (Drawing No.MEIL-D-001)
b) 765/400/220 kV Substation at Greater Noida – (Drawing No.MEIL-D-002)
c) 400/220 kV Substation at Sikandrabad– (Drawing No.MEIL-D-003)
d) 400/132 kV Substation at Nehtaur– (Drawing No.MEIL-D-004)
Tentative plot layouts are attached at Appendix-2
5.0 The following drawings / documents shall be submitted in addition to the documents proposed at
Annexure-I:
a) Type Test reports
b) Guaranteed Technical Particulars
c) Quality assurance plan
d) Equipment catalogues
e) Equipment O & M manuals
f) Complete System O & M Manual
g) Mechanical and Electrical Packages detail drawings
All the drawings/documents listed above shall be in the approval category.
VOLUME-I, Section-A (GTF) 4
6.0 Special Tools and Tackles
A complete list of tools and tackles shall be furnished by the contractor as under:
1. An exhaustive list of tools and tackles that shall be handed over to the owner for subsequent
Operation and Maintenance activities.
2. A list of tools and tackles that shall be brought by the contractor for completion of Erection,
Testing and Commissioning activity but taken back after accomplishment of work.
7.0 Specific Requirements
7.1 Training of Owner’s Personnel
The contractor shall organize and conduct complete and thorough training program (to be
conducted in English language). The traveling and living expenses of Owner’s personnel, if any,
shall be borne by Owner. The training shall be carried out at the place of manufacture and also at
site/s or as the case may require and as agreed by Owner so as to ensure the complete adequacy of
the program and imparting of detailed knowledge of system/equipment design engineering and
operation and maintenance aspects.
The minimum duration of the training shall be as follows:
Design, operation and maintenance of the AIS installations including procedures for fault
attending (at contractor works) for 5 man-weeks.
The contractor shall also provide training in the area of testing, commissioning and
maintenance for at-least 5 personnel for 5 days at one of the AIS Substations.
Design, operation, maintenance and commissioning aspect for 5 (Five) persons at
contractor’s works as per following
a) Circuit Breaker (controlled switching) 3 days
b) Protection and Automation (As Mentioned in Volume-II, Section J).
c) PLCC 2 days
d) SDH 2 days
7.2 The Contractor shall provide all auxiliary system (like battery, AC/DC feeders etc) taking into
consideration, the future bays also as per single line diagram in addition to bays under present
scope.
7.3 As 765, 400 kV, 220kV, 132kV AIS is likely be extended in future, the contractor shall make
available during detailed engineering and document Hand -Over stage, all necessary details.
VOLUME-I, Section-A (GTF) 5
7.4 Construction Power and Water: These shall be arranged by the contractor. However in case the
Owner is in a position to provide the same at a later date, the charges for the same shall be
intimated and if acceptable to contractor , these could be availed. It may be noted that reliability
of power and water would not be ensured by the Owner and in no case, he shall be held
responsible for any delay in works because of non-availability of power and water.
7.5 The contractor shall be responsible for safety of human and equipment during the working. It will
be the responsibility of the Contractor to co-ordinate and obtain Electrical Inspector's clearance
before commissioning. Any additional items, modification due to observation of such statutory
authorities shall be provided by the Contractor at no extra cost to the Owner.
8.0 Standards and Codes
All applicable standards and code as brought out in the technical specification (Volume-III Section-
E) shall be adhered to.
Further all Central and State Government (UP) guidelines and gazette notifications shall be
complied with. Some applicable notifications are:-
a) CEA notification No.CEA/TETD/MP/R/01/2010 Dt.20/08/10
b) Building Bye Laws-2003 ( inclusive all requirement stipulated in Clause 4g of the gazette
notification )
c) IE Rules 1956 with latest amendments.
d) CEA amendment on (installation & operation of meters)Reg.2006 issued on 04.06.2010
e) UP Grid Code-18/04/07
VOLUME-I, Section-A (GTF) 6
Annexure-I
Suggestive Drawing / Document List
S.No Document/Drawing Categorey Remarks
1 DESIGN CALCULATIONS
1.1 Short Circuit Force Calculation A
1.2 DSLP Calculation A
1.3 Sag & Swing Calculation A
1.4 Earthmat Design Calculation A
1.5 Battery and Battery Charger Sizing Document A
1.6 Relay Setting Calculations A
1.7 EHV Cable Sizing ( if applicable ) A
1.8 Cable Sizing A
1.9 CT-PT Sizing A
1.10 Stringing Charts I
2 LAYOUT DRAWINGS
2.1 Single Line Diagram A
2.2 Switchyard Layout A
2.3 Switchyard Sections A
2.4 Structure Loading Diagram Plan and Section I
2.5 Earth Mat Layout I
2.6 Equipment and Structure Earthing Details I
2.7 Cable Trench Layout and Cable Trench Sections I
2.8 Single Line drawing for AC/DC System A
2.9 Erection Key Diagram I
3 Control & Protection
3.1 Protection Key Diagram A
3.2 Interlocking schemes A
3.3 Cable Schedules I
4 All Individual Equipment
OGA A
Detailed Drawings I The drawing/ document details are not listed for individual equipment
but an exaustive submission of
drawings/ documents shall be ensured. The
Schematics A
Rating Plate Diagram
A
VOLUME-I, Section-A (GTF) 7
submission shall be complete in all
respects.
5 Packages
5.1 Illumination System
A The drawing/ document details are not listed for individual packages but an exaustive submission
of drawings/ documents shall be
ensured. The submission shall be
complete in all respects.
5.2 Air Conditioning & Ventillation System A
5.3 Fire Fighting System A
5.4 Sub-Station Automation System A
5.5
PLCC System ( including PABX Exchange )
A
6 Civil Works & Structures
6.1 Design of tower i/c foundation bolts.(400kV) A
6.2 Design of eqpt. support struct. i/c fdn bolts.(400kV) A
6.3 Design of tower foundation A
6.4 Design of eqpt.foundations A
6.5 Design of cable trenches. A
6.6 Details of foundation bolts for Towers I
6.7 Details of foundation bolts for Eqpt Structures I
6.8 Foundation layout for the yard. I
6.9 RCC Detail of tower foundation I
6.10 RCC details of eqpt.foundations. I
6.11 RCC details of cable trenches I
6.12 Details of road. I
6.13 Details of fencing & gates. I
6.14 Layout & details of drainage. I
6.15 Water Management System A
Legend:
A: For Approval
I: For Information. However, the owner still reserves the right to comment on the drawing/ document.
VOLUME-I, Section-B (TR) 8
SECTION-B
TECHNICAL REQUIREMENTS FOR AIS SUBSTATION
1.0 FOREWORD
1.1 The provisions under this section are intended to supplement general requirements for the
materials, equipments and services covered under other sections of tender documents and are not
exclusive.
2.0 GENERAL REQUIREMENT
2.1 The contractor shall furnish catalogues, engineering data, technical information, design documents,
drawings etc., fully in conformity with the technical specification during detailed engineering.
2.2 It is recognized that the Contractor may have standardized on the use of certain components,
materials, processes or procedures different from those specified herein. Alternate proposals
offering similar equipment based on the manufacturer’s standard practice will also be considered
provided such proposals meet the specified designs, standard and performance requirements and are
acceptable to Purchaser.
2.3 Wherever a material or article is specified or defined by the name of a particular brand,
Manufacturer or Vendor, the specific name mentioned shall be understood as establishing type,
function and quality and not as limiting competition.
2.4 Equipment furnished shall be complete in every respect with all mountings, fittings, fixtures and
standard accessories normally provided with such equipment and/or needed for erection,
completion and safe operation of the equipment as required by applicable codes though they may
not have been specifically detailed in the Technical Specifications unless included in the list of
exclusions. Materials and components not specifically stated in the specification and bid price
schedule but which are necessary for commissioning and satisfactory operation of the
switchyard/substation unless specifically excluded shall be deemed to be included in the scope of
the specification and shall be supplied without any extra cost. All similar standard
components/parts of similar standard equipment provided, shall be inter-changeable with one
another.
3.0 SERVICES TO BE PERFORMED BY THE EQUIPMENT BEING FURNISHED
3.1 The 800kV and 420kV system is being designed to limit the switching surge over voltage of 1.9
p.u. and 2.5 p.u., respectively and the power frequency over voltage of 1.4 p.u. and 1.5 p.u.,
respectively. In case of the 420kV system, the initial value of the temporary over voltages could be
2.0 p.u. for 1 - 2 cycles. The equipment furnished under this specification shall perform all its
VOLUME-I, Section-B (TR) 9
functions and operate satisfactorily without showing undue strain, restrike etc under such over
voltage conditions.
3.2 All equipments shall also perform satisfactorily under various other electrical, electromechanical
and meteorological conditions of the site of installation.
3.3 All equipment shall be able to withstand all external and internal mechanical, thermal and
electromechanical forces due to various factors like wind load, temperature variation, ice & snow,
(wherever applicable) short circuit etc for the equipment.
3.4 The bidder shall design terminal connectors of the equipment taking into account various forces
that are required to withstand.
3.5 The equipment shall also comply to the following:
a) To facilitate erection of equipment, all items to be assembled at site shall be “match marked”.
b) All piping, if any between equipment control cabinet / operating mechanism to marshalling box
of the equipment, shall bear proper identification to facilitate the connection at site.
3.6 For single phase transformer, automatic insertion of the spare transformer incase of problem
with a healthy transformer should be offered. Other options can also be given but estimated
time for changing the transformer and down time should be provided by the contractor.
3.7 Equipments and system shall be designed to meet the following major technical parameters as
brought out hereunder.
System Parameter
765kV, 400kV & 220kV System
S.No. Description of
parameters
765kV System
400kV System
220kV System
132kV System
33kV System
1. System operating
voltage
765kV 400kV 220kV 132kV 33kV
2. Maximum operating
voltage of the system (rms)
800kV 420kV 245kV 145kV 36kV
3. Rated frequency 50HZ 50HZ 50HZ 50 Hz 50 Hz
4. No. of phase 3 3 3 3 3
5. Rated Insulation levels
i) Full wave impulse
withstand voltage
(1.2/50 microsec.)
2100kVp 1550kVp 1050kVp 650kVp 170kVp
VOLUME-I, Section-B (TR) 10
S.No. Description of
parameters
765kV System
400kV System
220kV System
132kV System
33kV System
ii) Switching impulse
withstand voltage
(250/2500 micro sec.) dry and wet
1550kVp 1050kVp - 275kV 70kV
iii) One minute power
frequency dry withstand
voltage (rms)
830kV 630kV 105kV
iv) One minute power
frequency dry and wet
withstand voltage (rms)
- - 460kV 500 microvolt
6. Corona extinction
voltage
508 kV 320kV 156kV 105kV -
7. Max. radio interference
voltage for frequency
between 0.5 MHz and 2 MHz at 508 kVrms for 765kV, 266kVrms for
400kV system and 156kVrms for 220kV
system
2500
microvolt
1000 microvolt
1000
microvolt
500 microvolt
8. Minimum creepage
distance
31 mm/kV 31 mm/kV 31 mm/kV 31 mm/kV 31 mm/kV
9. Min. clearances
i. Phase to phase 7600mm
(for conductor-conductor
configuration)
9400mm (for rod-conductor
configuration)
4000mm
2100 mm 1300 mm 320 mm
ii. Phase to earth 4900mm
(for conductor-
3500 mm 2100 mm 1300 mm 320 mm
VOLUME-I, Section-B (TR) 11
S.No. Description of
parameters
765kV System
400kV System
220kV System
132kV System
33kV System
structure)
6400mm (for rod- structure)
iii. Sectional clearances
10300 mm 6500 mm 5000 mm 4000 mm 3000 mm
iv. Rated short circuit current for 1 sec duration
40kA 50kA
40kA
31.5 kA 25 kA
v. System neutral earthing Effectively
earthed
Effectively
earthed
Effectively
earthed
Effectively
earthed
Effectively
earthed
Note :
1. The above parameters are applicable for installations up to an altitude of 1000m above mean
sea level. For altitude exceeding 1000m, necessary altitude correction factor shall be
applicable.
2. The insulation and RIV levels of the equipments shall be as per values given in the
respective chapter of the equipments.
4.0 ENGINEERING DATA AND DRAWINGS
4.1 Drawings
4.1.1 All drawings submitted by the Contractor shall be in sufficient detail to indicate the type, size,
arrangement, material description, Bill of Materials, weight of each component, break-up for
packing and shipment, dimensions, internal & the external connections, fixing arrangement
required and any other information specifically requested in the specifications.
4.1.2 Drawings submitted by the Contractor shall be clearly marked with the name of the Purchaser, the
unit designation, the specifications title, the specification number and the name of the Project
4.1.3 The review of these data by the Purchaser will cover only general conformance of the data to the
specifications and documents interfaces with the equipment provided under the specifications,
external connections and of the dimensions which might affect substation layout. This review by
the Purchaser may not indicate a thorough review of all dimensions, quantities and details of the
equipment, materials, any devices or items indicated or the accuracy of the information submitted.
This review and/or approval by the Purchaser shall not be considered by the Contractor, as limiting
any of his responsibilities and liabilities for mistakes and deviations from the requirements,
specified under these specifications and documents.
VOLUME-I, Section-B (TR) 12
4.2 All manufacturing and fabrication work in connection with the equipment prior to the approval of
the drawings shall be at the Contractor’s risk. The Contractor may make any changes in the design
which are necessary to make the equipment conform to the provisions and intent of the Contract
and such changes will again be subject to approval by the Purchaser. Approval of Contractor’s
drawing or work by the Purchaser shall not relieve the contractor of any of his responsibilities and
liabilities under the Contract.
4.3 All engineering data submitted by the Contractor after final process including review and approval
by the Purchaser shall form part of the Contract Document and the entire works performed under
these specifications shall be performed in strict conformity, unless otherwise expressly requested by
the Purchaser in Writing.
NOTE :
1) The contractor may please note that all resubmissions must incorporate all comments given in the
earlier submission by the Purchaser or adequate justification for not incorporating the same must be
submitted failing which the submission of documents is likely to be returned.
2) All drawings should be submitted in softcopy form, however substation design drawings like SLD,
GA, all layouts etc. shall also be submitted in AutoCAD Version. SLD, GA & layout drawings shall
be submitted for the entire substation.
3) The instruction Manuals shall contain full details of drawings of all equipment being supplied under
this contract, their exploded diagrams with complete instructions for storage, handling, erection,
commissioning, testing, operation, trouble shooting, servicing and overhauling procedures.
4) If after the commissioning and initial operation of the substation, the instruction manuals require any
modifications/ additions/changes, the same shall be incorporated and the updated final instruction
manuals shall be submitted by the Contractor to the Purchaser.
5) The Contractor shall furnish to the Purchaser catalogues of spare parts.
6) All As-built drawings/documents shall be certified by site indicating the changes before final
submission.
5.0 MATERIAL/ WORKMANSHIP
5.1 General Requirement
5.1.1 Where the specification does not contain references to workmanship, equipment, materials and
components of the covered equipment, it is essential that the same must be new, of highest grade of
VOLUME-I, Section-B (TR) 13
the best quality of their kind, conforming to best engineering practice and suitable for the purpose
for which they are intended.
5.1.2 Incase where the equipment, materials or components are indicated in the specification as “similar”
to any special standard, the Purchaser shall decide upon the question of similarity. When required
by the specification or when required by the Purchaser the Contractor shall submit, for approval, all
the information concerning the materials or components to be used in manufacture. Machinery,
equipment, materials and components supplied, installed or used without such approval shall run
the risk of subsequent rejection, it being understood that the cost as well as the time delay
associated with the rejection shall be borne by the Contractor.
5.1.3 The design of the Works shall be such that installation, future expansions, replacements and
general maintenance may be undertaken with a minimum of time and expenses. Each component
shall be designed to be consistent with its duty and suitable factors of safety, subject to mutual
agreements. All joints and fastenings shall be devised, constructed and documented so that the
component parts shall be accurately positioned and restrained to fulfill their required function. In
general, screw threads shall be standard metric threads. The use of other thread forms will only be
permitted when prior approval has been obtained from the Purchaser.
5.1.4 Whenever possible, all similar part of the Works shall be made to gauge and shall also be made
interchangeable with similar parts. All spare parts shall also be interchangeable and shall be made
of the same materials and workmanship as the corresponding parts of the Equipment supplied under
the Specification. Where feasible, common component units shall be employed in different pieces
of equipment in order to minimize spare parts stocking requirements. All equipment of the same
type and rating shall be physically and electrically interchangeable.
5.1.5 All materials and equipment shall be installed in strict accordance with the manufacturer’s
recommendation(s). Only first-class work in accordance with the best modern practices will be
accepted. Installation shall be considered as being the erection of equipment at its permanent
location. This, unless otherwise specified, shall include unpacking, cleaning and lifting into
position, grouting, leveling, aligning, coupling of or bolting down to previously installed equipment
bases/foundations, performing the alignment check and final adjustment prior to initial operation,
testing and commissioning in accordance with the manufacturer’s tolerances, instructions and the
Specification. All factory assembled rotating machinery shall be checked for alignment and
adjustments made as necessary to re-establish the manufacturer’s limits suitable guards shall be
provided for the protection of personnel on all exposed rotating and / or moving machine parts and
shall be designed for easy installation and removal for maintenance purposes. The spare
equipment(s) shall be installed at designated locations and tested for healthiness.
VOLUME-I, Section-B (TR) 14
5.1.6 The Contractor shall apply oil and grease of the proper specification to suit the machinery, as is
necessary for the installation of the equipment. Lubricants used for installation purposes shall be
drained out and the system flushed through where necessary for applying the lubricant required for
operation. The Contractor shall apply all operational lubricants to the equipment installed by him.
5.1.7 All oil, grease and other consumables used in the Works/ Equipment shall be purchased in India
unless the Contractor has any special requirement for the specific application of a type of oil or
grease not available in India. In such is the case he shall declare in the proposal, where such oil or
grease is available. He shall help Purchaser in establishing equivalent Indian make and Indian
Contractor. The same shall be applicable to other consumables too.
5.1.8 Corona and radio interference voltage test and seismic withstand test (for 132kV and above voltage
level) procedures for equipments shall be in line with the procedure given at Annexure-I and II
respectively.
5.2 Provisions for Exposure to Hot and Humid climate
Outdoor equipment supplied under the specification shall be suitable for service and storage under
tropical conditions of high temperature, high humidity, heavy rainfall and environment favorable to
the growth of fungi and mildew. The indoor equipments located in non-air conditioned areas shall
also be of same type.
5.2.1 Space Heaters
5.2.1.1 The heaters shall be suitable for continuous operation at 240V as supply voltage. On-off switch
and fuse shall be provided.
5.2.1.2 One or more adequately rated thermostatically connected heaters shall be supplied to prevent
condensation in any compartment. The heaters shall be installed in the compartment and electrical
connections shall be made sufficiently away from below the heaters to minimize deterioration of
supply wire insulation. The heaters shall be suitable to maintain the compartment temperature to
prevent condensation.
5.2.1.3 Suitable anti condensation heaters with the provision of thermostat shall be provided.
5.2.2 FUNGI STATIC VARNISH
Besides the space heaters, special moisture and fungus resistant varnish shall be applied on parts
which may be subjected or predisposed to the formation of fungi due to the presence or deposit
of nutrient substances. The varnish shall not be applied to any surface of part where the
treatment will interfere with the operation or performance of the equipment. Such surfaces or
parts shall be protected against the application of the varnish.
VOLUME-I, Section-B (TR) 15
5.2.3 Ventilation opening
Wherever ventilation is provided, the compartments shall have ventilation openings with fine
wire mesh of brass to prevent the entry of insects and to reduce to a minimum the entry of dirt
and dust. Outdoor compartment openings shall be provided with shutter type blinds and suitable
provision shall be made so as to avoid any communication of air / dust with any part in the
enclosures of the Control Cabinets, Junction boxes and Marshalling Boxes, panels etc.
5.2.4 Degree of Protection
The enclosures of the Control Cabinets, Junction boxes and Marshalling Boxes, panels etc. to
be installed shall provide degree of protection as detailed here under:
a) Installed outdoor : IP- 55
b) Installed indoor in air conditioned area: IP-31
c) Installed in covered area: IP-52
d) Installed indoor in non air conditioned area where possibility of entry of water is limited:
IP-41
e) For LT Switchgear (AC & DC distribution Boards): IP-52
The degree of protection shall be in accordance with IS: 13947 (Part-I) / IEC-60947 (Part-I)
/ IS 12063 / IEC-60529. Type test report for degree of protection test, shall be submitted for
approval.
5.3 RATING PLATES, NAME PLATES AND LABELS
5.3.1 Each main and auxiliary item of substation is to have permanently attached to it in a conspicuous
position a rating plate of non-corrosive material upon which is to be engraved manufacturer’s name,
year of manufacture, equipment name, type or serial number together with details of the loading
conditions under which the item of substation in question has been designed to operate, and such
diagram plates as may be required by the Purchaser. The rating plate of each equipment shall be
according to IEC requirement.
5.3.2 All such nameplates, instruction plates, rating plates of transformers, reactors, CB, CT, CVT, SA,
Isolators, C & R panels and PLCC equipments shall be bilingual with Hindi inscription first
followed by English. Alternatively two separate plates one with Hindi and the other with English
inscriptions may be provided.
5.4 FIRST FILL OF CONSUMABLES, OIL AND LUBRICANTS
VOLUME-I, Section-B (TR) 16
All the first fill of consumables such as oils, lubricants, filling compounds, touch up paints,
soldering/brazing material for all copper piping of circuit breakers and essential chemicals etc.
which will be required to put the equipment covered under the scope of the specifications, into
successful Operation, shall be furnished by the Contractor unless specifically excluded under the
exclusions in these specifications and documents.
6.0 DESIGN IMPROVEMENTS / COORDINATION
6.1 The bidder shall note that the equipment offered by him in the offer only shall be accepted for
supply. However, the Purchaser or the Contractor may propose changes in the specification of the
equipment or quality thereof and if the Purchaser & contractor agree upon any such changes, the
specification shall be modified accordingly.
6.2 If any such agreed upon change is such that it affects the price and schedule of completion, the
parties shall agree in writing as to the extent of any change in the price and/or schedule of
completion before the Contractor proceeds with the change. Following such agreement, the
provision thereof, shall be deemed to have been amended accordingly.
6.3 The Contractor shall be responsible for the selection and design of appropriate equipments to
provide the best co-ordinate performance of the entire system. The basic design requirements are
detailed out in this Specification. The design of various components, sub-assemblies and assemblies
shall be so done that it facilitates easy field assembly and maintenance.
6.4 The Contractor has to coordinate designs and terminations with the agencies (if any) who are
Consultants/Contractor for the Purchaser. The names of agencies shall be intimated to the
successful bidders.
7.0 QUALITY ASSURANCE PROGRAMME
7.1 To ensure that the equipment and services under the scope of this Contract whether manufactured
or performed within the Contractor’s Works or at his Subcontractor’s premises or at the Purchaser’s
site or at any other place of Work are in accordance with the specifications, the Contractor shall
adopt suitable quality assurance program to control such activities at all points necessary. Such
program shall be broadly outlined by the contractor and finalized after discussions before the award
of contract. The detailed program shall be submitted by the contractor after the award for reference.
A quality assurance program of the contractor shall generally cover the following:
a) His organization structure for the management and implementation of the proposed quality
assurance program:
b) Documentation control system;
VOLUME-I, Section-B (TR) 17
c) Qualification data for bidder’s key personnel;
d) The procedure for purchases of materials, parts components and selection of sub-
Contractor’s services including vendor analysis, source inspection, incoming raw material
inspection, verification of material purchases etc.
e) System for shop manufacturing and site erection controls including process controls and
fabrication and assembly control;
f) Control of non-conforming items and system for corrective actions;
g) Inspection and test procedure both for manufacture and field activities.
h) Control of calibration and testing of measuring instruments and field activities;
i) System for indication and appraisal of inspection status;
j) System for quality audits;
k) System for authorizing release of manufactured product to the Purchaser.
l) System for maintenance of records;
m) System for handling storage and delivery; and
n) A quality plan detailing out the specific quality control measures and procedures adopted
for controlling the quality characteristics relevant to each item of equipment furnished
and/or services rendered. The Purchaser or his duly authorized representative reserves the
right to carry out quality audit and quality surveillance of the system and procedure of the
Contractor/his vendor’s quality management and control activities.
7.2 Quality Assurance Documents
The contractor would be required to submit all the Quality Plans for all equipments & packages at
the start of the Project for the approval of the owner. The Quality Assurance Documents as
stipulated in the approved Quality Plans would be made available at the time of purchaser’s
inspection of equipment/material
8.0 TYPE TESTING, INSPECTION, TESTING & INSPECTION CERTIFICATE
8.1 All equipment being supplied shall conform to type tests as per technical specification and shall be
subject to routine tests in accordance with requirements stipulated under respective sections.
8.2 The reports for all type tests as per technical specification shall be furnished by the Contractor
along with equipment / material drawings. However, type test reports of similar equipments/
material shall be acceptable for all project with similar requirement. The type tests conducted
VOLUME-I, Section-B (TR) 18
earlier should have either been conducted in accredited laboratory (accredited based on ISO / IEC
Guide 25 / 17025 or EN 45001 by the national accreditation body of the country where laboratory is
located) or witnessed by a Government agency/reputed customer or representative authorized by
Utility or representative of accredited test lab or reputed consultant. The test reports submitted shall
be of the tests conducted within last 10 (ten) years prior to the date of award of order. In case the
test reports are of the test conducted earlier than 10 (ten) years prior to the date of award of order,
the contractor shall repeat these test(s) at no extra cost to the purchaser. However, in case of
instrument transformers, the following type tests should have been conducted within 5 (five) years
prior to the date of bid opening.
i. Lightning Impulse Test
ii. Switching Impulse Test
iii. Multiple Chopped Impulse Test (For CT)
iv. Chopped Impulse Test (For CVT )
In case the test reports are of these tests (for instrument transformers) as mentioned above are
conducted earlier than 5 (five) years prior to the date of bid opening, the contractor shall repeat
these test(s) at no extra cost to the purchaser. Further, in the event of any discrepancy in the test
reports i.e. any test report not acceptable due to any design/manufacturing changes (including
substitution of components) or due to non-compliance with the requirement stipulated in the
Technical Specification or any/all type tests not carried out, same shall be carried out without any
additional cost implication to the Purchaser. The Contractor shall intimate the Purchaser the
detailed program about the tests atleast two (2) weeks in advance in case of domestic supplies & six
(6) weeks in advance in case of foreign supplies. Further, in case type tests are required to be
conducted/ repeated and the deputation of Inspector/Purchaser's representative is required, then all
the expenses shall be borne by the contractor.
8.3 Tests for all auxiliary equipment should have been conducted within last 5 years
8.4 Type testing requirements if given specifically for the individual equipment in Volume II shall be
complemented by the additional requirement. The price of conducting type tests shall be included in
price schedule and break up of these shall be given in the relevant schedule of Bid Proposal Sheets.
These Type test charges would be considered in bid evaluation. In case Bidder does not indicate
charges for any of the type tests or does not mention the name of any test in the price schedules, it
will be presumed that the particular test has been offered free of charge. Further, in case any Bidder
indicates that he shall not carry out a particular test, his offer shall be considered incomplete and
shall be liable to be rejected. The Purchaser reserves the right to witness any or all the type tests.
The Purchaser also reserves the right to waive the repeating of type tests partly or fully and in case
VOLUME-I, Section-B (TR) 19
of waival, test charges for the same shall not be payable. The Purchaser shall bear all expenses for
deputation of purchaser’s representative(s) for witnessing the type tests under this clause except in
the case of re-deputation if any, necessitated due to no fault of the purchaser.
8.5 The Purchaser, his duly authorized representative and/or outside inspection agency acting on behalf
of the Purchaser shall have at all reasonable times free access to the Contractor’s/sub-vendors
premises or Works and shall have the power at all reasonable times to inspect and examine the
materials and workmanship of the Works during its manufacture or erection if part of the Works is
being manufactured or assembled at other premises or works, the Contractor shall obtain for the
Engineer and for his duly authorised representative permission to inspect as if the works were
manufactured or assembled on the Contractor’s own premises or works. Inspection may be made at
any stage of manufacture, despatch or at site at the option of the Purchaser and the equipment if
found unsatisfactory due to bad workmanship or quality, material is liable to be rejected.
8.6 The Contractor shall give the Purchaser /Inspector fifteen (15) days written notice for on-shore and
six (6) weeks notice for off-shore material being ready for joint testing including contractor and
OWNER. Such tests shall be to the Contractor’s account except for the expenses of the Inspector.
The Purchaser /inspector, unless witnessing of the tests is virtually waived, will attend such tests
within fifteen (15) days of the date of which the equipment is notified as being ready for
test/inspection, failing which the Contractor may proceed alone with the test which shall be deemed
to have been made in the Inspector’s presence and he shall forthwith forward to the Inspector duly
certified copies of tests in triplicate.
8.7 The Purchaser or Inspector shall, within fifteen (15) days from the date of inspection as defined
herein give notice in writing to the Contractor, of any objection to any drawings and all or any
equipment and workmanship which in his opinion is not in accordance with the Contract. The
Contractor shall give due consideration to such objections and shall either make the modifications
that may be necessary to meet the said objections or shall confirm in writing to the Purchaser
/Inspector giving reasons therein, that no modifications are necessary to comply with the Contract.
8.8 When the factory tests have been completed at the Contractor’s or Sub-Contractor’s works, the
Purchaser /inspector shall issue a certificate to this effect within fifteen (15) days after completion
of tests but if the tests are not witnessed by the Purchaser /Inspector, the certificate shall be issued
within fifteen (15) days of receipt of the Contractor’s Test certificate by the Engineer/Inspector.
Failure of the Purchaser /Inspector to issue such a certificate shall not prevent the Contractor from
proceeding with the Works. The completion of these tests or the issue of the certificate shall not
bind the Purchaser to accept the equipment should, it, on further tests after erection, be found not to
VOLUME-I, Section-B (TR) 20
comply with the Contract. The equipment shall be dispatched to site only after approval of test
reports and issuance of CIP by the Purchaser.
8.9 In all cases where the Contract provides for tests whether at the premises or at the works of the
Contractor or of any Sub-Contractor, the Contractor except where otherwise specified shall provide
free of charge such items as labour, materials, electricity, fuel, water, stores, apparatus and
instruments as may be reasonably demanded by the Purchaser /Inspector or his authorized
representative to carry out effectively such tests of the equipment in accordance with the Contract
and shall give facilities to the Purchaser /Inspector or to his authorized representative to accomplish
testing.
8.10 The inspection by Purchaser and issue of Inspection Certificate thereon shall in no way limit the
liabilities and responsibilities of the Contractor in respect of the agreed quality assurance program
forming a part of the Contract.
8.11 The Purchaser will have the right of having at his own expenses any other test(s) of reasonable
nature carried out at Contractor’s premises or at site or in any other place in addition of aforesaid
type and routine tests, to satisfy that the material comply with the specification.
8.12 The Purchaser reserves the right for getting any field tests not specified in respective sections of the
technical specification conducted on the completely assembled equipment at site. The testing
equipments for these tests shall be provided by the Purchaser.
9.0 TESTS
9.1 Pre-commissioning Tests
On completion of erection of the equipment and before charging, each item of the equipment shall
be thoroughly cleaned and then inspected jointly by the Purchaser and the Contractor for
correctness and completeness of installation and acceptability for charging, leading to initial pre-
commissioning tests at Site. The lists of pre-commissioning tests to be performed are given in
respective chapters and shall be included in the Contractor’s quality assurance program.
9.2 Commissioning Tests
9.2.1 The available instrumentation and control equipment will to be used during such tests and the
Purchaser will calibrate all such measuring equipment and devices as far as practicable.
9.2.2 Any special equipment, tools and tackles required for the successful completion of the
Commissioning Tests shall be provided by the Contractor, free of cost.
9.2.3 The specific tests requirement on equipment have been brought out in the respective chapters of
the technical specification.
VOLUME-I, Section-B (TR) 21
9.3 The Contractor shall be responsible for obtaining statutory clearances from the concerned
authorities for commissioning the equipment and the switchyard. However necessary fee shall be
reimbursed by Owner on production of requisite documents.
10.0 PACKAGING & PROTECTION
10.1 All the equipments shall be suitably protected, coated, covered or boxed and crated to prevent
damage or deterioration during transit, handling and storage at Site till the time of erection. On
request of the Purchaser, the Contractor shall also submit packing details/associated drawing for
any equipment/material under his scope of supply, to facilitate the Purchaser to repack any
equipment/material at a later date, in case the need arises. While packing all the materials, the
limitation from the point of view of availability of Railway wagon sizes in India should be taken
into account. The Contractor shall be responsible for any loss or damage during transportation,
handling and storage due to improper packing. Any demurrage, wharfage and other such charges
claimed by the transporters, railways etc. shall be to the account of the Contractor. Purchaser takes
no responsibility of the availability of the wagons.
10.2 All coated surfaces shall be protected against abrasion, impact, discoloration and any other
damages. All exposed threaded portions shall be suitably protected with either a metallic or a non-
metallic protecting device. All ends of all valves and piping’s and conduit equipment connections
shall be properly sealed with suitable devices to protect them from damage.
11.0 FINISHING OF METAL SURFACES
11.1 All metal surfaces shall be subjected to treatment for anti-corrosion protection. All ferrous surfaces
for external use unless otherwise stated elsewhere in the specification or specifically agreed, shall
be hot-dip galvanized after fabrication. High tensile steel nuts & bolts and spring washers shall be
electro galvanized to service condition 4. All steel conductors including those used for
earthing/grounding (above ground level) shall also be galvanized according to IS: 2629.
11.2 HOT DIP GALVANISING
11.2.1 The minimum weight of the zinc coating shall be 610 gm/sq.m and minimum average thickness of
coating shall be 86 microns for all items having thickness 6mm and above. For items lower than
6mm thickness requirement of coating thickness shall be as per relevant ASTM. For surface which
shall be embedded in concrete, the zinc coating shall be 610 gm/sq. m minimum.
11.2.2 The galvanized surfaces shall consist of a continuous and uniform thick coating of zinc, firmly
adhering to the surface of steel. The finished surface shall be clean and smooth and shall be free
from defects like discoloured patches, bare spots, unevenness of coating, spelter which is loosely
attached to the steel globules, spiky deposits, blistered surface, flaking or peeling off, etc. The
VOLUME-I, Section-B (TR) 22
presence of any of these defects noticed on visual or microscopic inspection shall render the
material liable to rejection.
11.2.3 After galvanizing. no drilling or welding shall be performed on the galvanized parts of the
equipment excepting that nuts may be threaded after galvanizing. Sodium dichromate treatment
shall be provided to avoid formation of white rust after hot dip galvanization.
11.2.4 The galvanized steel shall be subjected to six one minute dips in copper sulphate solution as per
IS-2633.
11.2.5 Sharp edges with radii less than 2.5 mm shall be able to withstand four immersions of the Standard
Preece test. All other coatings shall withstand six immersions. The following galvanizing tests
should essentially be performed as per relevant Indian Standards.
- Coating thickness
- Uniformity of zinc
- Adhesion test
- Mass of zinc coating
11.2.6 Galvanised material must be transported properly to ensure that galvanized surfaces are not
damaged during transit. Application of zinc rich paint at site shall not be allowed.
11.3 PAINTING
11.3.1 All sheet steel work shall be degreased, pickled, phosphated in accordance with the IS-6005 “Code
of practice for phosphating iron and sheet”. All surfaces, which will not be easily accessible after
shop assembly, shall beforehand be treated and protected for the life of the equipment. The
surfaces, which are to be finished painted after installation or require corrosion protection until
installation, shall be shop painted with at least two coats of primer. Oil, grease, dirt and swaf shall
be thoroughly removed by emulsion cleaning. Rust and scale shall be removed by pickling with
dilute acid followed by washing with running water, rinsing with slightly alkaline hot water and
drying.
11.3.2 After phosphating, thorough rinsing shall be carried out with clean water followed by final rinsing
with dilute dichromate solution and oven drying. The phosphate coating shall be sealed with
application of two coats of ready mixed, stoving type zinc chromate primer. The first coat may be
“flash dried” while the second coat shall be stoved.
11.3.3 After application of the primer, two coats of finishing synthetic enamel paint shall be applied, each
coat followed by stoving. The second finishing coat shall be applied after inspection of first coat of
painting.
VOLUME-I, Section-B (TR) 23
11.3.4 The exterior and interior color of the paint in case of new substations shall preferably be RAL 7032
for all equipment, marshalling boxes, junction boxes, control cabinets, panels etc. unless
specifically mentioned under respective sections of the equipments. Glossy white colour inside the
equipments /boards /panels/junction boxes is also acceptable. The exterior colour for panels shall be
matching with the existing panels in case of extension of a substation. Each coat of primer and
finishing paint shall be of slightly different shade to enable inspection of the painting. A small
quantity of finishing paint shall be supplied for minor touching up required at site after installation
of the equipments.
11.3.5 In case the Bidder proposes to follow his own standard surface finish and protection procedures or
any other established painting procedures, like electrostatic painting etc., the procedure shall be
submitted alongwith the offer for Purchaser’s review & approval.
12.0 HANDLING, STORING AND INSTALLATION
12.1 In accordance with the specific installation instructions as shown on manufacturer’s drawings or as
directed by the Purchaser or his representative, the Contractor shall unload, store, erect, install,
wire, test and place into commercial use all the equipment included in the contract. Equipment shall
be installed in a neat, workmanlike manner so that it is level, plumb, square and properly aligned
and oriented. Commercial use of switchyard equipment means completion of all site tests specified
and energisation at rated voltage.
12.2 Contractor may engage manufacturer’s Engineers to supervise the unloading, transportation to site,
storing, testing and commissioning of the various equipment being procured by them separately.
Contractor shall unload, transport, store, erect, test and commission the equipment as per
instructions of the manufacturer’s supervisory Engineer(s) and shall extend full cooperation to
them.
12.3 The contractor shall have to ensure that the hard and flat indoor and outdoor storage areas are in
place prior to commencement of delivery of material at site. Contractor shall also ensure
availability of proper unloading and material handling equipment like cranes etc. and
polyester/nylon ropes of suitable capacity to avoid damage during unloading and handling of
material at site. All indoor equipments shall be stored indoors. Outdoor equipment may be stored
outdoors but on a hard and flat raised area properly covered with waterproof and dustproof covers
to protect them from water seepage and moisture ingress. However, all associated control panels,
marshalling boxes operating boxes etc. of outdoor equipments are to be stored indoors only.
Storage of equipment on top of another one is not permitted if the wooden packing is used. Material
opened for joint inspection shall be repacked properly as per manufacturer’s recommendations.
VOLUME-I, Section-B (TR) 24
During storage of material regular periodic monitoring of important parameters like oil level /
leakage, SF6 / Nitrogen pressure etc. shall be ensured by the contractor.
12.4 In case of any doubt/misunderstanding as to the correct interpretation of manufacturer’s drawings
or instructions, necessary clarifications shall be obtained from the Purchaser. Contractor shall be
held responsible for any damage to the equipment consequent to not following manufacturer’s
drawings/instructions correctly.
12.5 Where assemblies are supplied in more than one section, Contractor shall make all necessary
mechanical and electrical connections between sections including the connection between buses.
Contractor shall also do necessary adjustments/alignments necessary for proper operation of circuit
breakers, isolators and their operating mechanisms. All components shall be protected against
damage during unloading, transportation, storage, installation, testing and commissioning. Any
equipment damaged due to negligence or carelessness or otherwise shall be replaced by the
Contractor at his own expense.
12.6 Contractor shall be responsible for examining all the shipment and notify the Purchaser
immediately of any damage, shortage, discrepancy etc. for the purpose of Purchaser’s information
only. The Contractor shall submit to the Purchaser every week a report detailing all the receipts
during the weeks. However, the Contractor shall be solely responsible for any shortages or damages
in transit, handling and/or in storage and erection of the equipment at Site. Any demurrage,
wharfage and other such charges claimed by the transporters, railways etc. shall be to the account of
the Contractor.
12.7 The Contractor shall be fully responsible for the equipment/material until the same is handed over
to the Purchaser in an operating condition after commissioning. Contractor shall be responsible for
the maintenance of the equipment/material while in storage as well as after erection until taken over
by Purchaser, as well as protection of the same against theft, element of nature, corrosion, damages
etc.
12.8 Where material / equipment is unloaded by Purchaser before the Contractor arrives at site or even
when he is at site, Purchaser by right can hand over the same to Contractor and there upon it will be
the responsibility of Contractor to store the material in an orderly and proper manner.
13.9 The Contractor shall be responsible for making suitable indoor storage facilities, to store all
equipment which requires indoor storage.
12.10 The words ‘erection’ and ‘installation’ used in the specification are synonymous.
12.11 Exposed live parts shall be placed high enough above ground to meet the requirements of electrical
and other statutory safety codes.
VOLUME-I, Section-B (TR) 25
123.12 The design and workmanship shall be in accordance with the best engineering practices to ensure
satisfactory performance throughout the service life. If at any stage during the execution of the
Contract, it is observed that the erected equipment(s) do not meet the above minimum clearances as
given in clause 3.6 the Contractor shall immediately proceed to correct the discrepancy at his risks
and cost.
12.13 Equipment Bases
A cast iron or welded steel base plate shall be provided for all rotating equipment which is to be
installed on a concrete base unless otherwise agreed to by the Purchaser. Each base plate shall
support the unit and its drive assembly, shall be of a neat design with pads for anchoring the units,
shall have a raised lip all around, and shall have threaded drain connections.
13.0 TOOLS AND TACKLES
The Contractor shall supply with the equipment one complete set of all special tools and tackles for
the erection, assembly, dis-assembly and maintenance of the equipment. However, these tools and
tackles shall be separately, packed and brought on to Site.
14.0 Diagnostic Tools: List given at volume-III, Section-E. Quantity will be minimum 1 set. However
additional items which are not mentioned at annexure and are mandatory, bidder shall specify the
same.
15.0 AUXILIARY SUPPLY
15.1 The sub-station auxiliary supply is normally met through a system indicated under section
“Electrical & Mechanical Auxiliaries” having the following parameters. The auxiliary power for
station supply, including the equipment drive, cooling system of any equipment, air-conditioning,
lighting etc shall be designed for the specified Parameters as under. The DC supply for the
instrumentation and PLCC system shall also conform the parameters as indicated in the following.
Normal Voltage Variation in Voltage Frequency in
HZ
Phase/Wire Neutral connection
415V ±10% 50 ± 5% 3 / 4 Wire Solidly Earthed
240V ±10% 50 ± 5% 1 / 2 Wire Solidly Earthed
220V 190V to 240V DC - Isolated 2 wire
system
110V 95V to 120V DC Isolated 2 wire
system
VOLUME-I, Section-B (TR) 26
48V - DC - 2Wire System (+)
earthed
Combined variation of voltage and frequency shall be limited to ± 10%.
16.0 SUPPORT STRUCTURE
16.1 The equipment support structures shall be suitable for equipment connections at the first level i.e
14.0 meter, 8.0 meter and 5.9 meter from plinth level for 765 kV, 420 kV and 245 kV substations
respectively. All equipment support structures shall be supplied alongwith brackets, angles, stools
etc. for attaching the operating mechanism, control cabinets & marshalling box (wherever
applicable) etc.
16.2 Support structure shall meet the following mandatory requirements:
16.2.1 The minimum vertical distance from the bottom of the lowest porcelain part of the bushing,
porcelain enclosures or supporting insulators to the bottom of the equipment base, where it rests on
the foundation pad shall be 2.55 metres.
17.0 CLAMPS AND CONNECTORS INCLUDING TERMINAL CONNECTORS
17.1 All power clamps and connectors shall conform to IS:5561 & NEMA CC1 and shall be made of
materials listed below :
a) For connecting ACSR conductors Aluminum alloy casting, conforming to
designation A6 of IS:617 and all test shall
conform to IS:617
b) For connecting equipment Bimetallic connectors made from
aluminum
terminals made of copper with alloy casting conforming to designation
A6
ACSR conductors of IS:617 with 2mm thick bimetallic liner
and all test shall conform to IS:617
c) For connecting G.I Galvanised mild steel shield wire
d) i) Bolts, nuts & Plain, Washers i) Electro-galvanised for sizes below
M12,
for others hot dip galvanised.
VOLUME-I, Section-B (TR) 27
ii) Spring washers for items ii) Electro-galvanised mild steel suitable
for
‘a’ to ‘c’ at-least service condition-3 as per
IS:1573
17.2 Necessary clamps and connectors shall be supplied for all equipment and connections. The
requirement regarding external corona and RIV as specified for any equipment shall include its
terminal fittings. If corona rings are required to meet these requirements they shall be considered as
part of that equipment and included in the scope of work.
17.3 Where copper to aluminum connections are required, bi-metallic clamps shall be used, which shall
be properly designed to ensure that any deterioration of the connection is kept to a minimum and
restricted to parts which are not current carrying or subjected to stress.
17.4 Low voltage connectors, grounding connectors and accessories for grounding all equipment as
specified in each particular case, are also included in the scope of Work.
17.5 No current carrying part of any clamp shall be less than 10 mm thick. All ferrous parts shall be hot
dip galvanized. Copper alloy liner of minimum 2 mm thickness shall be cast integral with
aluminum body or 2 mm thick bi-metallic strips shall be provided for Bi-metallic clamps.
17.6 All casting shall be free from blow holes, surface blisters, cracks and cavities. All sharp edges and
corners shall be blurred and rounded off.
17.7 Flexible connectors, braids or laminated straps made for the terminal clamps for bus posts shall be
suitable for both expansion or through (fixed/sliding) type connection of 4" IPS AL. tube as
required. In both the cases the clamp height (top of the mounting pad to centre line of the tube)
should be same.
17.8 Clamp shall be designed to carry the same current as the conductor and the temperature rise shall be
equal or less than that of the conductor at the specified ambient temperature. The rated current for
which the clamp/ connector is designed with respect to the specified reference ambient temperature,
shall also be indelibly marked on each component of the clamp/connector, except on the hardware.
17.9 All current carrying parts shall be designed and manufactured to have minimum contact resistance.
17.10 Clamps and connectors shall be designed to be corona controlled.
17.11 Tests
Clamps and connectors should be type tested as per IS: 5561 and shall also be subjected to routine
tests as per IS:5561. Following type test reports shall be submitted for approval as per clause 9.2
VOLUME-I, Section-B (TR) 28
above except for sl. no.(ii) & (iii) for which type test once conducted shall be applicable (i.e. the
requirement of test conducted within last ten years shall not be applicable).
i. Temperature rise test (maximum temperature rise allowed is 35°C over 50°C ambient)
ii. Short time current test
iii. Corona (dry) and RIV (dry) test (for 220 KV and above voltage level clamps)
iv. Resistance test and tensile test
18.0 CONTROL CABINETS, JUNCTION BOXES, TERMINAL BOXES & MARSHALLING
BOXES FOR OUTDOOR EQUIPMENT
18.1 All types of boxes, cabinets etc. shall generally conform to & be tested in accordance with IS-
5039/IS-8623, IEC-60439, as applicable, and the clauses given below:
18.2 Control cabinets, junction boxes, Marshalling boxes & terminal boxes shall be made of sheet steel
or aluminum enclosure and shall be dust, water and vermin proof. Sheet steel used shall be atleast
2.0 mm thick cold rolled or 2.5 mm hot rolled or alternately 1.6 mm thick stainless steel can also be
used. The box shall be properly braced to prevent wobbling. There shall be sufficient reinforcement
to provide level surfaces, resistance to vibrations and rigidity during transportation and installation.
In case of aluminum enclosed box the thickness of aluminum shall be such that it provides adequate
rigidity and long life as comparable with sheet steel of specified thickness.
18.3 A canopy and sealing arrangements for operating rods shall be provided in marshalling boxes /
Control cabinets to prevent ingress of rain water.
18.4 Cabinet/boxes shall be provided with double hinged doors with padlocking arrangements. The
distance between two hinges shall be adequate to ensure uniform sealing pressure against
atmosphere. The quality of the gasket shall be such that it does not get damaged/cracked during the
operation of the equipment.
18.5 All doors, removable covers and plates shall be gasketed all around with suitably profiled
EPDM/Neoprene gaskets. The gasket shall be tested in accordance with approved quality plan,
IS:11149 and IS:3400. Ventilating Louvers, if provided, shall have screen and filters. The screen
shall be fine wire mesh made of brass.
18.6 All boxes/cabinets shall be designed for the entry of cables from bottom by means of weather proof
and dust-proof connections. Boxes and cabinets shall be designed with generous clearances to avoid
interference between the wiring entering from below and any terminal blocks or accessories
mounted within the box or cabinet. Suitable cable gland plate above the base of the marshalling
kiosk/box shall be provided for this purpose along with the proper blanking plates. Necessary
number of cable glands shall be supplied and fitted on this gland plate. Gland plate shall have
VOLUME-I, Section-B (TR) 29
provision for some future glands to be provided later, if required. The Nickel plated glands shall be
dust proof, screw on & double compression type and made of brass. The gland shall have provision
for securing armour of the cable separately and shall be provided with earthing tag. The glands shall
conform to BS: 6121.
18.7 A 240V, single phase, 50 Hz, 15 amp AC plug and socket shall be provided in the cabinet with ON-
OFF switch for connection of hand lamps. Plug and socket shall be of industrial grade.
18.8 For illumination, a fluorescent tube or CFL of approximately 9 to 15 watts shall be provided. The
switching of the fittings shall be controlled by the door switch. For junction boxes of smaller sizes
such as lighting junction box, manual operated earth switch mechanism box etc., plug socket, heater
and illumination is not required to be provided.
18.9 All control switches shall be of MCB/rotary switch type and Toggle/piano switches shall not be
accepted.
18.10 Positive earthing of the cabinet shall be ensured by providing two separate earthing pads. The earth
wire shall be terminated on to the earthing pad and secured by the use of self etching washer.
Earthing of hinged door shall be done by using a separate earth wire.
18.11 The bay marshalling kiosks shall be provided with danger plate and a diagram showing the
numbering/ connection/feruling by pasting the same on the inside of the door.
18.12 a) The following routine tests along with the routine tests as per IS: 5039 shall also be conducted:
i) Check for wiring
ii) Visual and dimension check
b) The enclosure of bay marshalling kiosk, junction box, terminal box shall conform to IP-55 as
per IS: 13947 including application of, 2.5 KV rms for 1 (one) minute, insulation resistance
and functional test after IP-55 test.
19.0 TERMINAL BLOCKS AND WIRING
19.1 Control and instrument leads from the switchboards or from other equipment will be brought to
terminal boxes or control cabinets in conduits. All interphase and external connections to
equipment or to control cubicles will be made through terminal blocks.
19.2 Terminal blocks shall be 650V grade and have continuous rating to carry the maximum expected
current on the terminals and non breakable type. These shall be of moulded piece, complete with
insulated barriers, stud type terminals, washers, nuts and lock nuts. Screw clamp, overall insulated,
insertion type, rail mounted terminals can be used in place of stud type terminals. But preferably the
VOLUME-I, Section-B (TR) 30
terminal blocks shall be non-disconnecting stud type of Elmex or Phoenix or Wago or equivalent
make.
19.3 Terminal blocks for current transformer and voltage transformer secondary leads shall be provided
with test links and isolating facilities. The current transformer secondary leads shall also be
provided with short circuiting and earthing facilities.
19.4 The terminal shall be such that maximum contact area is achieved when a cable is terminated. The
terminal shall have a locking characteristic to prevent cable from escaping from the terminal clamp
unless it is done intentionally.
19.5 The conducting part in contact with cable shall preferably be tinned or silver plated however
Nickel plated copper or zinc plated steel shall also be acceptable.
19.6 The terminal blocks shall be of extensible design.
19.7 The terminal blocks shall have locking arrangement to prevent its escape from the mounting rails.
19.8 The terminal blocks shall be fully enclosed with removable covers of transparent, non-deteriorating
type plastic material. Insulating barriers shall be provided between the terminal blocks. These
barriers shall not hinder the operator from carrying out the wiring without removing the barriers.
19.9 Unless otherwise specified terminal blocks shall be suitable for connecting the following
conductors on each side.
a) All circuits except Minimum of two of 2.5 sq mm CT/PT circuits copper flexible.
b) All CT/PT circuits Minimum of 4 nos. of 2.5 sq mm copper flexible.
19.10 The arrangements shall be in such a manner so that it is possible to safely connect or disconnect
terminals on live circuits and replace fuse links when the cabinet is live.
19.11 Atleast 20 % spare terminals shall be provided on each panel/cubicle/box and these spare terminals
shall be uniformly distributed on all terminals rows.
19.12 There shall be a minimum clearance of 250 mm between the First/bottom row of terminal block
and the associated cable gland plate for outdoor ground mounted marshalling box and the clearance
between two rows of terminal blocks shall be a minimum of 150 mm.
19.13 The Contractor shall furnish all wire, conduits and terminals for the necessary interphase electrical
connections (where applicable) as well as between phases and common terminal boxes or control
cabinets. For equipments rated for 400 kV and above the wiring required in these items shall be run
in metallic ducts or shielded cables in order to avoid surge overvoltages either transferred through
the equipment or due to transients induced from the EHV circuits.
VOLUME-I, Section-B (TR) 31
19.14 All input and output terminals of each control cubicle shall be tested for surge withstand capability
in accordance with the relevant IEC Publications, in both longitudinal and transverse modes. The
Contractor shall also provide all necessary filtering, surge protection, interface relays and any other
measures necessary to achieve an impulse withstand level at the cable interfaces of the equipment.
20.0 LAMPS & SOCKETS
20.1 Sockets
All sockets (convenience outlets) shall be suitable to accept both 5 Amp & 15 Amp pin round
Standard Indian plugs. They shall be switched sockets with shutters.
20.2 Hand Lamp:
A 240 Volts, single Phase, 50 Hz AC plug point shall be provided in the interior of each cubicle
with ON-OFF Switch for connection of hand lamps.
20.3 Switches and Fuses:
20.3.1 Each panel shall be provided with necessary arrangements for receiving, distributing, isolating and
fusing of DC and AC supplies for various control, signalling, lighting and space heater circuits.
The incoming and sub-circuits shall be separately provided with miniature circuit breaker / switch
fuse units. Selection of the main and Sub-circuit fuse ratings shall be such as to ensure selective
clearance of sub-circuit faults. Potential circuits for relaying and metering shall be protected by
HRC fuses.
20.3.2 All fuses shall be of HRC cartridge type conforming to IS: 9228 mounted on plug-in type fuse
bases. Miniature circuit breakers with thermal protection and alarm contacts will also be accepted.
All accessible live connection to fuse bases shall be adequately shrouded. Fuses shall have
operation indicators for indicating blown fuse condition. Fuse carrier base shall have imprints of
the fuse rating and voltage.
21.0 Bushings, Hollow Column Insulators, Support Insulators:
21.1 Bushings shall be manufactured and tested in accordance with IS: 2099 & IEC- 60137 while hollow
column insulators shall be manufactured and tested in accordance with IEC-62155/IS:5621.The
support insulators shall be manufactured and tested as per IS:2544/IEC-60168 and IEC-60273. The
insulators shall also conform to IEC-60815 as applicable. The bidder may also offer composite
hollow insulators, conforming to IEC-61462.
21.2 Support insulators, bushings and hollow column insulators shall be manufactured from high quality
porcelain. Porcelain used shall be homogeneous, free from laminations, cavities and other flaws or
VOLUME-I, Section-B (TR) 32
imperfections that might affect the mechanical or dielectric quality and shall be thoroughly vitrified
tough and impervious to moisture.
21.3 Glazing of the porcelain shall be uniform brown in colour, free from blisters, burrs and similar
other defects.
21.4 Support insulators/bushings/hollow column insulators shall be designed to have ample insulation,
mechanical strength and rigidity for the conditions under which they will be used.
21.5 When operating at normal rated voltage there shall be no electric discharge between the conductors
and bushing which would cause corrosion or injury to conductors, insulators or supports by the
formation of substances produced by chemical action. No radio interference shall be caused by the
insulators/bushings when operating at the normal rated voltage.
21.6 Bushing porcelain shall be robust and capable of withstanding the internal pressures likely to occur
in service. The design and location of clamps and the shape and the strength of the porcelain flange
securing the bushing to the tank shall be such that there is no risk of fracture. All portions of the
assembled porcelain enclosures and supports other than gaskets, which may in any way be exposed
to the atmosphere shall be composed of completely non hygroscopic material such as metal or
glazed porcelain.
21.7 All iron parts shall be hot dip galvanised and all joints shall be air tight. Surface of joints shall be
trued up porcelain parts by grinding and metal parts by machining. Insulator/bushing design shall
be such as to ensure a uniform compressive pressure on the joints.
21.8 Tests
In bushing, hollow column insulators and support insulators shall conform to type tests and shall be
subjected to routine tests in accordance with IS: 2099 & IS: 2544 & IS : 5621.
22.0 Motors
Motors shall be “Squirrel Cage” three phase induction motors of sufficient size capable of
satisfactory operation for the application and duty as required for the driven equipment and shall be
subjected to routine tests as per applicable standards. The motors shall be of approved make.
22.1 Enclosures
a) Motors to be installed outdoor without enclosure shall have hose proof enclosure equivalent
to IP-55 as per IS: 4691. For motors to be installed indoor i.e. inside a box, the motor
enclosure, shall be dust proof equivalent to IP-44 as per IS: 4691.
b) Two independent earthing points shall be provided on opposite sides of the motor for bolted
connection of earthing conductor.
VOLUME-I, Section-B (TR) 33
c) Motors shall have drain plugs so located that they will drain water resulting from
condensation or other causes from all pockets in the motor casing.
d) Motors weighing more than 25 Kg. shall be provided with eyebolts, lugs or other means to
facilitate lifting.
22.2 Operational Features
a) Continuous motor rating (name plate rating) shall be at least ten (10) percent above the maximum
load demand of the driven equipment at design duty point and the motor shall not be over loaded at
any operating point of driven equipment that will rise in service.
b) Motor shall be capable at giving rated output without reduction in the expected life span when
operated continuously in the system having the particulars as given in Clause 15.0 of this Section.
22.3 Starting Requirements:
a) All induction motors shall be suitable for full voltage direct-on-line starting. These shall be capable
of starting and accelerating to the rated speed alongwith the driven equipment without exceeding
the acceptable winding temperature even when the supply voltage drops down to 80% of the rated
voltage.
b) Motors shall be capable of withstanding the electrodynamic stresses and heating imposed if it is
started at a voltage of 110% of the rated value.
c) The locked rotor current shall not exceed six (6) times the rated full load current for all motors,
subject to tolerance as given in IS:325.
d) Motors when started with the driven equipment imposing full starting torque under the supply
voltage conditions specified under Clause 15.0 shall be capable of withstanding atleast two
successive starts from cold condition at room temperature and one start from hot condition without
injurious heating of winding. The motors shall also be suitable for three equally spread starts per
hour under the above referred supply condition.
e) The locked rotor withstand time under hot condition at 110% of rated voltage shall be more than
starting time with the driven equipment of minimum permissible voltage by at least two seconds or
15% of the accelerating time whichever is greater. In case it is not possible to meet the above
requirement, the Bidder shall offer centrifugal type speed switch mounted on the motor shaft which
shall remain closed for speed lower than 20% and open for speeds above 20% of the rated speed.
The speed switch shall be capable of withstanding 120% of the rated speed in either direction of
rotation.
22.4 Running Requirements:
VOLUME-I, Section-B (TR) 34
a) The maximum permissible temperature rise over the ambient temperature of 50 degree C shall be
within the limits specified in IS:325 (for 3 – phase induction motors) after adjustment due to
increased ambient temperature specified.
b) The double amplitude of motor vibration shall be within the limits specified in IS: 4729. Vibration
shall also be within the limits specified by the relevant standard for the driven equipment when
measured at the motor bearings.
c) All the induction motors shall be capable of running at 80% of rated voltage for a period of 5
minutes with rated load commencing from hot condition.
22.5 Testing and Commissioning
An indicative list of tests is given below. Contractor shall perform any additional test based on
specialties of the items as per the field Q.P./Instructions of the equipment Contractor or Purchaser
without any extra cost to the Purchaser. The Contractor shall arrange all instruments required for
conducting these tests along with calibration certificates and shall furnish the list of instruments to
the Purchaser for approval.
a) Insulation resistance.
b) Phase sequence and proper direction of rotation.
c) Any motor operating incorrectly shall be checked to determine the cause and the
conditions corrected.
23.0 Equipment Qualifying Requirements
23.1 All equipment should have been successfully type tested.
23.2 The equipment (of similar or higher rating) should be operating in a tropical country. Field report,
preferably a certificate from an end user/s may also be furnished.
24.0 Operation and Maintenance
The contractor will be responsible for O&M of substation for 6 months, during this period he will
trained the OWNER staff and for next 6 months O&M will be under contractor’s supervision.
25.0 Guarantee and Warrantee
The contractor has to provide 18 months guarantee from the date of commissioning.
VOLUME-I, Section-B (TR) 35
ANNEXURE-I
CORONA AND RADIO INTERFERENCE VOLTAGE (RIV) TEST
1. General
Unless otherwise stipulated, all equipment together with its associated connectors, where
applicable, shall be tested for external corona (for 400kV & above) both by observing the voltage
level for the extinction of visible corona under falling power frequency voltage and by
measurement of radio interference voltage (RIV) for 132kV above.
2. Test Levels:
The test voltage levels for measurement of external RIV and for corona extinction voltage are
listed under the relevant clauses of the specification.
3. Test Methods for RIV:
3.1. RIV tests shall be made according to measuring circuit as per International Special-
Committee on Radio Interference (CISPR) Publication 16-1(1993) Part -1. The measuring
circuit shall preferably be tuned to frequency with 10% of 0.5 Mhz but other frequencies in
the range of 0.5 MHz to 2 MHz may be used, the measuring frequency being recorded. The
results shall be in microvolts.
3.2. Alternatively, RIV tests shall be in accordance with NEMA standard Publication No. 107-
1964, except otherwise noted herein.
3.3. In measurement of, RIV, temporary additional external corona shielding may be provided. In
measurements of RIV only standard fittings of identical type supplied with the equipment and
a simulation of the connections as used in the actual installation will be permitted in the
vicinity within 3.5 meters of terminals.
3.4. Ambient noise shall be measured before and after each series of tests to ensure that there is
no variation in ambient noise level. If variation is present, the lowest ambient noise level will
form basis for the measurements. RIV levels shall be measured at increasing and decreasing
voltages of 85%, 100%, and 110% of the specified RIV test voltage for all equipment unless
otherwise specified. The specified RIV test voltage for 765kV, 400 kV, 220 KV is listed in
the detailed specification together with maximum permissible RIV level in microvolts.
3.5. The metering instruments shall be as per CISPR recommendation or equivalent device so
long as it has been used by other testing authorities.
VOLUME-I, Section-B (TR) 36
3.6. The RIV measurement may be made with a noise meter. A calibration procedure of the
frequency to which noise meter shall be tuned shall establish the ratio of voltage at the high
voltage terminal to voltage read by noisel meter.
4. Test Methods for Visible Corona
The purpose of this test is to determine the corona extinction voltage of apparatus, connectors
etc. The test shall be carried out in the same manner as RIV test described above with the
exception that RIV measurements are not required during test and a search technique shall be
used near the onset and extinction voltage, when the test voltage is raised and lowered to
determine their precise values. The test voltage shall be raised to 110% of specified corona
extinction voltage and maintained there for five minutes. In case corona inception does not take
place at 110%, test shall be stopped, otherwise test shall be continued and the voltage will then
be decreased slowly until all visible corona disappears. The procedure shall be repeated at least
4 times with corona inception and extinction voltage recorded each time. The corona extinction
voltage for purposes of determining compliance with the specification shall be the lowest of the
four values at which visible corona (negative or positive polarity) disappears. Photographs with
laboratory in complete darkness shall be taken under test conditions, at all voltage steps i.e.
85%, 100%, and 110%. Additional photographs shall be taken at corona inception and
extinction voltages. At least two views shall be photographed in each case using Panchromatic
film with an ASA daylight rating of 400 with an exposure of two minutes at a lens aperture of
f/5.6 or equivalent. The photographic process shall be such that prints are available for
inspection and comparison with conditions as determined from direct observation. Photographs
shall be taken from above and below the level of connector so as to show corona on bushing,
insulators and all parts of energized connectors. The photographs shall be framed such that test
object essentially, fills the frame with no cut-off. For recording purpose, modern devices
utilizing UV recording methods such as image intensifier may also be used.
4.1 The test shall be recorded on each photograph. Additional photograph shall be taken from
each camera position with lights on to show the relative position of test object to facilitate
precise corona location from the photographic evidence.
4.2 In addition to photographs of the test object preferably four photographs shall be taken of
the complete test assembly showing relative positions of all the test equipment and test
objects. These four photographs shall be taken from four points equally spaced around the
test arrangement to show its features from all sides. Drawings of the laboratory and test set
up locations shall be provided to indicate camera positions and angles. The precise location
VOLUME-I, Section-B (TR) 37
of camera shall be approved by Purchaser’s inspector, after determining the best camera
locations by trial energisation of test object at a voltage which results in corona.
4.3 The test to determine the visible corona extinction voltage need not be carried out
simultaneously with test to determine RIV levels.
4.4 However, both test shall be carried out with the same test set up and as little time duration
between tests as possible. No modification on treatment of the sample between tests will be
allowed. Simultaneous RIV and visible corona extinction voltage testing may be permitted
at the discretion of Purchaser’s inspector if, in his opinion, it will not prejudice other test.
5. Test Records:
In addition to the information previously mentioned and the requirements specified as per
CISPR or NEMA 107-1964 the following data shall be included in test report:
a) Background noise before and after test.
b) Detailed procedure of application of test voltage.
c) Measurements of RIV levels expressed in micro volts at each level.
d) Results and observations with regard to location and type of interference sources detected
at each step.
e) Test voltage shall be recorded when measured RIV passes through 100 microvolts in each
direction.
f) Onset and extinction of visual corona for each of the four tests required shall be recorded.
VOLUME-I, Section-B (TR) 38
ANNEXURE - II
SEISMIC WITHSTAND TEST PROCEDURE
The seismic withstanding test on the complete equipment (for 132kV and above) shall be carried
out alongwith supporting structure. The Bidder shall arrange to transport the structure from his
Contractor’s premises/OWNER sites for the purpose of seismic withstand test only. The seismic
level specified shall be applied at the base of the structure. The accelerometers shall be provided at
the Terminal Pad of the equipment and any other point as agreed by the Purchaser. The seismic test
shall be carried out in all possible combinations of the equipment. The seismic test procedure shall
be furnished for approval of the Purchaser.
VOLUME-II
Volume-II (Section-A), Circuit Breaker 1
SECTION- (A)
TECHNICAL DETAILS OF CIRCUIT BREAKER
1.0 GENERAL
1.1 The circuit breakers and accessories shall conform to IEC: 62271-100, IEC: 62271-01 and
other relevant IEC standards except to the extent explicitly modified in the specification and
shall also be in accordance with requirements specified in VOLUME-I, TR.
1.2 800/420/245/145 kV circuit breakers offered would be of sulphur hexafluoride (SF6) type
only and of class C2-M2 as per IEC. The bidder may also offer circuit breakers of either live
tank type or dead tank type of proven design.
1.3 The circuit breaker shall be complete with terminal connectors, operating mechanism,
control cabinets, piping, inter-pole cable, cable accessories like glands, terminal blocks,
marking ferrules, lugs, pressure gauges, density monitors (with graduated scale), galvanised
support structure for CB and control cabinets, their foundation bolts and all other circuit
breaker accessories required for carrying out all the functions the CB is required to perform.
All necessary parts to provide a complete and operable circuit breaker installation such as
main equipment, terminals, control parts, connectors and other devices whether specifically
called for herein or not shall be provided.
1.4 Painting shall be done in line with VOLUME-I, TR. Shade- 697 as per IS-5 or RAL- 7032 or
similar shades with Owner approval can be used for painting. The support structure of circuit
breaker shall be hot dip galvanised. Exposed hardware items shall be hot dip galvanised or
Electro-galvanised.
1.5 The circuit breakers shall be designed for use in the geographic and meteorological
conditions as given in VOLUME-I, TR.
2.0 DUTY REQUIREMENTS:
2.1 The circuit breakers shall be capable of performing their duties without opening resistors.
2.2 The circuit breaker shall meet the duty requirements for any type of fault or fault location
also for line switching when used on a 800/420/245/145 kV effectively grounded system,
and perform make and break operations as per the stipulated duty cycles satisfactorily.
2.2.1 PRE INSERTION RESISTER
800/420 kV circuit breakers wherever specified shall be provided with single step
pre-insertion closing resistors to limit the switching surges to a value of less than 1.9
p.u for 800 kV and 2.3 p.u. for 420 kV respectively. The resistor shall have thermal
rating for the following duties:
Volume-II (Section-A), Circuit Breaker 2
i) TERMINAL FAULT
Close -1 Min-Open-Close-open- 2 min-close-1 Min-open close open.
ii) RECLOSING AGAINST TRAPPED CHARGES
Duty same as under (i) above. The first, third and fourth closures are to be on
de-energized line while second closing is to be made with lines against trapped
charge of 1.2 p.u. of opposite polarity.
iii) OUT OF PHASE CLOSING
One closing operation under phase opposition that is with twice the voltage
across the terminals.
iv) No allowance shall be made for heat dissipation of resistor during time interval
between successive closing operations. The resistors and resistor supports shall
perform all these duties without deterioration. Calculations and test reports of
resistors proving thermal rating for duties specified above shall be furnished
during detailed engineering. The calculations shall take care of adverse
tolerances on resistance values and time settings.
2.3 The breaker shall be capable of interrupting the steady state and transient magnetising
current corresponding of power transformers.
2.4 The circuit breaker shall also be capable of:
i) Interrupting line/cable charging current as per IEC without use of opening resistors.
ii) Clearing short line fault (Kilometric faults) with source impedance behind the bus
equivalent to symmetrical fault current specified.
iii) Breaking 25% of the rated fault current at twice rated voltage under phase opposition
condition.
iv) 400kV breakers shall be able to switch in and out the 400kV shunt reactor for any value
from 50MVAR and above, without giving rise to overvoltage more than 2.3 p.u.
Laboratory test and / or field test reports in support of the same shall be furnished
during detailed engineering.
2.5 The Breaker shall satisfactorily withstand the high stresses imposed on them during fault
clearing, load rejection and re-energisation of lines with trapped charges.
2.6 CONTROLLED SWITCHING REQUIREMENTS
The Circuit Breaker shall be equipped with controlled switching with consequent
optimization of switching behavior, when used in:
Volume-II (Section-A), Circuit Breaker 3
a) For 800 kV
• Switching of transformer
• Switching of shunt reactor
The controller shall be provided in Circuit breaker of switchable line reactor and in Main &
Tie circuit breakers of Transformers and Bus reactors.
b) For 400 kV
• Switching of shunt reactor.
The controller shall be provided in Circuit breaker of switchable line reactor and in Main &
Tie circuit breakers of Bus reactors.
The controlling relay shall also record and monitor the switching operations and make
adjustments to the switching instants to optimize the switching behavior as necessary. It
shall provide self diagnostic facilities, signaling of alarms and enable downloading of data
captured from the switching events.
2.6.1 Technical Requirement for controlled switching device:
a) The controller shall be designed to operate at the correctly and satisfactorily
with the excursion of auxiliary A/C & DC voltages and frequency as specified in
VOLUME-I, TR.
b) The controller shall meet the requirements of IEC-60255-4 Appendix ‘E’ class
III regarding HF disturbance test, and fast transient test shall be as per IEC-
61000 – 4 level III and insulation test as per 60255 – 5.
c) The controller shall have functions for switching ON & OFF the circuit
breakers.
d) The controller shall get command to operate the breakers manually or through
auto re-close relay at random. The controller shall be able to analyze the current
and voltage waves available through the signals from secondaries of CTs &
CVTs for the purpose of calculation of optimum moment of the switching the
circuit breaker and issue command to circuit breaker to operate.
e) The controller shall also have an adaptive control feature to consider the next
operating time of the breaker in calculation of optimum time of issuing the
switching command. In calculation of next operating time of the breaker the
controller must consider all factors that may affect the operating time of the
breaker such as, but not limited to, ambient temperature, hydraulic/pneumatic
pressure of the operating mechanism, control voltage variation, SF6 gas density
Volume-II (Section-A), Circuit Breaker 4
variations etc. Schematic drawing for this purpose shall be provided by the
contractor. The accuracy of the operating time estimation by the controller shall
be better than + 0.5 ms.
f) The controller should have display facility at the front for the settings and
measured values.
g) The controller should be PC compatible for the setting of various parameters
and down loading of the settings and measured values date time of switching
etc. Window based software for this purpose shall be supplied by the contractor
to be used on the owner’s PC.
h) The controller shall have self-monitoring facility.
i) The controller shall be suitable for current input of 1 amp from the secondary of
the CTs. and 110 V (Ph to Ph) from the CVTs. The controller shall also take
care of transient and dynamic state values of the current from the secondary of
the CTs and CVTs.
j) The controller shall have time setting resolution of 0.1 ms or better.
k) The controller shall have sufficient number of output/input potential free
contacts for connecting the monitoring equipment and annunciation system
available in the control room. Necessary details shall be worked out during
engineering the scheme.
3.0 TOTAL BREAK TIME:
3.1 The total break time as specified under this Chapter shall not be exceeded under any of the
following duties:
i) Test duties T10, T30, T60, T100a, and T100s (TRV as per IEC: 62271-100)
ii) Short line fault L75, L90
3.2 The Bidder may please note that total break time of the breaker shall not be exceeded under
any duty conditions specified such as with the combined variation of the trip coil voltage,
(70-110%), pneumatic/hydraulic pressure and arc extinguishing medium pressure etc. While
furnishing the proof of the total break time of complete circuit breaker, the Bidders may
specifically bring out the effect of non-simultaneity between contacts within a pole or
between poles and show how it is covered in the guaranteed total break time.
3.3 The values guaranteed shall be supported with the type test reports.
4.0 CONSTRUCTIONAL FEATURES:
Volume-II (Section-A), Circuit Breaker 5
The features and constructional details of circuit breakers shall be in accordance with
requirements stated hereunder:
4.1 Contacts
The gap between the open contacts shall be such that it can withstand atleast the rated phase
to ground voltage for 8 hours at zero gauge pressure of SF6 gas due to the leakage. The
breaker should be able to withstand all dielectric stresses imposed on it in open condition at
lock out pressure continuously (i.e. 2 p.u. across the breaker continuously, for validation of
which a power frequency dielectric with stand test conducted for a duration of at least 15
minutes is acceptable).
4.2 If multi-break interrupters are used, these shall be so designed and augmented that a uniform
voltage distribution is developed across them. Calculations/ test reports in support of the
same shall be furnished. The thermal and voltage withstand of the grading elements shall be
adequate for the service conditions and duty specified.
4.3 The SF6 Circuit Breaker shall meet the following additional requirements:
a) The circuit breaker shall be single pressure type. The design and construction of the
circuit breaker shall be such that there is a minimum possibility of gas leakage and
entry of moisture. There should not be any condensation of SF6 gas on the internal
insulating surfaces of the circuit breaker.
b) All gasketted surfaces shall be smooth, straight and reinforced, if necessary, to
minimise distortion and to make a tight seal, the operating rod connecting the operating
mechanism to the arc chamber (SF6 media) shall have adequate seals. The SF6 gas
leakage should not exceed 0.5% per year and the leakage rate shall be guaranteed for at
least 10 years. In case the leakage under the specified conditions is found to be greater
than 0.5% after one year of commissioning of circuit breaker, the manufacturer will
have to supply free of cost, the total gas requirement for subsequent ten (10) years,
based on actual leakage observed during first year of operation after commissioning.
c) In the interrupter assembly there shall be an absorbing product box to minimise the
effect of SF6 decomposition products and moisture. The material used in the
construction of the circuit breakers shall be fully compatible with SF6 gas
decomposition products.
d) Each pole shall form an enclosure filled with SF6 gas independent of two other poles
(for 800, 420 & 245 kV CBs) and the SF6 density of each pole shall be monitored. For
CBs of voltage class of 145 kV or less, a common SF6 scheme/density monitor shall be
acceptable.
Volume-II (Section-A), Circuit Breaker 6
e) The dial type SF6 density monitor shall be adequately temperature compensated to
model the pressure changes due to variations in ambient temperature within the body of
circuit breaker as a whole. The density monitor shall have graduated scale and shall
meet the following requirements:
It shall be possible to dismantle the density monitor for checking/replacement without
draining the SF6 gas by providing suitable interlocked non return valve coupling.
f) Each Circuit Breaker shall be capable of withstanding a vacuum of minimum 8
millibars without distortion or failure of any part.
g) Sufficient SF6 gas including that will be required for gas analysis during filling shall be
provided to fill all the circuit breakers installed.
4.4 Provisions shall be made for attaching an operational analyser to record contact travel, speed
and making measurement of operating timings, pre-insertion timings of closing resisters if
used, synchronisation of contacts in one pole.
5.0 SULPHUR HEXAFLUORIDE GAS (SF6 GAS):
a) The SF6 gas shall comply with IEC 60376, 60376A and 60376B and shall be suitable in
all respects for use in the switchgear under the operating conditions.
b) The high pressure cylinders in which the SF6 gas is shipped and stored at site shall
comply with requirements of the relevant standards and regulations.
c) Test: SF6 gas shall be tested for purity, dew point, air, hydrolysable fluorides and water
content as per IEC 60376, 60376A and 60376B and test certificates shall be furnished to
Employer indicating all the tests as per IEC 60376 for each lot of SF6 gas in stipulated
copies as indicated in VOLUME-I, TR. Gas bottles should be tested for leakage during
receipt at site.
6.0 INSULATORS:
a) The porcelain of the insulators shall conform to the requirements stipulated under
VOLUME-I, TR.
b) The mechanical characteristics of insulators shall match with the requirements specified
under this Chapter.
c) All hollow insulators shall conform to IEC-62155. All routine and sample tests shall be
conducted on the hollow column insulators as per these standards with requirements and
procedures modified as under:
i) Pressure test as a routine test.
Volume-II (Section-A), Circuit Breaker 7
ii) Bending load test as a routine test.
iii) Bending load test as a sample test on each lot.
iv) Burst pressure test as a sample test on each lot.
v) In addition to above, ultrasonic test shall be carried out as additional routine test.
d) Hollow Porcelain for pressurised columns/chambers should be in one integral piece in
green and fired stage.
7.0 SPARE PARTS AND MANDATORY MAINTENANCE EQUIPMENT:
The bidder shall include in his proposal spare parts and maintenance equipment. Calibration
certificates of each maintenance equipment shall be supplied along with the equipment.
8.0 OPERATING MECHANISM AND CONTROL
8.1 General Requirements
8.1.1 Circuit breaker shall be operated by pneumatic mechanism (for 400 kV & 800 kV
ratings only) or spring charged mechanism or hydraulic mechanism or a
combination of these. The mechanism shall be housed in a weather proof and dust
proof control cabinet as stipulated in Section-VOLUME-I, TR.
8.1.2 The operating mechanism shall be strong, rigid, not subject to rebound.
8.1.3 The mechanism shall be anti-pumping and trip free (as per IEC definition) under
every method of closing.
8.1.4 The mechanism shall be such that the failure of any auxiliary spring will not prevent
tripping and will not cause trip or closing operation of the power operating devices.
8.1.5 A mechanical indicator shall be provided to show open and close position of the
breaker. It shall be located in a position where it will be visible to a man standing on
the ground level with the mechanism housing closed. An operation counter shall
also be provided in the central control cabinet.
8.1.6 Working parts of the mechanism shall be corrosion resisting material, bearings
which require grease shall be equipped with pressure type grease fittings. Bearing
pin, bolts, nuts and other parts shall be adequately pinned or locked to prevent
loosening or changing adjustment with repeated operation of the breaker.
8.1.7 The bidder shall furnish detailed operation and maintenance manual of the
mechanism along with the operation manual for the circuit breaker. The instruction
manuals shall contain exploded diagrams with complete storage, handling, erection,
commissioning, troubleshooting, servicing and overhauling instructions.
Volume-II (Section-A), Circuit Breaker 8
8.2 Control:
8.2.1 The close and trip circuits shall be designed to permit use of momentary contact
switches and push buttons.
8.2.2 Each breaker shall be provided with two (2) independent tripping circuits, pressure
switches and coils each to be fed from separate DC sources and connected to a
different set of protective relays.
8.2.3 The breaker shall normally be operated by remote electrical control. Electrical
tripping shall be performed by shunt trip coils. However, provisions shall be made
for local electrical control. For this purpose a local/remote selector switch and close
and trip control switch/push buttons shall be provided in the Breaker central control
cabinet.
8.2.4 The trip coils shall be suitable for trip circuit supervision during both open and close
position of breaker. The trip circuit supervision relay would be provided on relay
panels.
8.2.5 Closing coil and associated circuits shall operate correctly at all values of voltage
between 85% and 110% of the rated voltage. Shunt trip coil and associated circuits
shall operate correctly under all operating conditions of the circuit breaker upto the
rated breaking capacity of the circuit breaker and at all values of supply voltage
between 70% and 110% of rated voltage.
However, even at 50% of rated voltage the breaker shall be able to open. If
additional elements are introduced in the trip coil circuit their successful operation
and reliability for similar applications on outdoor circuit breakers shall be clearly
brought out in the additional information schedules.
8.2.6 Density Monitor contacts and pressure switch contact shall be suitable for direct use
as permissive in closing and tripping circuits. The density monitor shall be placed
suitably inclined in such a way so that the readings are visible from ground level
with or without using binoculars. Separate contacts have to be used for each of
tripping and closing circuits. If contacts are not suitably rated and multiplying relays
are used then fail safe logic/schemes are to be employed.
DC supplies for all auxiliary circuits shall be monitored and provision shall be made
for remote annunciations and operation lockout in case of D.C. failures. Density
monitors are to be so mounted that the contacts do not change on vibration during
operation of circuit Breaker.
Volume-II (Section-A), Circuit Breaker 9
8.2.7 The auxiliary switch of the breaker shall be positively driven by the breaker
operating rod.
8.3 Pneumatically operated mechanism (for 420 kV and 800 kV only)
a) Each pneumatic operated breaker shall be equipped with compressed air system in
accordance with Clause 16.0.
b) The breaker local air receivers shall comply with the requirements under Clause 16.4
and shall have sufficient capacity for at-least two CO operations of the breaker at the
lowest pressure for auto reclosing duty without refilling.
c) Independently adjustable pressure switches with potential free, ungrounded contacts to
actuate a lock out device shall be provided. This lockout device with provision of remote
alarm indication shall be incorporated in the circuit breaker to prevent operation
whenever the pressure of the operating mechanism is below that required for satisfactory
operation of the circuit breaker. The scheme should permit operation of all blocking and
alarm relays as soon as the pressure transient present during the rapid pressure drop has
been damped and a reliable pressure measurement can be made. Such facilities shall be
provided for following conditions:
i) Trip lockout pressure - 2 Nos.
ii) Close lockout pressure - 1 No.
iii) Auto re-close lockout pressure - 1 No.
iv) Extreme low pressure - 1 No.
d) The compressed air mechanism shall be capable of operating the circuit breaker under
all duty conditions with the air pressure immediately before operation between 85% and
110% of the rated supply pressure.
The make/break time at this supply pressure shall not exceed the specified make/break
time within any value of trip coil supply voltage as specified.
e) The compressed air piping shall comply to requirements under Clause 16.0.
8.4 Spring operated mechanism:
a) Spring operated mechanism shall be complete with motor in accordance with
VOLUME-I, TR. Opening spring and closing spring with limit switch for automatic
charging and other necessary accessories to make the mechanism a complete operating
unit shall also be provided.
Volume-II (Section-A), Circuit Breaker 10
b) As long as power is available to the motor, a continuous sequence of the closing and
opening operations shall be possible. The motor shall have adequate thermal rating for
this duty.
c) After failure of power supply to the motor one close open operation shall be possible
with the energy contained in the operating mechanism.
d) Breaker operation shall be independent of the motor which shall be used solely for
compressing the closing spring. Facility for manual charging of the closing spring shall
also be provided. The motor rating shall be such that it requires not more than 30
seconds for full charging of the closing spring.
e) Closing action of circuit breaker shall compress the opening spring ready for tripping.
f) When closing springs are discharged after closing a breaker, closing springs shall be
automatically charged for the next operation and an indication of this shall be provided
in the local and remote control cabinet.
g) Provisions shall be made to prevent a closing operation of the breaker when the spring is
in the partial charged condition. Mechanical interlocks shall be provided in the operating
mechanism to prevent discharging of closing springs when the breaker is already in the
closed position.
h) The spring operating mechanism shall have adequate energy stored in the operating
spring to close and latch the circuit breaker against the rated making current and also to
provide the required energy for the tripping mechanism in case the tripping energy is
derived from the operating mechanism.
8.5 Hydraulically operated mechanism:
a) Hydraulically operated mechanism shall comprise of operating unit with power cylinder,
control valves, high and low pressure reservoir, motor. Electrically driven motor shall
comply to VOLUME-I, TR.
b) The hydraulic oil used shall be fully compatible for the specified temperature range.
c) The oil pressure switch controlling the oil pump and pressure in the high pressure
reservoir shall have adequate number of spare contacts to be used for continuous
monitoring of low pressure, high pressure etc.
d) The mechanism shall be suitable for atleast two close open operations after failure of AC
supply to the motor starting at pressure equal to the lowest pressure of auto reclose duty
plus pressure drop for one close open operation.
Volume-II (Section-A), Circuit Breaker 11
e) The mechanism shall be capable of operating the circuit breaker correctly and
performing the duty cycle specified under all conditions with the pressure of hydraulic
operated fluid in the operating mechanism at the lowest permissible pressure before
make up. The opening time at the lowest pressure for a particular operation shall not
exceed the guaranteed operating time within any value of trip coil supply voltage as
specified.
f) Trip lockout shall be provided to prevent operations of the circuit breaker below the
minimum specified hydraulic pressure. Alarm contacts for loss of Nitrogen shall be
provided.
g) All hydraulic joints shall have no oil leakage under the site conditions and joints shall be
tested at factory against oil leakage at a minimum of 1.5 times maximum working
pressure.
9.0 SUPPORT STRUCTURE:
The structure design shall be such that during operation of circuit breaker vibrations are
reduced to minimum.
10.0 TERMINAL CONNECTOR PAD:
The circuit breaker terminal pads shall be made up of high quality electrolytic copper or
aluminium and shall be conforming to Australian standard AS-2935 for rated current. The
terminal pad shall have protective covers which shall be removed before interconnections.
11.0 INTERPOLE CABLING:
11.1 All cables to be used by contractor shall be armoured and shall be as per IS – 1554/ IEC-502
(1100 Volts Grade). All cables within & between circuit breaker poles shall be supplied by
the CB manufacturer.
11.2 Only stranded conductor shall be used. Minimum size of the conductor for interpole control
wiring shall be 1.5 sq.mm (Copper).
11.3 The cables shall be with oxygen index Min-29 and temp. index as 250°C as per relevant
standards.
12.0 FITTINGS AND ACCESSORIES
12.1 Following is a partial list of some of the major fittings and accessories to be furnished by
Contractor in the Central Control cabinet. Number and exact location of these parts shall be
indicated in the bid.
Volume-II (Section-A), Circuit Breaker 12
i) Cable glands (Double compression type), Lugs, Ferrules etc.
ii) Local/remote changeover switch.
iii) Operation counter
iv) Pneumatic/hydraulic pressure gauge, pump/compressor start counter (to be provided in
case of pneumatic/Hydraulic operating mechanism).
v) Control switches to cut off control power supply.
vi) Fuses as required.
vii) The number of terminals provided shall be adequate enough to wire out all contacts and
control circuits plus 24 terminals spare for future use.
viii)Antipumping relay.
ix) Pole discrepancy relay (for electrically ganged CBs).
x) D.C. Supervision relays.
xi) Rating and diagram plate in accordance with IEC incorporating year of manufacture.
xii) Controlled switching equipments like sensors, timers, relays etc.(as applicable)
12.2 Additional fittings for pneumatically operated circuit breaker
a) Unit compressed air system in accordance with Clause 16.0.
b) Breaker air receivers.
c) Pressure gauge, spring loaded safety valve and pressure switch with adjustable contacts.
d) Pressure switch to initiate an alarm if the pressure in the auxiliary reservoir remains
below a preset level for longer than it is normally necessary to refill the reservoir.
e) Stop, non-return and other control valves, pipings and all accessories upto breaker
mechanism housing.
13.0 ADDITIONAL DATA TO BE FURNISHED BY THE BIDDER:
a) The temperature v/s pressure curves for each setting of density monitor alongwith details
of density monitor.
b) Method of checking the healthiness of voltage distribution devices (condensers)
provided across the breaks at site.
c) Data on capabilities of circuit breakers in terms of time and number of operations at
duties ranging from 100% fault currents to load currents of the lowest possible value
without requiring any maintenance or checks.
Volume-II (Section-A), Circuit Breaker 13
d) The effect of non-simultaneity between contacts between poles and also show how it is
covered in the guaranteed total break time.
e) Sectional view of non-return couplings if used for SF6 pipes.
f) Details & type of filters used in interrupter assembly and also the operating experience
with such filters.
g) Details of SF6 gas:
i) The test methods used in controlling the quality of gas used in the circuit breakers
particularly purity and moisture content.
ii) Proposed tests to assess the conditions of the SF6 within a circuit breaker after a
period of service particularly with regard to moisture contents of the gas.
h) The bidders shall furnish along with the bid, curves supported by test data indicating the
opening time under close open operation with combined variation of trip coil voltage
and pneumatic/hydraulic pressure.
j) Detailed literature and schematic diagrams of switching mechanism for closing resistor
showing the duration of insertion shall also be furnished alongwith the calculations in
respect of thermal rating of resistors for the duties specified under clause 2.2 of this
chapter in case of 420 kV circuit breaker.
i) All duty requirements as applicable to 800 kV, 420 kV, 245 kV & 145 kV CBs specified
under Clause 2.0 of shall be provided with the support of adequate test reports.
j) Field test report or laboratory test report in case of CB meant for reactor switching duty.
14.0 TESTS:
14.1 In accordance with the requirements stipulated under VOLUME-I, TR the circuit breaker
along with its operating mechanism shall conform to IEC: 62271-100.
14.2 The test reports of the type tests and the following additional type tests shall also be
submitted for Purchaser’s review:
i) Corona extinction voltage test (as per Annexure-I of VOLUME-I, TR).
ii) Out of phase closing test as per IEC: 62271-100.
iii) Line charging breaking current for proving parameters as per clause no. 3.2 (B) (i).
iv) Test to demonstrate the Power Frequency withstand capability of breaker in open
condition at Zero Gauge pressure and at lockout pressure (Ref. Clause 4.1).
Volume-II (Section-A), Circuit Breaker 14
v) Seismic withstand test (As per Annexure-II of VOLUME-I, TR) in unpressurised
condition.
vi) Verification of the degree of protection.
vii) Low & high temperature test. (if applicable)
viii) Humidity test. (if applicable)
ix) Static Terminal Load test.
x) Critical Currents test (if applicable).
xi) Switching of Shunt Reactors.
xii) Controlled switching performance and validation tests(wherever applicable)
14.3 Routine Tests
Routine tests as per IEC: 62271-100 shall be performed on all circuit breakers. In addition to
the mechanical and electrical tests specified by IEC, the following tests shall also be
performed.
i) Speed curves for each breaker shall be obtained with the help of a suitable operation
analyser to determine the breaker contact movement during opening, closing, auto-
reclosing and trip free operation under normal as well as limiting operating conditions
(control voltage, pneumatic/hydraulic pressure etc.). The tests shall show the speed of
contacts directly at various stages of operation, travel of contacts, opening time, closing
time, shortest time between separation and meeting of contacts at break make operation
etc. This test shall also be performed at site for which the necessary operation analyser
alongwith necessary transducers, cables, console, etc. where included in scope of supply
shall be furnished and utilised. In case of substations where operation analyser is
existing, the bidder shall utilise the same. However necessary adopter and transducers
etc. if required shall have to be supplied by the bidder.
ii) Measurement of Dynamic Contact resistance measurement for arcing & main contacts.
Signature of Dynamic contact resistance measurements shall be taken as reference for
comparing the same during operation and maintenance in order to ascertain the
healthiness of contacts.
iii) Routine tests on Circuit breakers with Controlled switching equipment as per draft IEC.
15.0 DEAD TANK TYPE CIRCUIT BREAKER
15.1 In case dead tank type circuit breaker is offered, the Bidder shall offer bushing type CTs on
either side of dead tank circuit breaker instead of conventional outdoor CTs.
Volume-II (Section-A), Circuit Breaker 15
15.2 The enclosure shall be made of either Al/Al Alloy or mild steel (suitably hot dip galvanised).
The enclosure shall be designed for the mechanical and thermal loads to which it is
subjected in service. The enclosure shall be manufactured and tested according to the
pressure vessel codes i.e., latest edition of the ASME code for pressure vessel - Section
VIII of BS-5179, IS4379, IS-7311 (as applicable) and also shall meet Indian Boiler
Regulations.
The maximum temperature of enclosure with CB breaker carrying full load current shall not
exceed the ambient by more than 20 deg C.
15.3 The enclosure has to be tested as a routine test at 1.5 times the design pressure for one
minute. A bursting pressure test shall be carried out at 5 times the design pressure as type
test on the enclosure.
16.0 UNIT COMPRESSED AIR SYSTEM FOR CIRCUIT BREAKERS:
16.1 The unit compressed air system shall meet the following requirements:
a) The compressed air system shall be provided with necessary piping, piping accessories,
control valves, safety valves, filters, reducing valves, isolating valves, drain ports,
automatic condensate drain valve etc. The Unit compressed air system shall be provided
with suitable anti-vibration pads wherever required.
b) The compressors or pumps shall be of the air cooled type and mounted within the
operating mechanism housing or a separate weather-proof and dust-proof housing.
c) The air receiver shall have stored energy for 2 CO operations of the breaker at the
blocking pressure for auto reclosing duty without refilling. The unit compressor shall be
capable of building up required pressure for another 2 CO operations within 30 minutes.
d) The size of the compressor shall be determined by the bidder. The compressor shall be
of sufficient capacity for performing all the operations above mentioned.
16.2 Air Compressor:
a) The air compressor shall be of air cooled type complete with cylinder lubrication, drive
motor etc. The compressor shall be rated for the following duty:
i) Total running time of not exceeding 80 minutes compressor to build up the rated
pressure from atmospheric pressure
ii) Normal running air not exceeding 15 minutes charging considering 10%
leakage/day.
Volume-II (Section-A), Circuit Breaker 16
iii) Air charging time not exceeding 15 minutes. After one close-open operation from
rated pressure.
b) Compressor shall be driven by automatically controlled motors conforming to
requirements of VOLUME-I, TR.
c) The compressor shall be provided with automatic adjustable unloading device during
starting.
d) The compressor shall be equipped with a Time totaliser and a Pressure gauge.
16.3 Intercooler and after cooler: (If applicable)
Intercooler between compressor stage and after cooler at discharge if any of H.P. cylinder
shall be included in Contractor’s scope. They shall be of air cooled type and shall be
designed as per ASME Code of IEMA Standards. The design pressure on the air side of
cooler shall be 1.25 times the working pressure. A corrosion allowance of 3 mm shall be
included for all steel parts.
16.4 Air Receivers:
a) Air receiver shall be designed in accordance with the latest edition of the ASME Code
for Pressure Vessel - Section VIII of BS: 5179. If the air receiver is not fully hot dip
galvanised, it shall be coated on the inside face with antirust medium and a corrosion
allowance of 3.0 mm shall be provided for shell and dished ends.
b) Connections for air inlet and outlet, drain and relief valves shall be flanged type or
screwed type. Pressure gauge and pressure switch connections shall be screwed type
only.
c) Accessories such as suitable sized safety valve to relieve full compressor discharge at a
set pressure equal to 1.1 times the maximum operating pressure, blow off valve, auto
drain tap with isolating and bypass valve, dial type pressure gauge with isolating and
drain valve and test connection shall be provided.
d) Air receiver shall be offered with atleast 50% spare capacity, calculated on the basis of
total air requirement for 2 CO operations.
16.5 Quality of Air:
Compressed air used shall be dry and free of dust particles and fully compatible with the
materials used in the pneumatic operating mechanism. Arrangement for conditioning the
compressed air if required shall be provided as an integral part of air compressor system.
If situation warrants, because of the severe ambient conditions, the supplier may offer
centralised compressed air system.
Volume-II (Section-A), Circuit Breaker 17
16.6 Control and Control Equipment:
a) The compressor control shall be of automatic start/stop type initiated by pressure
switches.
b) Duplicate incoming supply of 415 V, AC shall be provided by the Employer at
switchyard bay marshaling box from where the Contractor shall take the feed to the
operating mechanism.
c) All the necessary compressor control equipment shall be housed in a totally enclosed
sheet steel cabinet also conforming to requirements of VOLUME-I, TR. Pressure gauges
and other indicating devices, control switches shall be mounted on the control cabinet.
d) A glass window shall be provided for viewing the indicating instrument/gauges. The
maximum height shall be 2000 mm.
16.7 Compressed Air Piping, Valves and Fittings:
a) The flow capacity of all valves shall be at least 20% greater than the total compressor
capacity.
b) The high pressure pipe and air system shall be such that after one O-0.3 sec-CO-
operation the breaker shall be capable of performing one CO operation within 3 minutes.
c) All compressed air piping shall be bright annealed, seamless phosphorous Deoxidized
Non-Arsenical Copper alloy as per BS: 2874 or stainless steel pipe (C - 106 of BS:
2871-1957).
d) All joints and connections in the piping system shall be brazed or flared as necessary.
e) All compressed air piping shall be carried out in accordance with BS: 162.
f) Compressed air piping system shall be complete with Saddle clamps to support the
piping system at suitable intervals. Necessary bolts, nuts, pipe fixing clamps etc shall be
included in the scope of Contractor.
16.8 Tests:
In accordance with the requirements stipulated under VOLUME-I, TR, the compressors and
its accessories shall conform to the type tests and shall be subjected to routine tests as per
applicable standards.
17.0 PRE-COMMISSIONING TESTS
17.1 An indicative list of tests is given below. All routine tests except power frequency voltage
dry withstand test on main circuit breaker shall be repeated on the completely assembled
breaker at site. This document will be available at respective sites and shall be referred by
Volume-II (Section-A), Circuit Breaker 18
the contractor. Contractor shall perform any additional test based on specialties of the items
as per the field Q.P./instructions of the equipment Supplier or Employer without any extra
cost to the Employer. The Contractor shall arrange all instruments required for conducting
these tests along with calibration certificates and shall furnish the list of instruments to the
Employer for approval.
(a) Insulation resistance of each pole.
(b) Check adjustments, if any suggested by manufacturer.
(c) Breaker closing and opening time.
(d) Slow and Power closing operation and opening.
(e) Trip free and anti pumping operation.
(f) Minimum pick-up voltage of coils.
(g) Dynamic Contact resistance measurement.
(h) Functional checking of compressed air plant and all accessories.
(i) Functional checking of control circuits interlocks, tripping through protective relays
and auto reclose operation.
(j) Insulation resistance of control circuits, motor etc.
(k) Resistance of closing and tripping coils.
(l) SF6 gas leakage check.
(m) Dew Point Measurement
(n) Operation check of pressure switches and gas density monitor during gas filling.
(o) Checking of mechanical ‘CLOSE’ interlock, wherever applicable.
(p) Testing of grading capacitor.
(q) Resistance measurement of main circuit.
(r) Checking of operating mechanisms
(s) Check for annunciations in control room.
(t) Point of wave switching test(wherever applicable)
17.2 The contractor shall ensure that erection, testing and commissioning of circuit breaker shall
be carried out under the supervision of the circuit breaker manufacturer's representative. The
commissioning report shall be signed by the manufacturers representative.
Volume-II (Section-A), Circuit Breaker 19
Volume-II (Section-A), Circuit Breaker 20
TECHNICAL PARTICULARS OF CIRCUIT BREAKER
I. 800 kV CIRCUIT BREAKER:
a) Rated continuous current (A) 3000
at design ambient temperature.
b) Rated short circuit 40 kA with percentage DC
current breaking capacity component as per IEC: at
rated voltage 62271-100
corresponding to
minimum opening time
under
operating conditions
specified.
c) Symmetrical interrupting 40 capability
(kA rms)
d) Rated short circuit 102
making current (kAp)
e) i) Short time current 40
carrying capability for one second (kArms)
ii) Out of phase breaking 10
current capacity (kA rms)
f) Rated operating duty O-0.3sec-CO-3min-CO
cycle
g) Reclosing Single phase & three phase
auto-reclosing
h) First pole to clear 1.3
factor
i) Rated line charging 900 A
interrupting current at 90 deg.
leading power factor angle (A. rms)
(The breaker shall be able to interrupt the rated line charging current with test voltage
immediately before opening equal to the product of U/√3 & 1.4 as per IEC: 62271-
100).
Volume-II (Section-A), Circuit Breaker 21
j) Temperature rise over the As per IEC: 62271-100
design ambient temperature
k) Rated break time 40
l) Total closing time (ms) Not more than 150
m) Operating mechanism Spring/Hydraulic
or a combination of these
o) Max. difference in the instants of
closing/ opening of contacts (ms)
a) Within a pole 2.5
b) Between poles 3.3
c) Between poles (closing) 5.0
The above shall be at rated control voltage and rated operating and quenching media
pressures.
p) Trip coil and closing 220 V DC with variation as
coil voltage specified
q) Rated terminal load As per IEC
r) Auxiliary contacts Besides requirement of
specification, the bidder
shall wire up 5 NO + 5 NC
contacts for future use of
purchaser.
s) No of Terminals in common All contacts & control
circuits to be Control
cabinet wired out up to
common control cabinet
plus 24 terminals
exclusively for Purchaser’s
use.
t) Maximum allowable 1.9 p.u.
switching overvoltage under any
switching condition
u) TRV (kVp) As per IEC: 62271-100
Volume-II (Section-A), Circuit Breaker 22
v) Pre-insertion resistor requirement
i) Rating (ohms) 450 (Maximum)
ii) Minimum pre-insertion 9 time (ms)
iii) Opening of PIR contacts a) PIR Contacts should
open immediately after
closing of main circuits.
OR
b) Atleast 5 ms prior to
opening of main contacts at
rated air/gas pressure,
where the PIR Contacts
remain closed.
II. 420 kV CIRCUIT BREAKER:
a) Rated continuous current (A) at 2000 / 3150 (as applicable)
design ambient temperature.
b) Rated short circuit current breaking 50 kA
with percentage DC component
as per at rated voltage IEC: 62271-100
corresponding to minimum opening time
under operating conditions specified
c) Symmetrical interrupting 50
capability (kA rms)
d) Rated short circuit 125
making current (kAp)
e) i) Short time current carrying 50
capability for one second (kArms)
ii) Out of phase breaking 12.5
current capacity (kArms)
f) Rated operating duty O-0.3sec-CO-3min-CO
cycle
g) Reclosing Single phase & three phase
autoreclosing
Volume-II (Section-A), Circuit Breaker 23
h) First pole to clear 1.3 factor
i) Rated line charging interrupting current 600 A
at 90 deg. leading power factor
angle (A. rms)
(The breaker shall be able to interrupt the rated line charging current with test
voltage immediately before opening equal to the product of U/√3 & 1.4 as per
IEC: 62271-100).
j) Temperature rise over the As per IEC: 62271-100
design ambient
temperature
k) Rated break time as per IEC (ms) 40
l) Total closing time (ms) Not more than 150
m) Operating mechanism Pneumatic/spring/hydraulic
or a combination of these
n) Max. difference in the instants of
closing/ opening of contacts (ms)
i) Within a pole 2.5
ii) Between poles (opening) 3.3
iii) Between poles (closing) 5.0
The above shall be at rated control voltage and rated operating and quenching
media pressures.
o) Trip coil and closing 220 V DC with variation as
specified coil voltage
p) Noise level at base and upto 50 m 140 dB (Max.)
(distance from base of breaker)
q) Rated terminal load As per IEC
r) Auxiliary contacts Besides requirement of
specification, the bidder
shall wire up 5 NO + 5 NC
contacts for future use of
purchaser.
Volume-II (Section-A), Circuit Breaker 24
s) No of Terminals in common All contacts & control
circuits Control cabinet to be
wired out upto common
control cabinet plus
24 terminals
exclusively for Purchaser’s
use.
t) Maximum allowable 2.3 p.u.
switching overvoltage under any
switching condition
u) Pre-insertion resistor requirement
i) Rating (ohms) 400
ii) Minimum pre-insertion 8
time (ms)
iii) Opening of PIR contacts a) PIR Contacts should
open immediately after
closing of main circuits.
OR
b) Atleast 5 ms prior to
opening of main contacts at
rated air/gas pressure,
where the PIR Contacts
remain closed.
III. 245 kV CIRCUIT BREAKER:
a) Rated continuous current (A) 1600/2000/3000
at design ambient temperature.
b) Rated short circuit 40 kA
current breaking capacity
at rated voltage
c) Symmetrical interrupting 40
capability (kArms)
d) Rated short circuit 100
making current (kAp)
e) Short time current 40
Volume-II (Section-A), Circuit Breaker 25
carrying capability for one second (kArms)
f) Rated operating duty O-0.3sec-CO-3min-CO
cycle
g) Reclosing Single phase & three phase
autoreclosing
h) First pole to clear 1.3
factor
i) Rated line/cable charging As per IEC interrupting
current at 90 deg. leading power
factor angle (A. rms)
(The breaker shall be able to interrupt the rated line/cable charging current with test
voltage immediately before opening equal to the product of U/√3 & 1.4 as per IEC:
62271-100).
j) Temperature rise over the As per IEC: 62271-100
design ambient temperature
k) Rated break time 60
l) Total closing time (ms) Not more than 200
m) Operating mechanism spring/hydraulic or a
combination of these
n) Max. difference in the instants of
closing/ opening of contacts (ms)
i) Between poles (opening) 3.3
ii) Between poles (closing) 5.0
The above shall be at rated control voltage and rated operating and quenching
media pressures.
o) Trip coil and closing 220 V DC with variation as
coil voltage specified
p) Noise level at base and 140 dB (Max.) upto 50 m
(distance from base of breaker)
q) Rated terminal load As per IEC
r) Auxiliary contacts Besides requirement of
specification, the bidder
shall wire up 5 NO + 5 NC
Volume-II (Section-A), Circuit Breaker 26
contacts for future use of
purchaser.
s) No of Terminals in common All Contacts & control
circuits to be Control
cabinet wired out upto
common control cabinet
plus 24 terminals
exclusively for Purchaser’s
use.
t) Maximum allowable switching As per IEC
overvoltage under any switching condition
IV. 145 kV CIRCUIT BREAKER:
a) Rated continuous current (A) 1600/2000
at design ambient temperature.
b) Rated short circuit current breaking 31.5 kA with percentage
DC
capacity at rated voltage component as per IEC:
62271-100 corresponding
to at rated voltage
minimum opening time
under operating conditions
specified
c) Symmetrical interrupting 31.5
capability (kA rms)
d) Rated short circuit 80
making current (kAp)
e) Short time current 31.5
carrying capability for one second (kA rms)
f) Out of phase breaking As per IEC
current capacity (kA rms)
g) Rated operating duty O-0.3sec-CO-3min-CO
cycle
h) Reclosing Three phase autoreclosing
i) First pole to clear factor 1.3
Volume-II (Section-A), Circuit Breaker 27
j) Rated line/cable charging As per IEC
interrupting current at 90 deg. leading
power factor angle (A. rms)
(The breaker shall be able to interrupt the rated line/cable charging current with test
voltage immediately before opening equal to the product of U/√3 & 1.4 as per IEC:
62271-100).
k) Temperature rise over the As per IEC: 62271-100
design ambient temperature
l) Rated break time as per IEC (ms) 60
m) Total closing time (ms) Not more than 150
n) Operating mechanism spring/hydraulic or a
combination of these
o) Max. difference in the instants of 3.3
closing/ opening of contacts (ms)
between poles at rated control voltage
and rated operating and quenching
media pressures.
p) Trip coil and closing coil voltage 220 V DC with variation
q) Noise level at base and 140 dB (Max.)
upto 50 m (distance from base of breaker)
r) Rated terminal load As per IEC
s) Auxiliary contacts Besides requirement of
specification, the bidder
shall wire up 5 NO + 5 NC
contacts for future use of
Purchaser.
t) No. of Terminals in common All contacts & control
circuits
control cabinet to be wired out upto
common control cabinet
plus 24 terminals
exclusively for Purchaser’s
use.
Volume-II (Section-A), Circuit Breaker 28
u) Maximum allowable As per IEC
switching overvoltage under any switching
condition
v) Rated small inductive current switching 0.5 to 10
capability with overvoltage less than
2.3 p.u.(A)
Volume-II (Section-B), Isolator 29
SECTION- (B)
TECHNICAL PARTICULARS OF ISOLATORS
1.0 General
1.1 The Isolators and accessories shall conform in general to IEC: 62271-102 (or IS: 9921)
except to the extent explicitly modified in specification and shall be in accordance with
requirement of VOLUME-I, TR.
1.2 Isolators shall be outdoor, off-load type. Earth switches shall be provided on isolators
wherever called for, with possibility of being mounted on any side of the isolator. 800 kV
isolator design shall be double break or vertical break or knee-type. 420 kV & below rated
isolators shall be double break type, unless specified otherwise.
1.3 Complete isolator with all the necessary items for successful operation shall be supplied
including but not limited to the following:
1.3.1 Isolator assembled with complete Support Insulators, operating rod insulator, base
frame, linkages, operating mechanism, control cabinet, interlocks etc.
1.3.2 All necessary parts to provide a complete and operable isolator installation, control
parts and other devices whether specifically called for herein or not.
1.3.3 The isolator shall be designed for use in the geographic and meteorological
conditions as given in VOLUME-I, TR.
2.0 Duty Requirements
a) Isolators and earth switches shall be capable of withstanding the dynamic and thermal
effects of the maximum possible short circuit current of the systems in their closed
position. They shall be constructed such that they do not open under influence of short
circuit current.
b) The earth switches, wherever provided, shall be constructionally interlocked so that the
earth switches can be operated only when the isolator is open and vice versa. The
constructional interlocks shall be built in construction of isolator and shall be in addition
to the electrical interlocks. Suitable mechanical arrangement shall also be provided for
delinking electrical drive for manual operation.
c) In addition to the constructional interlock, isolator and earth switches shall have
provision to prevent their electrical and manual operation unless the associated and other
interlocking conditions are met. All these interlocks shall be of fail safe type. Suitable
individual interlocking coil arrangements shall be provided. The interlocking coil shall
Volume-II (Section-B), Isolator 30
be suitable for continuous operation from DC supply and within a variation range as
stipulated in VOLUME-I, TR.
d) The earthing switches shall be capable of discharging trapped charges of the associated
lines.
e) The isolator shall be capable of making/breaking normal currents when no significant
change in voltage occurs across the terminals of each pole of isolator on account of
make/break operation.
3.0 Constructional Features
The features and constructional details of Double Break Isolators/Vertical Break/Knee-type
isolators, earth switches and accessories shall be in accordance with requirements stated
hereunder:
3.1 Contacts
a) The contacts shall be self aligning and self cleaning and so designed that binding cannot
occur after remaining closed for prolonged periods of time in a heavily polluted
atmosphere.
b) No undue wear or scuffing shall be evident during the mechanical endurance tests.
Contacts and spring shall be designed so that readjustments in contact pressure shall not
be necessary throughout the life of the isolator or earthing switch. Each contact or pair
of contacts shall be independently sprung so that full pressure is maintained on all
contacts at all time.
c) Contact springs shall not carry any current and shall not loose their characteristics due to
heating effects.
d) The moving contact of double break isolator shall have turn-and -twist type or other
suitable type of locking arrangement to ensure adequate contact pressure.
3.2 Base
Each single pole of the isolator shall be provided with a complete galvanised steel base
provided with holes and designed for mounting on a supporting structure.
3.3 Blades
a) All metal parts shall be of non-rusting and non-corroding material. All current carrying
parts shall be made from high conductivity electrolytic copper/aluminium Bolts, screws
and pins shall be provided with lock washers. Keys or equivalent locking facilities if
Volume-II (Section-B), Isolator 31
provided on current carrying parts, shall be made of copper silicon alloy or stainless
steel or equivalent. The bolts or pins used in current carrying parts shall be made of non-
corroding material. Ferrous parts, other than stainless steel shall not be used in close
proximity of main current path. All ferrous castings, if used elsewhere shall be made of
malleable cast iron or cast-steel. No grey iron shall be used in the manufacture of any
part of the isolator.
b) The live parts shall be designed to eliminate sharp joints, edges and other corona
producing surfaces, where this is impracticable adequate corona rings shall be provided.
Corona shields are not acceptable. Corona rings shall be made up of
aluminum/aluminum alloy.
c) Isolators and earthing switches including their operating parts shall be such that they
cannot be dislodged from their open or closed positions by short circuit forces, gravity,
wind pressure, vibrations, shocks, or accidental touching of the connecting rods of the
operating mechanism.
d) The switch shall be designed such that no lubrication of any part is required except at
very infrequent intervals. i.e. after every 1000 operations or after 5 years whichever is
earlier.
3.4 Insulator
a) The insulator shall conform to IS: 2544 and/or IEC-60168. The porcelain of the insulator
shall conform to the requirements stipulated under VOLUME-I, TR and shall have a
minimum cantilever strength of 1000/1000/1000/600 kgs for 800/420/245/145 kV
insulators respectively.
b) Pressure due to the contact shall not be transferred to the insulators after the main blades
are fully closed.
c) The parameters of the insulators shall meet the requirements specified under VOLUME-
I, TR.
d) Insulator shall be type and routine tested as per IEC-60168. Besides following additional
tests shall also be conducted:
(i) Bending load test in four directions at 50% of minimum bending load guaranteed
on all insulators, as a routine test.
(ii) Bending load test in four directions at 100% of minimum bending load as a sample
test on each lot.
(iii) Torsional test on sample insulators of a lot.
Volume-II (Section-B), Isolator 32
(iv) Ultrasonic test as a routine test.
Name Plate:
The name plate shall conform to the requirements of IEC incorporating year of manufacture.
4.0 Earthing Switches
a) Where earthing switches are specified these shall include the complete operating
mechanism and auxiliary contacts.
b) The earthing switches shall form an integral part of the isolator and shall be mounted on
the base frame of the isolator.
c) Earthing switches shall be only locally operated.
d) The earthing switches shall be constructionally interlocked with the isolator so that the
earthing switches can be operated only when the isolator is open and vice versa. The
constructional interlocks shall be built in construction of isolator and shall be in addition
to the electrical interlocks. Suitable mechanical arrangement shall be provided for de-
linking electrical drive for manual operation.
e) Each earth switch shall be provided with flexible copper/aluminum braids for connection
to earth terminal. These braids shall have the same short time current carrying capacity
as the earth blade. The transfer of fault current through swivel connection will not be
accepted.
f) The plane of movement and final position of the earth blades shall be such that adequate
electrical clearances are obtained from adjacent live parts in the course of its movement
between ON and OFF position.
g) The frame of each isolator and earthing switches shall be provided with two reliable
earth terminals for connection to the earth mat.
h) Isolator design shall be such as to permit addition of earth switches at a future date. It
should be possible to interchange position of earth switch to either side.
i) The earth switch should be able to carry the same fault current as the main blades of the
Isolators and shall withstand dynamic stresses.
j) 420 kV & 245 kV earth switches shall also comply with the requirements of IEC-62271-
102, in respect of induced current switching duty as defined for Class-B and short circuit
making capability class E0 for earthing switches.
5.0 Operating Mechanism
Volume-II (Section-B), Isolator 33
a) The bidder shall offer motor operated Isolators and earth switches. Earth switches of 36
kV and below rating shall be manual operated.
b) Control cabinet/operating mechanism box shall conform to the requirement stipulated in
VOLUME-I, TR and shall be made of cast aluminium/aluminum sheet of adequate
thickness (minimum 3 mm) or stainless steel (grade-304)of minimum thickness 2mm.
c) A “Local/Remote” selector switch and a set of open/ close push buttons shall be
provided on the control cabinet of the isolator to permit its operation through local or
remote push buttons.
d) Provision shall be made in the control cabinet to disconnect power supply to prevent
local/remote power operation.
e) Motor shall be an AC motor and conform to the requirements of VOLUME-I, TR.
f) Suitable reduction gearing shall be provided between the motor and the drive shaft of the
isolator. The mechanism shall stop immediately when motor supply is switched off. If
necessary a quick electromechanical brake shall be fitted on the higher speed shaft to
effect rapid braking.
g) Manual operation facility (with handle) should be provided with necessary interlock to
disconnect motor.
h) Gear should be of forged material suitably chosen to avoid bending/jamming on
operation after a prolonged period of non operation. Also all gear and connected
material should be so chosen/surface treated to avoid rusting.
i) Only stranded conductor shall be used for wiring. Minimum size of the conductor for
control circuit wiring shall be 1.5 sq.mm. (Copper).
j) The operating mechanism shall be located such that it can be directly mounted on any
one of the support structure.
6.0 Operation
a) The main Isolator and earth switches shall be individual pole operated for 800/420 kV
and gang operated in case of 245 kV & 145 kV. However, 245 kV Tandem Isolators
shall be individual-pole operated. The operating mechanism of the three poles shall be
well synchronized and interlocked.
b) The design shall be such as to provide maximum reliability under all service conditions.
All operating linkages carrying mechanical loads shall be designed for negligible
deflection. The length of inter insulator and interpole operating rods shall be capable of
adjustments, by means of screw thread which can be locked with a lock nut after an
Volume-II (Section-B), Isolator 34
adjustment has been made. The isolator and earth switches shall be provided with “over
center” device in the operating mechanism to prevent accidental opening by wind,
vibration, short circuit forces or movement of the support structures.
c) Each isolator/pole of isolator and earth switch shall be provided with a manual operating
handle enabling one man to open or close the isolator with ease in one movement while
standing at ground level. Non-detachable type manual operating handle shall have
provision for padlocking. For detachable type manual operating handles, suitable
provision shall be made inside the operating mechanism box for parking the detached
handles. The provision of manual operation shall be located at a convenient operating
height from the base of isolator support structure.
d) The isolator shall be provided with positive continuous control throughout the entire
cycle of operation. The operating pipes and rods shall be sufficiently rigid to maintain
positive control under the most adverse conditions and when operated in tension or
compression for isolator closing. They shall also be capable of withstanding all torsional
and bending stresses due to operation of the isolator. Wherever supported the operating
rods shall be provided with bearings on either ends. The operating rods/ pipes shall be
provided with suitable universal couplings to account for any angular misalignment.
e) All rotating parts shall be provided with grease packed roller or ball bearings in sealed
housings designed to prevent the ingress of moisture, dirt or other foreign matter.
Bearings pressure shall be kept low to ensure long life and ease of operation. Locking
pins wherever used shall be rustproof.
f) Signaling of closed position shall not take place unless it is certain that the movable
contacts, have reached a position in which rated normal current, peak withstand current
and short time withstand current can be carried safely. Signaling of open position shall
not take place unless movable contacts have reached a position such that clearance
between contacts is atleast 80% of the isolating distance.
g) The position of movable contact system (main blades) of each of the Isolators and
earthing switches shall be indicated by a mechanical indicator at the lower end of the
vertical rod of shaft for the Isolators and earthing switch. The indicator shall be of metal
and shall be visible from operating level.
h) The contractor shall furnish the following details along with quality norms, during
detailed engineering stage.
(i) Current transfer arrangement from main blades of isolator alongwith milli volt drop
immediately across transfer point.
Volume-II (Section-B), Isolator 35
(ii) Details to demonstrate smooth transfer of rotary motion from motor shaft to the
insulator along with stoppers to prevent over travel.
7.0 Terminal Connector Stud/Pad
The isolator terminal pads/studs shall be made of high quality copper or aluminum and shall
be conforming to Australian standard AS-2935 for rated current. The terminal pad shall have
protective covers which shall be removed before interconnections.
8.0 Support Structure
800 kV/420 kV/245 kV/145 kV Isolators shall be suitable for mounting on support structures
to be supplied in accordance with stipulations of VOLUME-I, TR.
9.0 Tests
9.1 In continuation to the requirements stipulated under VOLUME-I, TR the isolator alongwith
its earthing switch and operating mechanism should have been type tested as per IEC/IS and
shall be subjected to routine tests in accordance with IEC-62271-102. Minimum 1000 Nos.
mechanical operations in line with mechanical endurance test, M0 duty, shall be carried out
on 1 (one) isolator out of every lot of Isolators, assembled completely with all accessories, as
acceptance test for the lot. The travel characteristics measured at a suitable location in the
base of insulator along with motor current/power drawn, during the entire travel duration are
to be recorded at the start and completion and shall not vary by more than (+/-) 10% after
completion of 1000 cycles of operation. After completion of test, mechanical interlock
operation to be checked.
9.2 The test reports of the type tests and the following additional type tests (additional type tests
are required for isolators rated above 72.5 kV only) shall also be submitted for the
Purchaser’s review.
(i) Radio interference voltage test as per Annexure-I of Volume-I, TR.
(ii) Corona Extinction Voltage test as per Annexure- I of Volume-I, TR (for 800/420 kV
Isolators only).
(iii) Seismic withstand test on isolator mounted on Support structure as per Annexure-II of
Volume-I, TR. The test shall be performed in the following position:
Isolator open E/S Closed
Isolator open E/S Open
Isolator Closed E/S Open
Volume-II (Section-B), Isolator 36
10.0 Spare Parts and Maintenance Equipment
Bidder shall include in his proposal mandatory spare parts in accordance with the
requirements.
11.0 Pre-Commissioning Tests
11.1 An indicative list of tests on isolator and earth switch is given below. Contractor shall
perform any additional test based on specialties of the items as per the field Q.P./instructions
of the equipment Supplier or Purchaser without any extra cost to the Purchaser. The
Contractor shall arrange all instruments required for conducting these tests along with
calibration certificates and shall furnish the list of instruments to the
Purchaser for approval
(a) Insulation resistance of each pole.
(b) Manual and electrical operation and interlocks.
(c) Insulation resistance of control circuits and motors.
(d) Ground connections.
(e) Contact resistance.
(f) Proper alignment so as to minimize vibration during operation.
(g) Measurement of operating Torque for isolator and Earth switch.
(h) Resistance of operating and interlocks coils.
(i) Functional check of the control schematic and electrical & mechanical interlocks.
(j) 50 operations test on isolator and earth switch.
Volume-II (Section-B), Isolator 37
TECHNICAL PARTICULARS OF ISOLATORS
1.0 Technical Particulars:
a) 800 kV ISOLATORS:
i) Type Outdoor
ii) Rated current at 50°C ambient 3150 A
temperature
iii) Rated short time withstand current 40 kA for 1 Sec.
of isolator and earth switch
iv) Rated dynamic short circuit withstand 102 kAp
current of isolator and earth switch
v) Temperature rise over design As per Table-3 of IEC-62271-1
ambient temperature of 50°C
vi) Rated mechanical terminal load As per Table-3 ofIEC:62271-102
(for 4000A) or as per value
calculated in Section – VOLUME-I,
TR whichever is higher
vii) Operating mechanism of isolator A.C. Motor operated /earth switch
viii) No. of auxiliary contacts on each 5 NO + 5 NC contacts wired to
isolator terminal block exclusively for
Purchaser’s use in future
ix) No. of auxiliary contacts on each 3 NO + 3 NC Contacts wired
earthing switch to terminal block
exclusively for Purchaser’s use in
future.
x) Operating time 20 sec. or less
xi) Number of terminal in control All contacts & control circuits are to
cabinet (Interpole cabling shall be wired up to control cabinet plus
be supplied by Contractor) 24 spare terminals evenly distributed.
Volume-II (Section-B), Isolator 38
b) 420 kV ISOLATORS:
i) Type Outdoor
ii) Rated current at 50°C 2000 A / 3150 A (as applicable)
ambient temperature
iii) Rated short time withstand 50 kA
current of isolator and earth switch
(for 1 Sec.)
iv) Rated dynamic short circuit withstand 125 kAp
current of isolator and earth switch
v) Temperature rise over design As per Table-3 of IEC-62271-1
ambient temperature
vi) Rated mechanical terminal load. As per table III of IEC-62271-102 or
as per value calculated in Section-
VOLUME-I, TR whichever is higher.
vii) Operating mechanism of A.C. Motor operated
Isolator/earth switch
viii) No. of auxiliary contacts on each 5 NO + 5 NC contacts wired to
isolator terminal block exclusively for
Purchaser’s use in future.
ix) No. of auxiliary contacts on each NO + 3 NC Contacts wired to
earthing switch 3 terminal block
exclusively for Purchaser’s use in
future.
x) Operating time 12 sec. or less
xi) Number of terminal in control All contacts & control circuits are
to
cabinet (Interpole cabling shall be wired upto control cabinet
be supplied by Contractor) plus 24 spare terminals evenly
distributed.
c) 245 kV ISOLATORS:
i) Type Outdoor
ii) Rated current at 50°C 3000A/ 2000A/ 1600A
ambient temperature
Volume-II (Section-B), Isolator 39
iii) Rated short time withstand current 40 kA
of isolator and earth switch (for 1 Sec.)
iv) Rated dynamic short circuit withstand 100 kAp
current of isolator and earth switch
v) Temperature rise over design ambient As per Table-3 of IEC-62271-1
temperature vi) Rated mechanical terminal load As per table III of IEC-62271-102
or
as per value calculated in Section-
VOLUME-I, TR whichever is
higher.
vii) Operating mechanism of isolator/ A.C. Motor operated
earth switch
viii) No. of auxiliary contacts on each Besides requirement of this spec.,
isolator 5 NO + 5 NC to contacts, wired to
terminal block exclusively for
Purchaser’s use in future
ix) No. of auxiliary contacts on each Besides requirement of this spec.,
earthing switch the bidder shall
wire up 3 NO + 3 NC to TBs
(Reversible) for Purchaser’s future
use.
x) Operating time 12 sec. or less
xi) Number of terminal in control All contacts & control circuits are to
cabinet (Interpole cabling shall be be wired upto control cabinet plus
supplied by Contractor) 24 spare terminals evenly
distributed
d) 145 kV ISOLATORS:
i) Type Outdoor
ii) Rated current at 50°C 2000A/ 1250 A
ambient temperature
Volume-II (Section-B), Isolator 40
iii) Rated short time withstand current 31.5 kA for 1 Sec.
of isolator and earth switch (for 1 Sec.)
iv) Rated dynamic short circuit withstand 80 kAp
v) Temperature rise over design ambient As per Table-3 of IEC-62271-1
temperature vii) Rated mechanical terminal load As per table III of IEC-62271-102
Or as per value calculated in
Section-VOLUME-I, TR
whichever is higher.
x) Operating mechanism of isolator/ A.C. Motor operated
earth switch
xi) No. of auxiliary contacts on each Besides requirement of this spec.,
isolator 5 NO + 5 NC to contacts, wired to
terminal block exclusively for
Purchaser’s use in future.
xii) No. of auxiliary contacts on each Besides requirement of this spec.,
earthing switch the bidder shall wire up 3 NO + 3
NC to TBs (Reversible) for
Purchaser’s future use.
x) Operating time 12 sec. or less
xi) Number of terminal in control All contacts & control circuits are to cabinet (Interpole cabling shall be be wired upto control cabinet plus supplied by Contractor) 24 spare terminals evenly distributed
e) TECHNICAL PARAMETERS FOR 36 KV ISOLATOR
1. Rated voltage 36kV
2. Rated current 400 A
3. Standards IEC 62271-102
4. Rated short time 25KA for 3 sec
5. Operating drive Motor operated
6. Type Double break Isolator without E/S, 3
Volume-II (Section-B), Isolator 41
pole, outdoor, Gang operated.
7. Interlock Pad locking of operating handle for
preventing unauthorized preventing
operation.
8. Construction All ferrous parts to be galvanized
except nuts and bolts which shall be
electroplated as per relevant IS.
9. Terminal connector To suit site conditions and layout
requirements.
10 Operating time As applicable
Volume-II (Section-C), Instrument Transformer 42
SECTION-C
TECHNICAL DETAILS OF INSTRUMENT TRANSFORMERS
1.0 GENERAL:
1.1 The instrument transformers and accessories shall conform to the latest version of the
standards specified below except to the extent explicitly modified in the specification and
shall be in accordance with the requirements in VOLUME-I, TR.
Current Transformers : IEC: 60044-1 (or IS: 2705)
Capacitive Voltage Transformers : IEC: 60044-5 / IEC-60358
Inductive Voltage Transformers : : IEC: 60044-2
1.2 The instrument transformers shall be complete with its terminal box and a common
marshalling box for a set of 3 instrument transformers.
1.3 The external surface of instrument transformer, if made of steel, shall be hot dip galvanized
or painted as per VOLUME-I, TR.
1.4 The impregnation details alongwith tests/checks to ensure successful completion of
impregnation cycle shall be furnished for approval.
1.5 The instrument transformers shall be designed for use in geographic and meteorological
conditions as given in VOLUME-I, TR.
2.0 CONSTRUCTION FEATURES:
The features and constructional details of instrument transformers shall be in accordance
with requirements stipulated hereunder:
2.1 a) Instrument transformers shall be of 800/420/245/145 kV class, oil filled/ SF6 gas filled,
suitable for outdoor service and upright mounting on steel structures. 420/245/145 kV
Instrument transformers and 800 kV CVT shall be with shedded porcelain/ polymer
bushings/Insulators However, 800kV CTs shall be acceptable only with polymer
Insulator.
b) Bushings/Insulators shall conform to requirements stipulated in, VOLUME-I, TR. The
bushing/insulator for CT shall be one piece without any metallic flange joint.
c) Oil filling and drain plugs, oil sight glass shall be provided for CT and for
electromagnetic unit of CVT etc. The Instrument transformer shall have cantilever
strength of not less than 500 kg, 500 kg, 350 kg and 350 kg respectively for
800/420/245/145 kV Instrument transformers. For CVT with polymer housing, the
Volume-II (Section-C), Instrument Transformer 43
cantilever strength shall not be less than 150kg. Oil filling and drain plugs are not
required with SF6 gas filled CT.
d) Instruments transformers shall be hermetically sealed units. Bidder/ Manufacturer shall
furnish details of the arrangements made for the sealing of instrument transformers
during detailed engineering.
Bidder/Manufacturer shall also furnish the details of site tests to check the effectiveness
of hermetic sealing for approval.
e) Polarity marks shall indelibly be marked on each instrument transformer and at the lead
terminals at the associated terminal block.
f) In case of SF6 filled CTs/Inductive VTs, it shall be provided with a suitable SF6 gas
density monitoring device, with NO/NC contacts to facilitate the remote annunciation
and tripping in case of SF6 leakage. Provisions shall be made for online gas filling.
Suitable rupture disc shall be provided to prevent explosion.
2.2 Terminal box/Marshalling Box:
Terminal box shall conform to the requirements of VOLUME-I, TR.
2.3 Insulating Oil:
a) Insulating oil to be used for instrument transformers shall be of EHV grade and shall
conform to IS-335 / IEC - 60296 (required for first filling). Non–PCB based synthetic
insulating oil conforming to IEC 60867 can also be used in the capacitor units of CVT
with specific approval from the owner, the proposal for which shall be submitted during
detailed engineering stage.
b) The SF6 gas shall comply with IEC-60376, 60376A and 60376B and shall be suitable in
all respects for use in the switchgear under operating conditions.
2.4 Name Plate:
Name plate shall conform to the requirements of IEC incorporating the year of manufacture.
The rated current, extended current rating in case of current transformers and rated voltage,
voltage factor in case of voltage transformers shall be clearly indicated on the name plate.
The rated thermal current in case of CT shall also be marked on the name plate.
The intermediate voltage in case of capacitor voltage transformer shall be indicated on the
name plate.
Volume-II (Section-C), Instrument Transformer 44
3.0 CURRENT TRANSFORMERS:
a) Current transformers shall have single primary either ring type, or hair pin type and
suitably designed for bringing out the secondary terminals in a weather proof (IP 55)
terminal box at the bottom. PF Terminal for measurement of tan delta and capacitance of
the unit shall be provided. These secondary terminals shall be terminated to stud type
non disconnecting terminal blocks inside the terminal box. In case “Bar primary”
inverted type current transformers are offered the manufacturer will meet following
additional requirements:
(i) The secondaries shall be totally encased in metallic shielding providing a uniform
equi-potential surface for even electric field distribution.
(ii) The lowest part of the insulation assembly shall be properly secured to avoid any
risk of damage due to transportation stresses.
(iii) The upper part of insulation assembly resting on primary bar shall be properly
secured to avoid any damage during transportation due to relative movement
between insulation assembly & top dome.
(iv) Nitrogen if used for hermetic sealing (in case of live tank design) should not come in
direct contact with oil.
(v) Bidder/Manufacturer shall recommend whether any special storage facility is
required for spare CT.
b) Different ratios specified shall be achieved by secondary taps only and primary
reconnection shall not be accepted.
c) Core lamination shall be of cold rolled grain oriented silicon steel or other equivalent
alloys. The cores used for protection shall produce undistorted secondary current under
transient conditions at all ratios with specified CT parameters.
d) The expansion chamber at the top of the porcelain insulators should be suitable for
expansion of oil.
e) Facilities shall be provided at terminal blocks in the marshalling box for star delta
formation, short circuiting and grounding of CT secondary terminals.
f) Current transformer’s guaranteed burdens and accuracy class are to be intended as
simultaneous for all cores.
g) The rated extended currents for 800 kV and 420 kV class Current transformers shall be
as given below:
Volume-II (Section-C), Instrument Transformer 45
800kV, 3000A 400kV, 3000A 400kV, 2000A
Tap Ratio Rated extended currents in % of rated current
500/1 200 200 200
1000/1 -- -- 200
2000/1 180 180 120 (200 for 15 min)
3000/1 120 (200 for 15 min) 120 --
The secondary winding shall be rated for 2A continuously.
Further, the intermediate tapping at 3000-2000 of metering core of 3000 A rated 400 kV
and 800 kV CTs shall be suitable for using as 1000/1 ratio. The requirements of 3000A
CTs are given at TABLE-7.
For 245/145 kV class CTs, the rated extended primary current shall be 120% (or 150% if
applicable) on all cores of the CTs.
h) For 800/420/245/145 kV current transformer, characteristics shall be such as to provide
satisfactory performance of burdens ranging from 25% to 100% of rated burden over a
range of 5% to 120%(or specified rated extended current whichever is higher) of rated
current in case of metering CTs and up to the accuracy limit factor/knee point voltage in
case of relaying CTs.
i) The current transformer shall be suitable for horizontal transportation. It shall be ensured
that the CT is able to withstand all the stresses imposed on it while transporting and
there shall be no damage in transit. The Contractor shall submit the details of packing
design to the Purchaser for review.
j) For 800 kV CTs the instrument security factor at all ratios shall be less than ten (10) for
metering core. For 420/245/145 kV CTs the instrument security factor at all ratios shall
be less than five (5) for metering core. If any auxiliary CTs/reactor are used in the
current transformers then all parameters specified shall have to be met treating auxiliary
CTs as an integral part of the current transformer. The auxiliary CTs/reactor shall
preferably be inbuilt construction of the CTs. In case these are to be mounted separately
these shall be mounted in the central marshalling box suitably wired upto the terminal
blocks.
k) The wiring diagram plate for the interconnections of the three single phase CTs shall be
provided inside the marshalling box.
Volume-II (Section-C), Instrument Transformer 46
l) The current transformers should be suitable for mounting on lattice support structure (for
800 kV) or pipe structure (for 420 kV and below) to be provided by the Contractor in
accordance with stipulations of VOLUME-I, TR.
m) The CT shall be so designed as to achieve the minimum risks of explosion in service.
Bidder/Manufacturer shall bring out in his offer, the measures taken to achieve this.
n) 800/420/245/145 kV current transformers shall be suitable for high speed auto reclosing.
4.0 VOLTAGE TRANSFORMERS:
a) 800/420/245/145 kV Voltage transformers shall be capacitor voltage divider type with
electromagnetic units and shall be suitable for carrier coupling.
b) Voltage transformers secondaries shall be protected by HRC cartridge type fuses for all
the windings. In addition fuses shall be provided for the protection and metering
windings for fuse monitoring scheme. The secondary terminals of the CVTs shall be
terminated to the stud type non - disconnecting terminal blocks in the individual phase
secondary boxes via the fuse.
c) CVTs shall be suitable for high frequency (HF) coupling required for power line carrier
communication. Carrier signal must be prevented from flowing into potential
transformer (EMU) circuit by means of a RF choke/reactor suitable for effectively
blocking the carrier signals over the entire carrier frequency range i.e. 40 to 500 KHz.
Details of the arrangement shall be furnished along with the bid. H.F. terminal of the
CVT shall be brought out through a suitable bushing and shall be easily accessible for
connection to the coupling filters of the carrier communication equipment, when
utilised. Further, earthing link with fastener to be provided for HF terminal.
d) The electromagnetic unit comprising compensating reactor, intermediate transformer
and protective and damping devices should have separate terminal box with all the
secondary terminals brought out.
e) The damping device, which should be permanently connected to one of the secondary
windings, should be capable of suppressing the ferroresonance oscillations.
f) The accuracy of 0.2 on secondary III for all CVTs should be maintained throughout the
entire burden range upto 50 VA on all the windings without any adjustments during
operation.
g) 420/245/145 kV CVTs shall be suitable for mounting on tubular GI pipe in accordance
with stipulations of VOLUME-I, TR.
Volume-II (Section-C), Instrument Transformer 47
h) It should be ensured that access to secondary terminals is without any danger of access
to high voltage circuit.
i) A protective surge arrester shall be provided if required, to prevent breakdown of
insulation by incoming surges and to limit abnormal rise of terminal voltage of shunt
capacitor/primary winding, tuning reactor/RF choke etc. due to short circuit in
transformer secondaries. In case of an alternate arrangement, bidder shall bring out the
details in the bid.
j) The wiring diagram for the interconnection of the three single phase CVTs shall be
provided inside the marshalling box in such a manner that it does not deteriorate with
time.
5.0 TERMINAL CONNECTORS:
The terminal connectors shall meet the requirements as given in VOLUME-I, TR.
6.0 TESTS:
6.1 In accordance with the requirements in VOLUME-I, TR, Current and Voltage Transformers
should have been type tested and shall be subjected to routine tests in accordance with
IEC:60044-1/IS:2705 and IEC: 60044-5/60044-2 respectively.
6.2 The test reports of the type tests and the following additional type tests (additional type tests
are required for Instrument Transformers, rated above 72.5 kV only) shall also be submitted
for the Purchaser’s review.
a) Current Transformers:
i) Corona & Radio interference voltage test as per Annexure-1 of VOLUME-I, TR &
IEC 60044-1.
ii) Seismic withstand test as per Annexure-2 of VOLUME-I, TR.
iii) Thermal stability test, i.e. application of rated voltage and rated extended thermal
current simultaneously by synthetic test circuit. (not applicable for SF6 filled CT)
iv) Thermal co-efficient test i.e. measurement of tan delta as a function of temperature
(at ambient and between 80°C & 90°C) and voltage (at 0.3, 0.7, 1.0 and 1.1 Um/√3)
(not applicable for SF6 filled CT)
v) The current transformer shall be subjected to Multiple chopped impulse test (not
applicable for SF6 filled CT) by any one of the following two methods given below
to assess the CT performance in service to withstand the high frequency over
voltage generated due to closing & opening operation of isolators. Alternatively,
method as per IEC: 60044-1 may be followed:
Volume-II (Section-C), Instrument Transformer 48
Method I: 600 negative polarity lightning impulses chopped on crest will be applied
to current transformer. The opposite polarity amplitude must be limited to 50% of
crest value when the wave is chopped. Impulse crest values will be 1000 kVp for
420 kV CTs. One impulse per minute shall be applied and every 50 impulse high
frequency currents form the windings and total current to earth will be recorded and
be compared with reference currents recorded applying one or more (max 20)
reduced chopped impulses of 50% of test value.
Oil samples will be taken before and 3 days after the test. Gas analysis must not
show appreciable rate of increase in various gases related with the results of the
analysis performed before test.
Total sum of crest values of current through secondaries must not exceed 5% of the
crest value of total current to earth. CT must withstand dielectric tests after this test
to pass the test.
Method II: 100 negative polarity impulses with a rise and fall time of less than 0.25
microsecond having 950 kV for 420 kV CT corrected to atmospheric condition shall
be applied at one minute interval and total current through insulation of earth will be
recorded. The amplitude of first opposite polarity should be limited to 50% of the
chopped impulse crest value. Voltage and total current wave shapes shall be
recorded after every 10 impulses, and will be compared with reference wave shapes
recorded before test at 50% of test values.
Oil sample shall be taken before and 3 days after the test and CT shall be deemed to
have passed the test if the increase in gas content before and after test is not
appreciable.
b) Voltage transformers:
i) High frequency capacitance and equivalent series resistance measurement (as per
IEC-60358).
ii) Seismic withstand test (as per Annexure-II of VOLUME-I, TR).
iii) Stray capacitance and stray conductance measurement of the low voltage terminal
(as per IEC-60358).
iv) Determination of temperature coefficient test (as per IEC-60358).
v) Corona & Radio interference voltage test as per IEC-60044-5, IEC- 60044-2 or as
per Annexure-I of VOLUME-I, TR. However the RIV level shall be as specified in
clause Major Technical Parameters in VOLUME-I, TR.
Volume-II (Section-C), Instrument Transformer 49
vi) Apart from the above, report of all special tests mentioned in IEC- 60044-5 for
Capacitive Voltage Transformer shall also be submitted for approval.
6.3 The current and voltage transformer shall be subjected to the following routine tests in
addition to routine tests as per IEC/IS.
a) CURRENT TRANSFORMERS:
ROUTINE TESTS:
For Oil filled CTs:
i) Measurement of Capacitance.
ii) Oil leakage test.
iii) Measurement of tan delta at 0.3, 0.7, 1.0 and 1.1 Um/√3.
For SF6 filled CTs:
i) Dew point measurement
ii) SF6 alarm/ lockout check.
iii) SF6 gas leakage test: Gas leakage rate shall be maintained within 0.2% per
annum.
b) VOLTAGE TRANSFORMERS:
Routine tests on Capacitive voltage transformer shall be done in line with IEC-60044-
5.
7.0 SPARE PARTS AND MAINTENANCE EQUIPMENT:
The Bidder shall include in his proposal spare parts equipment.
8.0 PRE-COMMISSIONING TESTS
8.1 An indicative list of tests is given below. Contractor shall perform any additional test based
on specialties of the items as per the field Q.P./Instructions of the equipment Supplier or
Purchaser without any extra cost to the Purchaser. The Contractor shall arrange all
instruments required for conducting these tests along with calibration certificates and shall
furnish the list of instruments to the Purchaser for approval.
8.2 Current Transformers
(a) Insulation Resistance Test for primary and secondary.
(b) Polarity test
Volume-II (Section-C), Instrument Transformer 50
(c) Ratio identification test - checking of all ratios on all cores by primary injection of
current.
(d) Dielectric test of oil (wherever applicable).
(e) Magnetizing characteristics test.
(f) Tan delta and capacitance measurement
(g) Secondary winding resistance measurement
(h) Contact resistance measurement (wherever possible/accessible).
(i) Test for SF6 (for SF6 filled CTs) – Dew point measurement, SF6 alarm/ lockout
check.
(j) DGA test of oil.
Dissolved gas analysis to be carried out at the time of commissioning. CTs must have
adequate provision for taking oil samples from the bottom of the CT without exposure to
atmosphere. Bidder/Manufacturer shall recommend the frequency at which oil samples
should be taken and norms for various gases in oil after being in operation for different
durations. Bidder/Manufacturer should also indicate the total quantity of oil which can be
withdrawn from CT for gas analysis before refilling or further treatment of CT becomes
necessary.
8.3 Voltage Transformers/Capacitive Voltage Transformers
(a) Insulation Resistance test for primary (if applicable) and secondary winding.
(b) Polarity test
(c) Ratio test
(d) Dielectric test of oil (wherever applicable).
(e) Tan delta and capacitance measurement of individual capacitor stacks.
(f) Secondary winding resistance measurement.
NOTE: Even Though metering CT & VT are not shown in the Single Line Diagram,
same shall be included in Scope and quoted accordingly. They should comply
with necessary guidelines issued by CEA.
Volume-II (Section-C), Instrument Transformer 51
TECHNICAL PARTICULARS OR INSTRUMENT TRANSFORMERS
1.1 420 kV Current Transformers:
i) Rated Primary current 2000 A/3150A (as applicable)
ii) Rated short time thermal 50kA
current for 1 sec.
iii) Rated dynamic current 125kA (peak)
iv) Maximum temperature rise As per IEC: 60044-1
over design ambient temperature
v) One minute power frequency 5 kV withstand voltage sec.
terminal & earth
vi) Number of terminals All terminals of control circuits are
to be wired upto marshaling box
plus 20% spare terminals evenly
distributed on all TBs.
vii) Type of insulation Class A
Current transformers shall also comply with requirements of Table - 6.
1.2 245 kV Current Transformers:
i) Rated Primary current 1600 A
ii) Rated short time thermal 40 kA for 1 sec/50 kA
current for 1 sec. (as applicable)
iii) Rated dynamic current kA (peak) 100
iv) Maximum temperature rise As per IEC: 60044-1
over design ambient temperature
v) One minute power frequency 5 kV
withstand voltage sec. terminal & earth
Volume-II (Section-C), Instrument Transformer 52
vi) Number of terminals All terminals of control circuits are
to be wired upto marshaling box
plus 20% spare terminals evenly
distributed on all TBs.
vii) Type of insulation Class A
Current transformers shall also comply with requirements of Table - 7.
1.3 145 kV Current Transformers:
i) Rated Primary current 1250A
ii) Rated short time thermal 31.5 kA for 1 sec.
current
iii) Rated dynamic current 80 kA (peak)
iv) Maximum temperature rise As per IEC: 60044-1
over design ambient temperature
v) One minute power frequency 5 kV
withstand voltage sec. terminal & earth
vi) Number of terminals All terminals of control circuits are
to be wired upto marshaling box
plus 20% spare terminals evenly
distributed on all TBs.
vii) Type of insulation Class A
Current transformers shall also comply with requirements of Table-8/ or 9 as
applicable.
1.4 Technical Particulars For 800 kV CT:
i) Rated Primary current 3000A
ii) Rated short time thermal 40 kA for one (1) second current
iii) Rated dynamic current 102 kA (peak)
iv) Maximum temperature rise As per IEC: 60044-1
over design ambient temperature
Volume-II (Section-C), Instrument Transformer 53
v) One minute power frequency 5 kV
withstand voltage sec. terminal & earth
vi) Number of terminals All terminals of control circuits are
to be wired up to marshaling box
plus 20% spare terminals evenly
distributed on all TBs.
vii) Class of insulation A
800 kV Current transformers shall also comply with requirements of Table -5.
2.1 420 kV Voltage Transformers:
i) System fault level (for 1 second) 50 kA
ii) Standard reference range 96% to 102% for protection and
of frequencies for which 99% to 101% for measurement
the accuracies are valid
iii) High frequency capacitance Within 80% to 150% of rated for
entire carrier frequency range
capacitance (for CVT only)
iv) Equivalent series resistance Less than 40 ohms (for CVT only)
over the entire carrier frequency range
v) Stray capacitance and stray As per IEC: 358 (for CVT only)
conductance of the LV
terminal over entire carrier frequency
vi) One minute power frequency withstand voltage:
i) Between LV (HF) terminal 10 kV (rms) for exposed terminals
and earth terminal and 4 KV (rms) for terminals
enclosed
in a weather proof box
ii) For secondary winding 3 kV (rms)
vii) Maximum temperature rise As per IEC: 60044-2 or 60044-5
over design ambient temperature
viii) Number of terminals in All terminals are wired upto control
cabinet (interpole cabling is to marshaling box plus 12 terminals
Volume-II (Section-C), Instrument Transformer 54
be supplied by Purchaser) exclusively for Purchaser’s use.
ix) Rated Total Thermal 300 (100VA/winding)
burden (VA)
Voltage Transformers shall also comply with the requirements of Table-2 of this
Section.
2.2 245 kV Voltage Transformers:
i) System fault level (for 1 second) 40 kA
ii) Standard reference range 96% to 102% for protection and
of frequencies for which 99% to 101% for
measurement the accuracies are valid
ii) High frequency capacitance Within 80% to 150% of rated
for entire carrier frequency capacitance (for CVT only) range
iv) Equivalent series resistance Less than 40 ohms (for CVT only)
over the entire carrier frequency range
v) Stray capacitance and As per IEC: 358 (for CVT only)
stray conductance of the LV terminal
over entire carrier frequency range
vi) One minute power frequency withstand voltage:
i) Between LV (HF) terminal 10 kV (rms) for exposed terminals
and earth terminal and 4 KV (rms) for terminals
enclosed in a weather proof box.
ii) For secondary winding 3 kV (rms)
vii) Maximum temperature rise As per IEC: 60044-2 or 60044-5
over design ambient temperature
viii) Number of terminals in control All terminals are wired upto
cabinet (interpole cabling is to marshaling box plus 12 terminals
be supplied by Purchaser) exclusively for Purchaser’s use.
ix) Rated Total Thermal burden (VA) 300 (100VA/winding)
Voltage Transformers shall also comply with the requirements of Table-3 of
this Section.
2.3 145 kV Voltage Transformers:
Volume-II (Section-C), Instrument Transformer 55
i) System fault level 31.5 kA for 1 second
ii) Standard reference range 96% to 102% for protection and
of frequencies for which 99% to 101% for measurement
the accuracies are valid
iii) High frequency capacitance Within 80% to 150% of rated
for entire carrier frequency capacitance (for CVT only)
range
iv) Equivalent series resistance Less than 40 ohms (for CVT only)
over the entire carrier frequency
range
v) Stray capacitance and stray As per IEC: 358 (for CVT only)
conductance of the LV terminal
over entire carrier frequency range
vi) One minute power frequency withstand voltage:
i) Between LV (HF) terminal and 10 kV (rms) for exposed terminals
earth terminal and 4 KV (rms) for
terminals enclosed in
a weather proof box
ii) For secondary winding 3 kV (rms)
vii) Maximum temperature rise As per IEC: 60044-2 or 60044-5
over design ambient temperature
viii) Number of terminals in control All terminals are wired upto
cabinet (interpole pole cabling is marshaling box plus 12 terminals
to be supplied by Purchaser) exclusively for Purchaser’s use.
ix) Rated Total Thermal 300 (100VA/winding)
burden (VA)
Voltage Transformers shall also comply with the requirements of Table-4 of this
Section.
2.4 800 kV Capacitive Voltage Transformers:
i) System fault level 40 kA for one (1) second
Volume-II (Section-C), Instrument Transformer 56
ii) Standard reference range 96% to 102% for protection and
of frequencies for which 99% to 101% for
measurement the accuracies are valid
iii) High frequency capacitance Within 80% to 150% of rated
for entire carrier frequency range capacitance
iv) Equivalent series resistance over Less than 40 ohms.
the entire carrier frequency range
v) Stray capacitance and stray As per IEC: 60358
conductance of the LV terminal
over entire carrier frequency range
vi) One minute power frequency withstand voltage :
i) Between LV (HF) terminal 10 kV (rms) for exposed terminals
and earth terminal and 4 KV (rms) for terminals
enclosed in a weather proof box
ii) For secondary winding 3 kV (rms)
vii) Maximum temperature rise IEC: 60044-2 or IEC: 60044-5
over design ambient temperature
viii) Number of terminals in control All terminals of control circuits are
cabinet (interpole cabling is to be wired upto marshaling box plus 12
supplied by Purchaser) by terminals exclusively for
Purchaser’s use.
ix) Rated Total Thermal 300 VA
burden (VA) Voltage
Volume-II (Section-C), Instrument Transformer 57
TABLE - 1
REQUIREMENTS OF 800 KV CAPACITIVE VOLTAGE TRANSFORMERS
S.No. PARTICULAR
1. Rated primary voltage (kV rms)
800
2. Type Single phase capacitor VT
3. No. of secondaries 3
4. Rated voltage factor 1.2 continuous 1.5 - 30 seconds
5. Phase angle error ±10 minutes (For metering core)
6. Capacitance (pf) 4400/8800 + 10% - 5%
Secondary I Secondary II Secondary III
7. Application Protection Protection Metering
8. Accuracy 3 P 3 P 3 P
9. Output burden (VA) (minimum)
50 50 50
10. Voltage Ratio 765/0.11 √3 √3
765/0.11 √3 √3
765/0.11 √3 √3
Volume-II (Section-C), Instrument Transformer 58
TABLE – 2
REQUIREMENTS OF 420 KV CAPACITIVE VOLTAGE TRANSFORMERS
S.No. PARTICULAR
1. Rated primary voltage (kV rms)
420
2. Type Single phase capacitor VT
3. No. of secondaries 3
4. Rated voltage factor 1.2 continuous 1.5 - 30 seconds
5. Phase angle error ±10 minutes (For metering core)
6. Capacitance (pf) 4400/8800 + 10% - 5%
Secondary I Secondary II Secondary III
7. Application Protection Protection Metering
8. Accuracy 3 P 3 P 3 P
9. Output burden (VA) (minimum)
50 50 50
10. Voltage Ratio 400/0.11 400/0.11 400/0.11
Volume-II (Section-C), Instrument Transformer 59
TABLE – 3
REQUIREMENTS OF 245 KV CAPACITIVE VOLTAGE TRANSFORMERS
S.No. PARTICULAR
1. Rated primary voltage (kV rms)
245
2. Type Single phase capacitor VT
3. No. of secondaries 3
4. Rated voltage factor 1.2 continuous 1.5 - 30 seconds
5. Phase angle error ±10 minutes (For metering core)
6. Capacitance (pf) 4400/8800* + 10% - 5%
Secondary I Secondary II Secondary III
7. Application Protection Protection Metering
8. Accuracy 3 P 3 P 0.2 P
9. Output burden (VA) (minimum)
50 50 50
10. Voltage Ratio 220/0.11 220/0.11 220/0.11
Volume-II (Section-C), Instrument Transformer 60
TABLE – 4
REQUIREMENTS OF 145 KV CAPACITIVE VOLTAGE TRANSFORMERS
S.No. PARTICULAR
1. Rated primary voltage (kV rms)
145
2. Type Single phase capacitor VT
3. No. of secondaries 3
4. Rated voltage factor 1.2 continuous 1.5 - 30 seconds
5. Phase angle error ±10 minutes (For metering core)
6. Capacitance (pf) 8800 + 10%/-5%
Secondary I Secondary II Secondary III
7. Application Protection Protection Metering
8. Accuracy 3 P 3 P 0.2 P
9. Output burden (VA) (minimum)
50 50 50
10. Voltage Ratio 132/0.11 132/0.11 132/0.11
Volume-II (Section-C), Instrument Transformer 61
TABLE-5
REQUIREMENTS FOR 800 KV CURRENT TRANSFORMERS
No. of Cores
Core No.
Application Current Ratio
Output Burden (VA)
Accuracy Class
Min.Knee Pt.Voltage (Vk)
Max. CT Sec. wdg. Resistance (in Ω )
Max. Excit. Current at Vk ( in mA)
6 1 BUS DIFF. CHECK
3000/ 2000/ 500/1
- TPS* 3000/ 2000/ 500
15 20 on 3000/1 TAP; 30 on 2000/1; 120 on 500/1 tap
2 BUS DIFF. MAIN
3000/ 2000/ 500/1
- TPS* 3000/ 2000/ 500
15 20 on 3000/1 TAP; 30 on 2000/1; 120 on 500/1 tap
3 METERING 3000/ 2000/ 500/1
20 20 20
0.2S 0.2S 0.2S
- - -
- - -
4 METERING 3000/ 2000/ 500/1
20 20 20
0.2S 0.2S 0.2S
- - -
- - -
5 TRANSF DIFF./LINE
PROTN.
3000/ 2000/ 500/1
- TPS* 3000/ 2000/ 500
15 20 on 3000/1 TAP; 30 on 2000/1; 120 on 500/1 tap
6 LINE PROTN/LBB PROTN.
3000- 2000- 500/1
- TPS* 3000/ 2000/ 500
15 20 on 3000/1 TAP; 30 on 2000/1; 120 on 500/1 tap
Note 1. * All Protection Cores shall be of accuracy class TPS as per IEC 60044-1. However, if a higher accuracy class CT is required for protection the same shall be provided.
2. Metering Core shall be of accuracy class 0.2 as per IEC: 60044-1
Volume-II (Section-C), Instrument Transformer 62
TABLE-6(a)
REQUIREMENTS FOR 420 KV CURRENT TRANSFORMERS RATED FOR 2000 A
No. of Cores
Core No.
Application Current Ratio
Output Burden (VA)
Accuracy Class as per IEC: 44-1
Min.Knee Pt.Voltage (Vk)
Max. CT Sec. wdg. Resistance (in Ω )
Max. Excit. Current atVk ( in mA)
5 1 BUS DIFF. CHECK
2000- 1000/1
- - 3000/ 2000/ 500
15 20 on 3000/1 TAP; 30 on 2000/1 Tap; 120 on 500/1 tap
2 BUS DIFF. MAIN
2000- 1000/1
- - 3000/ 2000/ 500
15 20 on 3000/1 TAP; 30 on 2000/1 Tap; 120 on 500/1 tap
3 METERING 2000- 1000- 500/1
20 20 20
0.2S 0.2S 0.2S
- - -
- - -
4 TRANS. BACK
UP./LINE PROTN
2000- 1000- 500/1
- - 3000/ 2000/ 500
15 20 on 3000/1 TAP; 30 on 2000/1 Tap; 120 on 500/1 tap
5 TRANS. DIFF./LINE
PROTN.
3000- 2000- 500/1
- - 3000/ 2000/ 500
15 20 on 3000/1 TAP; 30 on 2000/1 Tap; 120 on 500/1 tap
All relaying CTs shall be of accuracy class PS as per IS: 2705.
Volume-II (Section-C), Instrument Transformer 63
TABLE-6(a) cont’d
REQUIREMENTS FOR 420 KV CURRENT TRANSFORMERS RATED FOR 3000 A
Core No.
Application Current Ratio
Output Burden (VA)
Accuracy Class
Min.Knee Pt.Voltage (Vk)
Max. CT Sec. wdg. Resistance (in Ω )
Max. Excit. Current atVk ( in mA)
1 BUS DIFF. CHECK
3000/ 2000/ 500/1
- PS 2000/ 1000
10/5 20 on 3000/1 TAP; 30 on 2000/1 Tap; 120 on 500/1 tap
2 BUS DIFF. MAIN
3000/ 2000/ 500/1
- PS 2000/ 1000
10/5 20 on 3000/1 TAP; 30 on 2000/1 Tap; 120 on 500/1 tap
3 METERING 3000/ 2000/ 500/1
20 20 20
0.2S 0.2S 0.2S
-
- - -
4 TRANS. BACK
UP./LINE PROTN
3000/ 2000/ 500/1
- PS 4000/ 2000/ 1000
10/5/2.5 20 on 3000/1 TAP; 30 on 2000/1 Tap; 120 on 500/1 tap
5 TRANS. DIFF./LINE
PROTN.
3000/ 2000/ 500/1
- PS 4000/ 2000/ 1000
10/5/2.5 20 on 3000/1 TAP; 30 on 2000/1 Tap; 120 on 500/1 tap
All relaying CTs shall be of accuracy class PS as per IS: 2705.
Volume-II (Section-C), Instrument Transformer 64
TABLE - 7
REQUIREMENTS FOR 245 KV CURRENT TRANSFORMERS
No. of Cores
Core No.
Application Current Ratio
Output Burden (VA)
Accuracy Class as per IEC: 44-1
Min.Knee Pt.Voltage (Vk)
Max. CT Sec. wdg. Resistance (in Ω )
Max. Excit. Current at Vk ( in mA)
5 1 BUS DIFF. CHECK
1600- 800/1
- - 1600/ 800
8/4 25 on 1600/1 TAP; 50 on 800/1 Tap;
2 BUS DIFF. MAIN
1600- 800/1
- - 1600/ 800
8/4 25 on 1600/1 TAP; 50 on 800/1 Tap;
3 METERING 1600- 800/1
20
0.2S
-
-
4 TRANS. BACK
UP./LINE PROTN.
1600- 800/1
- - 1600/ 800
8/4 25 on 1600/1TAP; 50 on 800/1 Tap;
5 TRANS. DIFF./LINE
PROTN
1600- 800/1
- - 1600/ 800
8/4 25 on 1600/1 TAP; 50 on 800/1 Tap;
Volume-II (Section-C), Instrument Transformer 65
TABLE - 8
REQUIREMENTS FOR 145 KV CURRENT TRANSFORMERS
No. of
Cores
Core No.
Application Current Ratio
Output Burden (VA)
Accuracy Class as per IEC:
44-1
Min.Knee Pt.Voltage
(Vk)
Max. CT Sec. wdg. Resistance
(in Ω )
Max. Excit. Current at Vk ( in mA)
5 1 BUS DIFF. CHECK
800- 400/1
- - 800/ 400
8/4 25 on 1600/1 TAP; 50 on 400/1 Tap;
2 BUS DIFF. MAIN
800- 400/1
- - 800/ 400
8/4 25 on 1600/1 TAP; 50 on 400/1 Tap;
3 METERING 800- 400/1
20
0.2S
-
-
4 TRANS. BACK
UP./LINE PROTN.
800- 400/1
- - 800/ 400
8/4 25 on 1600/1 TAP; 50 on 400/1 Tap;
5 TRANS. DIFF./LINE
PROTN
800- 400/1
- - 800/ 400
8/4 25 on 1600/1 TAP; 50 on 400/1 Tap;
All relaying CTs shall be of accuracy class PS as per IS: 2705.
Volume-II (Section-C), Instrument Transformer 66
TABLE – 9
REQUIREMENTS FOR 145 kV CURRENT TRANSFORMERS
No. of
Cores
Core No.
Application Current Ratio
Output Burden (VA)
Accuracy Class as per IEC:
44-1
Min.Knee Pt.Voltage
(Vk)
Max. CT Sec. wdg. Resistance
(in Ω )
Max. Excit. Current at Vk ( in mA)
5 1 BUS DIFF. CHECK
600- 300/1
- - 600/ 300
6/3 30 on 600/1 TAP; 60 on 300/1 Tap
2 BUS DIFF. MAIN
600- 300/1
- - 600/ 300
6/3 30 on 600/1 TAP; 60 on 300/1 Tap
3 METERING 300- 150/1
20
0.2S
-
-
-
4 TRANS. BACK
UP./LINE PROTN.
600- 300/1
- - 600/ 300
6/3 30 on 600/1 TAP; 60 on 300/1 Tap
5 TRANS. DIFF./LINE
PROTN
600- 300/1
- - 600/ 300
6/3 30 on 600/1 TAP; 60 on 300/1 Tap
All relaying CTs shall be of accuracy class PS as per IS: 2705
Note: Details for 33kV Instrument Transformer are not furnished here, same may be decided
be Bidder/ Contractor.
Volume-II (Section-D), Surge Arrester 67
SECTION-D
TECHNICAL DETAILS OF SURGE ARRESTERS
1.0 GENERAL
1.1 The Surge arresters shall conform to IEC: 60099-4 except to the extent modified in the
specification and shall also be in accordance with requirements under VOLUME-I, TR.
1.2 Arresters shall be of hermetically sealed units, self supporting construction, suitable for
mounting on tubular support structures to be supplied by the Contractor.
1.3 The Surge Arrestors shall be designed for use in the geographic and meteorological
conditions as given in VOLUME-I, TR.
2.0 DUTY REQUIREMENTS:
a) The surge arresters shall be of heavy duty station class and gapless type without any
series or shunt gaps.
b) The surge arresters shall be capable of discharging over-voltages occurring during
switching of unloaded transformers, reactors and long lines.
c) 420 kV class Surge arresters shall be capable of discharging of severe re-energisation
switching surges on a 400 kV, 450 km long line with Surge impedance of 300 ohms
and capacitance of 11.986nF/km and over voltage factor of 2.3 p.u. 800 kV class Surge
arresters shall be capable of discharging of severe re-energisation switching surges on a
765 kV, 450 km line with Surge impedance of 270 ohms and capacitance of 13 nF/km.
d) 420 kV class arrester shall be capable of discharging energy equivalent to class 4 of
IEC for a 420 kV system on two successive operations followed immediately by 50 Hz
energisation with a sequential voltage profile as specified below:
650 kVp for 3 peaks
575 kVp for 0.1 Sec
550 kVp for 1 seconds
475 kVp for 10 seconds
800 kV class arrester shall be capable of discharging energy equivalent to class 5 of
IEC for an 800 kV system on two successive operation followed immediately by 50 Hz
energisation with a sequential voltage profile as specified below:
1000 kVp for 3 peaks
910 kVp for 0.1 Sec
Volume-II (Section-D), Surge Arrester 68
885 kVp for 1 seconds
866 kVp for 10 seconds
e) 245/145 kV class arrester shall be capable for discharging energy equivalent to class 3
of IEC for 245/145 kV system on two successive operations.
f) The surge arresters shall be suitable for withstanding forces as defined in VOLUME-I,
TR.
g) The reference current of the arresters shall be high enough to eliminate the influence of
grading and stray capacitance on the measured reference voltage.
h) The duty cycle of CB installed in 800/420/245/145 kV System of the Purchaser shall be
O-0.3 sec-CO-3 min-CO. The Surge Arrester shall be suitable for such circuit breaker
duties in the system.
3.0 CONSTRUCTIONAL FEATURES:
The features and constructional details of surge arresters shall be in accordance with
requirement stipulated hereunder:
a) The non-linear blocks shall be of sintered metal oxide material. These shall be provided
in such a way as to obtain robust construction, with excellent mechanical and electrical
properties even after repeated operations.
b) The surge arresters shall be fitted with pressure relief devices suitable for preventing
shattering of porcelain housing and providing path for flow of rated fault currents in the
event of arrester failure. Details shall be furnished in the bids along with quality checks.
c) The arresters shall not fail due to arrester porcelain contamination.
d) Seals shall be provided in such a way that these are always effectively maintained even
when discharging rated lightning current.
e) Outer insulator shall be porcelain/polymer conforming to requirements stipulated in
VOLUME-I, TR. Terminal connectors shall conform to requirements stipulated under
VOLUME-I, TR. The outer insulator housing shall be so coordinated that external
flashover will not occur due to application of any impulse or switching surge voltage
upto the maximum design value for arrester.
f) The end fittings shall be made of corrosion proof material and preferably be
nonmagnetic.
g) The name plate shall conform to the requirements of IEC incorporating the year of
manufacture.
Volume-II (Section-D), Surge Arrester 69
h) The heat treatment cycle details alongwith necessary quality checks used for individual
blocks alongwith insulation layer formed across each block are to be furnished.
Metalizing coating thickness for reduced resistance between adjacent discs is to be
furnished with additional information schedule of bid proposal sheets alongwith
procedure for checking the same. Details of thermal stability test for uniform
distribution of current on individual disc is to be furnished.
i) The manufacturer will submit Data for rejection rate of ZnO blocks during
manufacturing/operation for the past three years.
j) The sealing arrangement of the Surge Arrester stacks shall be done incorporating
grooved flanges with the O-rings/elliptical cross-section gaskets of Neoprene or Butyl
rubber.
k) The Surge arrester with porcelain housing shall have cantilever strength of not less than
500kg, 500 kg, 350 kg and 350 kg for 624/336/216/120kV surge arresters respectively
or as per the value obtained vide VOLUME-I, TR, whichever is higher. For Surge
arrester with polymer housing, the cantilever strength shall not be less than 150kg.
4.0 FITTINGS AND ACCESSORIES:
a) 624/336/216/120 kV/ 30 W Arresters shall be complete with insulating base having
provision for bolting to flat surface of structure.
b) Self contained discharge counters, suitably enclosed for outdoor use and requiring no
auxiliary or battery supply for operation shall be provided for each single pole unit
along with necessary connection. Suitable leakage current meters should also be
provided. The reading of milliammeter and counters shall be visible through an
inspection glass panel. The terminals shall be robust and of adequate size and shall be
so located that incoming and outgoing connections are made with minimum possible
bends.
c) Surge monitor consisting of discharge counters and milliammeters should be suitable to
be mounted on support structure of the arrester and should be tested for IP66 degree of
protection. The standard supporting structure for surge arrester should be provided with
a mounting pad, for fixing the surge monitor. The surge monitor should be suitable for
mounting on this standard mounting pad. Also all nuts, bolts, washers etc. required for
fixing the surge monitor shall have to be supplied by the Contractor. The arrangement
for Surge Monitor enclosure fixing to the structure shall be at its rear/bottom.
Connection between the Surge Arrester base and Surge Monitor shall be through a 2.0
m (minimum) long insulated copper rod/strip of at least 75 sq.mm cross sectional area.
Volume-II (Section-D), Surge Arrester 70
The cable shall be terminated at rear/bottom side of the Surge Monitor. The gaskets of
the surge monitors shall be of Neoprene, Butyl or equivalent material.
d) Grading/corona rings shall be provided on each complete arrester unit as required.
Suitable terminal connectors shall be supplied by the Contractor.
5.0 TESTS:
5.1 In accordance with the requirements stipulated under VOLUME-I, TR, the surge arresters
should have been type tested as per IEC/IS and shall be subjected to routine and acceptance
tests in accordance with IEC document For contamination test, procedures outlined in
60099-3 shall be followed.
The test reports of the type tests and the following additional type tests (additional type tests
are required for Surge Arresters above 72.5 kV class only) shall also be submitted for the
Purchaser’s review.
i) Radio interference voltage test as per IEC 60099-4.
ii) Seismic withstand test as per Annexure-II of VOLUME-I, TR.
iii) Contamination test.
iv) Test to verify the Power frequency versus time characteristics. Temporary over voltage
profile for 216 kV and below rated arresters to be mutually agreed. Each metal oxide
block of surge arresters shall be tested for the guaranteed specific energy capability in
addition to the routine/acceptance test as per IEC: 60099-4.
5.2 (a) Acceptance Tests:
1. Measurement of power frequency reference voltage of the arrester units.
2. Lightning Impulse Residual voltage on arrester units. (IEC clause 6.3.2).
3. Internal Ionisation or partial Discharge test.
(b) Special Acceptance Test:
1. Thermal stability test on three sections. (IEC Clause 7.2.2).
2. Aging & Energy Capability test on blocks (procedure to be mutually agreed).
3. Wattloss test.
(c) Routine Tests:
1. Sealing test: Water dip test at 1.5m depth from top of Surge Arrestor for 30 minutes
shall be performed during assembly of Surge Arrester stacks (followed by other
Volume-II (Section-D), Surge Arrester 71
routine tests, i.e. P.D. Measurement, Reference Voltage, Residual Voltage & IR
measurement).
2. Measurement of reference voltage.
3. Residual voltage test of arrester unit.
4. Internal Ionisation test or partial discharge test.
5. Verticality check on completely assembled Surge arresters as a sample test on each
lot.
(d) Test on Surge Monitors:
The Surge monitors shall also be connected in series with the test specimens during
residual voltage and current impulse withstand tests to verify efficacy of the same.
Additional routine/ functional tests with one 100A and 10kA current impulse (8/20
micro sec.) shall also be performed on the Surge monitor. Surge monitors shall be
routinely tested for water dip test at 1.5m for 30 minutes. No water vapors shall be
visible on the monitor glass.
(e) Test on insulators
All routine tests shall be conducted on the hollow column insulators as per IEC 62155.
The following additional tests shall be carried out on 800kV, 420 kV, 245 kV and 145
kV Insulators:
i) Ultrasonic test as a routine test.
ii) Pressure test as a routine test.
iii) Bending load test in 4 directions at 50% specified bending load as a routine test.
iv) Bending load test in 4 directions at 100% specified bending load as a sample test on
each lot.
v) Burst pressure test as a sample test on each lot. Polymer housing shall be tested in
accordance to IEC-61462.
6.0 SPARE PARTS AND MAINTENANCE EQUIPMENT:
Bidder shall include in his proposal spare parts and maintenance equipment.
7.0 PRE-COMMISSIONING TESTS
7.1 An indicative list of tests is given below.
(a) Operation check of LA counter.
(b) Insulation resistance measurement
Volume-II (Section-D), Surge Arrester 72
(c) Capacitance and Tan delta measurement of individual stacks.
(d) Third harmonic resistive current measurement (to be conducted after energisation.)
Contractor shall perform any additional test based on specialties of the items as per the
field Q.P./Instructions of the equipment Supplier or Purchaser without any extra cost
to the Purchaser. The Contractor shall arrange all instruments required for conducting
these tests alongwith calibration certificates and shall furnish the list of instruments to
the Purchaser for approval.
Volume-II (Section-D), Surge Arrestor 73
TECHNICAL PARTICULARS OF SURGE ARRESTERS
1.0 TECHNICAL PARTICULARS:
A. 800 kV CLASS SURGE ARRESTER
(a) Rated arrester voltage 624 kV
(b) i) Nominal discharge 20kA of 8/20 microsecond wave.
current
ii) Discharge current at 20kA of 8/20 microsecond which
insulation co-ordination wave
will be done.
(c) Minimum discharge capability 13kJ/kV
(d) Continuous operating 490 kV (rms)
voltage at 50 deg.C
(e) Max. Switching surge residual voltage
-at 1kA 1180 kVp
-at 2kA 1220 kVp
(f) Max. residual voltage at
i) 20kA nominal 1480 kVp
discharge current
ii) Steep fronted wave 1480 kVp
residual voltage at 10 kA
(g) Long duration discharge 5
class
(h) High current short 100 kAp
duration test value (4/10 micro second wave)
(i) Current for pressure 40 kA rms
relief test
(j) Low current long duration As per IEC.
test value (2000 micro sec)
(k) Prospective symmetrical 40kA (rms) for 0.2 Sec.
fault current
(l) Pressure relief class A
Volume-II (Section-D), Surge Arrestor 74
B. 420 kV CLASS SURGE ARRESTER
(a) Rated arrester voltage 390 kV
(b) i) Nominal discharge current 20kA of 8/20 microsecond wave
ii) Discharge current at which
insulation co-ordination will be done 20kA of 8/20microsecond wave
(c) Minimum discharge Capability 8kJ/kV
(d) Continuous operating voltage at 303 kV (rms)
50 deg.C
(e) i) Min. switching surge residual 670 kVp
voltage (2kA)
ii) Max. switching surge residual 650 kVp
voltage (500A)
(f) Max. residual voltage at
i) 10kA nominal discharge current 900 kVp
ii) 20kA nominal discharge current 975 kVp
iii) Steep fronted wave residual 1050 kVp
voltage at 20 kA
(g) Long duration discharge class 4
(h) High current short duration test 100 kAp
value (4/10 micro second wave)
(i) Current for pressure relief test (kA rms) 50
(j) Low current long duration test value As per IEC
(2400 micro sec)
(k) Prospective symmetrical fault current 50kA (rms) for 0.2 Sec.
(l) Pressure relief class A
C. 245 kV CLASS SURGE ARRESTER
(a) Rated arrester voltage 216 kV
(b) Nominal discharge 10 kA of 8/20 microsecond wave
current
(c) Minimum discharge 5kJ/kV
capability
Volume-II (Section-D), Surge Arrestor 75
(d) Continuous operating 168 kV rms
voltage at 50 deg.C
(e) Max. switching surge 500 kVp
residual voltage (1kA)
(f) Max. residual voltage at
i) 5 kA 560 kVp
ii) 10 kA nominal 600 kVp
discharge current
(g) Max. steep current impulse 650 kVp
residual voltage at 10 kA.
(h) Long duration discharge 3
class
(i) High current short 100 kAp
duration test value (4/10 micro
second wave)
(j) Current for pressure 40 kA rms
relief test
(k) Low current long duration As per IEC.
test value (2400 micro sec)
(l) Pressure relief class A
D. 145 kV CLASS SURGE ARRESTER
(a) Rated arrester voltage 120 kV
(b) Nominal discharge 10 kA of 8/20 microsecond wave
current
(c) Minimum discharge 5kJ/kV
capability
(d) Continuous operating 102 kV rms
voltage at 50 deg.C
(e) Max. switching surge 280 kVp
Volume-II (Section-D), Surge Arrestor 76
residual voltage (1kA)
(f) Max. residual voltage at
i) 5 kA 310 kVp
ii) 10 kA nominal 330 kVp
discharge current
(g) Long duration discharge class 3
(h) High current short duration 100 kAp
test value (4/10 micro second wave)
(i) Current for pressure 31.5 kA rms
relief test
(j) Low current long duration As per IEC.
test value (2400 micro sec)
(k) Pressure relief class A
E. 36 kV SURGE ARRESTER
(a) Rated arrester voltage 30 kV
(b) Nominal discharge 10 kA of 8/20 microsecond wave
current
(c) Minimum discharge 5kJ/kV
(d) Continuous operating 25 kV rms
voltage at 50 deg.C
(e) Max. switching surge 72 kVp
residual voltage (1kA)
(f) Max. residual voltage at
i) 5 kA 85 kVp
ii) 10 kA nominal 90 kVp
discharge current
(g) Long duration discharge 2
class
(h) Pressure relief class A
Volume-II (Section-E), Battery And Battery Charger 77
SECTION- (E)
TECHNICAL DETAILS OF BATTERY & BATTERY CHARGER
1.1 GENERAL TECHNICAL REQUIREMENTS
1.1.1 All materials/components used in battery chargers and batteries shall be free from
flaws and defects and shall conform to the relevant Indian/IEC standards and good
engineering practice.
1.1.2 The DC System shall consist of two(2) float-cum-boost chargers and two(2) battery
sets for each of 220V and 48 V systems respectively.
1.1.4 Bidder shall select number of cells, float and Boost voltage to achieve following
system requirement:
System Voltage
Maximum Voltage during Float operation
Minimum voltage available when no charger working and battery fully discharged upto 1.85V per cell.
Minimum Nos of cell
220 Volt 242 Volt 198 Volt 107
48 Volt 52.8 Volt 43.2 Volt 23
Bidder shall furnish calculation in support of battery sizing, selection of number of
cells, float and Boost voltages during detailed engineering for Owners acceptance.
Battery sizing calculations shall be done as per IEEE- 485 on the basis of following
duty cycle:
220V
DC
System
Load Duration Type Of Loads
Continuous Load 3 hours Relays, IEDs, Station HMIs, spring charging, Isolator interlocking load, Miscellaneous permanently connected loads etc.
Emergency Load 1 hour Substation emergency lighting loads.
Momentary Load 1 minute Breaker closing, Tripping loads (taking simultaneous occurrence as per system)
48V DC
System
Continuous Load 3 hours Continuous load associated with PLCs.(when speech is not working)
Momentary Load 15 minute Loads associated with PLCs (when speech is working)
No extra claim would be admissible if a higher capacity battery is technically
required later. The same condition applies to battery Charger;s also.
Volume-II (Section-E), Battery And Battery Charger 78
1.2 BATTERY
1.2.1 Type
The DC Batteries shall be VRLA (Valve Regulated Lead-Acid) type and shall be
Normal Discharge type. These shall be suitable for a long life under continuous float
operations and occasional discharges. Air-conditioning shall be provided in Battery
room the requirement of which has been specified elsewhere in the Technical
Specification. The 220 V DC system is unearth and 48 V DC system is +ve earth
system.
1.2.2 Constructional Requirements
The design of battery shall be as per field proven practices. Partial plating of cells is
not permitted. Paralleling of cells externally for enhancement of capacity is not
permitted. Protective transparent front covers with each module shall be provided to
prevent accidental contact with live module/electrical connections.
1.2.3 Containers
The container material shall have chemical and electro-chemical compatibility and
shall be acid resistant. The material shall meet all the requirements of VRLA
batteries and be consistent with the life of battery. The container shall be fire
retardant and shall have an Oxygen Index of at least 28 %. The porosity of the
container shall be such as not to allow any gases to escape except from the
regulation valve. The tensile strength of the material of the container shall be such as
to handle the internal cell pressure of the cells in the worst working condition. Cell
shall not show any deformity or bulge on the sides under all working conditions.
The container shall be capable of withstanding the rigours of transport, storage and
handling. The containers shall be enclosed in a steel tray.
1.2.4 Cell Covers
The cell covers shall be made of suitable material compatible with the container
material and permanently fixed with the container. It shall be capable to withstand
internal pressure without bulging or cracking. It shall also be fire retardant. Fixing of
Pressure Regulation Valve & terminal posts in the cover shall be such that the
seepage of electrolyte, gas escapes and entry of electro-static spark are prevented.
1.2.5 Separators
The separators used in manufacturing of battery cells, shall be of glass mat or
synthetic material having high acid absorption capability, resistant to sulphuric acid
Volume-II (Section-E), Battery And Battery Charger 79
and good insulating properties. The design of separators shall ensure that there is no
misalignment during normal operation and handling.
1.2.6 Pressure Regulation Valve
Each cell shall be provided with a pressure regulation valve. The valve shall be self
re-sealable and flame retardant. The valve unit shall be such that it cannot be opened
without a proper tool. The valve shall be capable to withstand the internal cell
pressure specified by the manufacturer.
1.2.7 Terminal Posts
Both the +ve and –ve terminals of the cells shall be capable of proper termination
and shall ensure its consistency with the life of the battery. The surface of the
terminal post extending above the cell cover including bolt hole shall be coated with
an acid resistant and corrosion retarding material. Terminal posts or any other metal
part which is in contact with the electrolyte shall be made of the same alloy as that
of the plates or of a proven material that does not have any harmful effect on cell
performance. Both +ve and –ve posts shall be clearly and unambiguously
identifiable.
1.2.8. Connectors, Nuts & Bolts, Heat Shrinkable Sleeves
Where it is not possible to bolt the cell terminals directly to assemble a battery,
separate non-corroding lead or copper connectors of suitable size shall be provided
to enable connection of the cells. Copper connections shall be suitably lead coated to
withstand corrosion due to sulphuric acid at a very high rate of charge or discharge.
Nuts and bolts for connecting the cells shall be made of copper, brass or stainless
steel. Copper or brass nuts and bolts shall be effectively lead coated to prevent
corrosion. Stainless steel bolts and nuts can be used without lead coating.
All inter cell connectors shall be protected with heat shrinkable silicon sleeves for
reducing the environmental impact including a corrosive environment.
1.2.9. Flame Arrestors
Each cell shall be equipped with a Flame Arrestor to defuse the Hydrogen gas
escaped during charge and discharge. Material of the flame arrestor shall not affect
the performance of the cell.
Volume-II (Section-E), Battery And Battery Charger 80
1.2.10. Battery Bank Stand
All batteries shall be mounted in a suitable metallic stand/frame. The frame shall be properly
painted with the acid resistant paint. The suitable insulation shall be provided between
stand/frame and floor to avoid the grounding of the frame/stand.
1.2.11. Capacity Requirements
When the battery is discharged at 10 hour rate, it shall deliver 80% of C (rated
capacity, corrected at 27º Celsius) before any of the cells in the battery bank reaches
1.85V/cell.
The battery shall be capable of being recharged from the fully exhausted condition
(1.75V/cell) within 10 hrs up to 90% state of charge. All the cells in a battery shall
be designed for continuous float operation at the specified float voltage throughout
the life.
The capacity (corrected at 27ºCelcius) shall also not be less than C and not more
than 120% of C before any cell in the battery bank reaches 1.75V/cell. The battery
voltage shall not be less than the following values, when a fully charged battery is
put to discharge at C/10 rate:
(a) After Six minutes of discharge : 1.98V/cell
(b) After Six hours of discharge : 1.92V/cell
(c) After 8 hours of discharge : 1.85V/cell
(d) After 10 hours of discharge : 1.75V/cell
Loss in capacity during storage at an average ambient temperature of 35º Celcius for
a period of 6 months shall not be more than 60% and the cell/battery shall achieve
85% of its rated capacity within 3 charge/discharge cycles and full rated capacity
within 5 cycles, after the storage period of 6 months. Voltage of each cell in the
battery set shall be within 0.05V of the average voltage throughout the storage
period. Ampere hour efficiency shall be better than 90% and watt hour efficiency
shall be better than 80%.
1.2.12. Expected Battery Life
The battery shall be capable of giving 1200 or more charge/discharge cycles at 80%
Depth of discharge (DOD) at an average temperature of 27º Celsius. DOD (Depth of
Discharge) is defined as the ratio of the quantity of electricity (in Ampere-hour)
removed from a cell or battery on discharge to its rated capacity. The battery sets
shall have a minimum expected life of 20 years at float operation.
Volume-II (Section-E), Battery And Battery Charger 81
1.2.13. Routine Maintenance of Battery system
For routine maintenance of battery system, the contractor shall supply 1 set of
following tools:
a) Torque wrench.
b) Cell test voltmeter(-3-0-+3) volts with least count of 0.01Volt.
1.2.14. Type Test of Battery
i) Contractor shall submit type test reports of following tests as per IEC 60896-21
& IEC 60896-22, 2004. The type test reports shall be submitted in accordance
with the requirements stipulated in clause no. 9.2 of Technical Specification,
VOLUME-I, TR except that the requirement of tests having been conducted
within last five years as mentioned therein shall not be applicable).
S.No. Description of test
1. Gas emission
2. High current tolerance
3. Short circuit current and d.c internal resistance
4. Protection against internal ignition from external spark sources
5. Protection against ground short propensity
6. Content & durability of required markings
7. Material identification
8. Valve operation
9. Flammability rating of materials
10. Intercell connector performance
11. Discharge Capacity
12. Charge retention during storage
13. Float service with daily discharges for reliable mains power
14. Recharge behaviour
15. Service life at an operating temperature of 400°C for brief duration exposure time.
16. Impact of a stress temperature of 600°C for brief duration exposure time with 3 h rate discharge test
17. Abusive over-discharge
18. Thermal runaway sensitivity
19. Low temperature sensitivity
20. Dimensional sensitivity at elevated internal pressure and temperature
21. Stability against mechanical abuse of units during installation
Volume-II (Section-E), Battery And Battery Charger 82
Tests shall be conducted in accordance with IEC 60896-21 & IEC 60896-22,
2004
ii) List of Factory & Site Tests for Battery
Sl. No.
Test Factory Tests
Site Tests
1. Physical Verification √
2. C/10 Capacity test on then cell √
3. 8 Hrs. Charge and 15 minutes discharge test at full rated load
√
1.2.15 Installation and commissioning
i) Manufacturer of Battery shall supervise the installation and commissioning and
perform commissioning tests as recommended in O&M manual / or relevant
standards. All necessary instruments, material, tools and tackles required for
installation, testing at site and commissioning are to be arranged by Battery
manufacturer/ Contractor
1.3. BATTERY CHARGER
The DC system for 220 V DC is unearthed and for 48 V DC is +ve earthed. The Battery
Chargers as well as their automatic regulators shall be of static type and shall be compatible
with offered VRLA batteries. All battery chargers shall be capable of continuous operation
at the respective rated load in float charging mode, i.e. Float charging the associated Lead-
Acid Batteries at 2.13 to 2.27 Volts per cell while supplying the DC load. The chargers shall
also be capable of Boost charging the associated DC Battery at 2.28 to 2.32 volts per cell at
the desired rate.
Charger shall regulate the float/boost voltage in case of prescribed temperature rise of
battery as per manufacturer’s recommendation to avoid thermal runaway. Necessary
temperature sensors shall be provided in mid location of battery banks and shall be wired up
to the respective charger for feedback control. The manufacturer shall demonstrate this
feature during testing of each charger.
1.3.1. All Battery Chargers shall be provided with facility for both automatic and manual
control of output voltage and current. A selector switch shall be provided for
selecting the mode of output voltage/current control, whether automatic or manual.
When on automatic control mode during Float charging, the Charger output voltage
shall remain within ±1% of the set value, for AC input voltage variation of ±10%,
Volume-II (Section-E), Battery And Battery Charger 83
frequency variation of ±5%, a combined voltage and frequency variation of ±10%,
and a DC load variation from zero to full load.
1.3.2. All battery chargers shall have a constant voltage characteristics throughout the
range (from zero to full load) at the floating value of the voltage so as to keep the
battery fully charged but without harmful overcharge.
1.3.3. All chargers shall have load limiters having drooping characteristic, which shall
cause, when the voltage control is in automatic mode, a gradual lowering of the
output voltage when the DC load current exceeds the Load limiter setting of the
Charger. The Load-limiter characteristics shall be such that any sustained overload
or short circuit in DC System shall not damage the Charger, nor shall it cause
blowing of any of the Charger fuses. The Charger shall not trip on overload or
external short circuit.
1.3.4. Uniform and step less adjustments of voltage setting (in both manual and automatic
modes) shall be provided on the front of the Charger panel covering the entire float
charging output range specified. Step less adjustments of the Load limiter setting
shall also be possible from 80% to 100% of the rated output current for Charging
mode.
1.3.5. During Boost Charging, the Battery Charger shall operate on constant current mode
(when automatic regulator is in service). It shall be possible to adjust the Boost
charging current continuously over a range of 50 to 100% of the rated output current
for Boost charging mode.
1.3.6. The Charger output voltage shall automatically go on rising, when it is operating on
Boost mode, as the Battery charges up. For limiting the output voltage of the
Charger, a potentiometer shall be provided on the front of the panel, whereby it shall
be possible to set the upper limit of this voltage any where in the output range
specified for Boost Charging mode.
1.3.7. The Charger manufacturer may offer an arrangement in which the voltage setting
device for Float charging mode is also used as output voltage limit setting device for
Boost charging mode and the Load-limiter of Float charging mode is used as current
setting device in boost charging mode.
1.3.8. Suitable filter circuits shall be provided in all the chargers to limit the ripple content
(Peak to Peak) in the output voltage to 1%, irrespective of the DC load level, when
they are not connected to a Battery.
Volume-II (Section-E), Battery And Battery Charger 84
1.3.9. MCCB
All Battery Chargers shall have 2 Nos. MCCBs on the input side to receive cables
from two sources. Mechanical interlock should be provided such that only one shall
be closed at a time. It shall be of P2 duty and suitable for continuous duty. MCCB’s
should have auxiliary contacts for annunciation.
1.3.10. Rectifier Transformer
The rectifier transformer shall be continuously rated, dry air cooled (A.N) and of
class F insulation type. The rating of the rectifier transformer shall have 10%
overload capacity.
1.3.11. Rectifier Assembly
The rectifier assembly shall be fully/half controlled bridge type and shall be
designed to meet the duty as required by the respective Charger. The rectifier shall
be provided with heat sink having their own heat dissipation arrangements with
natural air cooling. Necessary surge protection devices and rectifier type fast acting
HRC fuses shall be provided in each arm of the rectifier connections.
1.3.12. Instruments
One AC voltmeter and one AC ammeter alongwith selector switches shall be
provided for all chargers. One DC voltmeter and DC ammeter (with shunt) shall be
provided for all Chargers. The instruments shall be flush type, dust proof and
moisture resistant. The instruments shall have easily accessible means for zero
adjustment. The instruments shall be of 1.5 accuracy class. In addition to the above a
centre zero voltmeter with selector switch shall also be provided for 220 V chargers
for testing purpose.
1.3.13. Air Break Switches
One DC output switch shall be provided in all chargers. They shall be air break type
suitable for 500 volts AC/ 250 DC. The contacts of the switches shall open and close
with a snap action. The operating handle of the switch shall be fully insulated from
circuit. `ON’ and `OFF’ position on the switch shall be clearly indicated. Rating of
switches shall be suitable for their continuous load. Alternatively, MCCB’s of
suitable ratings shall also acceptable in place of Air Break Switch.
1.3.14. Fuses
All fuses shall be HRC Link type. Fuses shall be mounted on fuse carriers which are
in turn mounted on fuse bases. Wherever it is not possible to mount fuses on
Volume-II (Section-E), Battery And Battery Charger 85
carriers, fuses shall be directly mounted on plug-in type base. In such case one
insulated fuse pulling handle shall be supplied for each charger. Fuse rating shall be
chosen by the Bidder depending on the circuit requirement. All fuses in the chargers
shall be monitored. Fuse failure annunciation shall be provided on the failure of any
fuse.
1.3.15. Blocking Diode
Blocking diode shall be provided in the positive pole of the output circuit of each
charger to prevent current flow from the DC Battery into the Charger.
1.3.16. Annunciation System
Audio-visual indications through bright LEDs shall be provided in all Chargers for
the following abnormalities:
a) AC power failure
b) Rectifier/chargers fuse blown.
c) Over voltage across the battery when boost charging.
d) Abnormal voltage (High/Low)
e) Any other annunciation if required.
Potential free NO Contacts of above abnormal conditions shall also be provided for
common remote indication “CHARGER TROUBLE” in Owner’s Control Board.
Indication for charger in float mode and boost mode through indication lamps shall
be provided for chargers. A potential free contact for float/boost mode shall be
provided for external interlocks.
1.3.17. Name Plates and Marking
The name plates shall be white with black engraved letters. On top of each Charger,
on front as well as rear sides, larger and bold name plates shall be provided to
identify the Charger. Name plates with full and clear inscriptions shall also be
provided on and inside of the panels for identification of the various equipments and
ease of operation and maintenance.
1.3.18. Charger Construction
The Chargers shall be indoor, floor-mounted, self-supporting sheet metal enclosed
cubicle type. The Contractor shall supply all necessary base frames, anchor bolts and
hardware. The Chargers shall be fabricated from 2.0mm cold rolled sheet steel and
shall have folded type of construction. Removable gland plates for all cables and
Volume-II (Section-E), Battery And Battery Charger 86
lugs for power cables shall be supplied by the Contractor. The lugs for power cables
shall be made of electrolytic copper with tin coat. Power cable sizes shall be advised
to the Contractor at a later date for provision of suitable lugs and drilling of gland
plates. The Charger shall be tropicalised and vermin proof. Ventilation louvers, if
provided shall be backed with screens. All doors and covers shall be fitted with
synthetic rubber gaskets. The chargers shall have hinged double leaf doors provided
on front and on backside for adequate access to the Charger’s internals. All the
charger cubicle doors shall be properly earthed. The degree of protection of Charger
enclosure shall be at least IP-42 as per IS: 13947 Part I.
i) All indicating instruments, control switches and indicating lamps shall be
mounted on the front side of the Charger.
ii) Each Charger shall be furnished completely wired upto power cable lugs and
terminal blocks and ready for external connections. The control wiring shall be
carried out with PVC insulated, 1.5 sq.mm. stranded copper wires. Control
terminals shall be suitable for connecting two wires, with 2.5 sq.mm stranded
copper conductors. All terminals shall be numbered for ease of connections and
identification. Each wire shall bear a ferrule or tag on each end for
identification. At least 20% spare terminals shall be provided for control
circuits.
iii) The insulation of all circuits, except the low voltage electronic circuits shall
withstand test voltage of 2 KV AC for one minute. An air clearance of at least
ten (10) mm shall be maintained throughout for such circuits, right up to the
terminal lugs. Whenever this clearance is not available, the live parts shall be
insulated or shrouded.
1.3.19. Painting
All sheet steel work shall be pre-treated, in tanks, in accordance with IS:6005.
Degreasing shall be done by alkaline cleaning. Rust and scale shall be removed by
pickling with acid. After pickling, the parts shall be washed in running water. Then
these shall be rinsed in slightly alkaline hot water and dried. The phosphate coating
shall be `Class-C’ as specified in IS:6005. Welding shall not be done after
phosphating. The phosphating surfaces shall be rinsed and passivated prior to
application of stoved lead oxide primer coating. After primer application, two coats
of finishing synthetic enamel paint of shade-692 (smoke grey) of IS:5 shall be
applied, unless required otherwise by the Owner. The inside of the chargers shall be
Volume-II (Section-E), Battery And Battery Charger 87
glossy white. Each coat of finishing synthetic enamel paint shall be properly staved.
The paint thickness shall not be less than fifty (50) microns.
1.3.20. TESTS
i) Battery chargers shall conform to all type tests as per relevant Indian Standard.
Performance test on the Chargers as per Specification shall also be carried out
on each Charger as per specification. Rectifier transformer shall conform to all
type tests specified in IS : 4540 and short circuit test as per IS:2026. Following
type tests shall be carried out for compliance of specification requirements:
a) Voltage regulation test
b) Load limiter characteristics test
c) Efficiency tests
d) High voltage tests
e) Temperature rise test
f) Short circuit test at no load and full load at rated voltage for sustained
short-circuit.
g) Degree of protection test
h) Measurement of ripple by oscilloscope.
i) Temperature compensation feature demonstration
ii) The Contractor may be required to demonstrate to the OWNER that the
Chargers conform to the specification particularly regarding continuous rating,
ripple free output, voltage regulation and load limiting characteristic, before
despatch as well as after installation at site. At site the following tests shall be
carried out:
a) Insulation resistance test
b) Checking of proper annunciation system operation.
iii) If a Charger fails to meet the specified requirements, the Contractor shall
replace the same with appropriate Charger without affecting the commissioning
schedule of the Sub-station, and without any extra cost to the OWNER.
iv) The Contractor shall present for inspection, the type and routine test certificates
for the following components whenever required by the OWNER.
a) Switches.
b) Relays/ MCCBs
Volume-II (Section-E), Battery And Battery Charger 88
c) Instruments.
d) DC fuses.
e) SCR.
f) Diodes.
g) Condensers.
h) Potentiometers.
i) Semiconductor
j) Annunciator.
k) Control wiring
l) Push buttons and contactors.
Makes of above equipment shall be subject to Owner’s approval.
Volume-II (Section-F), LT Transformer 89
SECTION- (F)
TECHNICAL DETAILS OF LT TRANSFORMER
1.0 INTENT
This specification is intended to cover outdoor type oil filled 33/0.433KV, 800/ 630/400
kVA transformers.
2.0 Scope of Work
2.1 Scope of Supply
- Transformers as listed above, with insulating oil, all materials and accessories, and
complete in all respects.
- Gland plates, power cable, lugs, anchor bolts and hardwares.
- Mandatory & optional spares and special maintenance equipments if any.
2.2 Scope of Service
The scope includes but is not limited to the following items of work to be performed for all
equipment and materials furnished under this section:
a) Design, manufacturing, shop testing, packing & despatch
b) Transportation inclusive of insurance and delivery, FOR site basis
c) Unloading, handling, storing, transportation at site upto foundations, oil filling and
treatment, erection, testing and commissioning
d) Civil Works
e) Supply of external cables and termination as required.
f) Fire protection system.
3.0 General Information
3.1 All temperature indicators, Buchholz relays and other auxiliary devices shall be suitable for
220 V DC Control supply. All alarm and trip Contacts shall also be suitable for connection
in 220V DC Circuits.
3.2 Bidders may specifically note that Purchaser proposes to insist on short circuit test as per
Clause 16.11 of IS:2026 (Part-I)-1977 and dielectric test as per IS-2026. Any deviation in
this regard shall be sufficient ground for rejection of the bid.
4.0 TECHNICAL REQUIREMENTS
4.1 Core
Volume-II (Section-F), LT Transformer 90
The core shall be constructed from high grade, nonaging, cold rolled grain-oriented silicon
steel laminations. The maximum flux density in any part of the cores and yoke at normal
voltage and frequency shall be such that the flux density at any tap position with 10%
voltage variation from the voltage corresponding to the tap shall not exceed 1.9 Wb/sq-m.
4.2 Windings
The conductor shall be of electrolytic copper, free from scales and burrs.
4.3 Insulating Oil
The oil supplied with transformer shall be unused and have the parameters for unused new
oil conforming to IS:335 while tested at oil Contractor's premises, No inhibitors shall be
used in oil. Ten percent extra oil shall be supplied for topping up after commissioning in
nonreturnable containers suitable for outdoor storage.
4.4 Terminal Arrangement
a) Bushing terminals shall be provided with suitable terminal connectors of approved
type and size for cable/overhead conductors termination of HV side and cable
termination on LV side.
b) The neutral terminals of 433V winding shall be brought out on a bushing along with
the 433 volt phase terminals to form a 4 wire system for the 415 volt. Additional
neutral bushing shall also be provided for earthing.
4.5 Off Circuit Tap Changing Equipment
The tap change switch shall be three phase, hand operated for simultaneous switching of
similar taps on the three phases by operating an external hand wheel.
4.6 Marshalling Box
A metal enclosed, weather, vermin & dust proof marshalling box shall be provided with each
transformer to accommodate temperature indicators, terminal blocks etc. It shall have a
degree of protection of IP 55 as per IS: 2147
4.7 Cable boxes
Whenever cable connections are required, suitable cable boxes shall be provided and shall be
air insulated. They shall be of sufficient size to accommodate Purchaser's cables and shall
have suitable removable side/top cover to facilitate cable termination and inspection.Cable
boxes shall be dust & vermin proof.
Volume-II (Section-F), LT Transformer 91
5.0 Inspection and Testing
a) The Contractor shall draw up and carry out a comprehensive inspection and testing
program during manufacture and commissioning of the transformer. The programme
shall be duly approved by the Purchaser.
b) The Contractor shall carryout all type tests and routine tests on the transformers as per
relevant standards. Type tests shall be carried out on one transformer of each type and
routine tests shall be carried out on all transformers.
6.0 Inspection
6.1 Tank and Accessories
a) Physical and dimensional check of transformer tank and accessories.
b) Crack detection of major strength weld seams by dye penetration test.
6.2 Core
a) Physical inspection and check of quality of varnish, if used.
b) Sample testing of core material for checking specific loss, bend properties,
magnestisation, characteristics and thickness.
c) Check on completed core for measurement of iron loss and check for any hot spot by
exciting the core so as to induce the designed value of flux density in the core.
d) HV Test
6.3 Insulating Material
a) Sample checks for physical properties of the material
b) Check for dielectric strength
c) Check for the reaction of hot oil on insulating material
6.4 Winding
a) Sample check on winding conductor for mechanical properties and electrical
conductivity and on installation covering.
b) Sample check on insulation paper for pH value, Bursting strength, Electric strength.
6.5 Assembled Transformer
a) Check complete transformer against approved outline drawing provision for all fittings,
finish etc.
b) Jacking test on all the assembled transformers.
Volume-II (Section-F), LT Transformer 92
6.6 Oil
All standard tests in accordance with relevant Standards shall be carried out on oil samples
taken from the transformer before and after testing of the transformer. The contractor shall
also prepare a comprehensive inspection and testing program for all bought out sub-
contracted items and shall submit the same to the Purchaser for approval. Such program
shall include the following components:
a) Buchholz Relay
b) Winding temperature Indicator
c) Bushings
d) Marshaling Box
e) Tap changer switch
f) Oil temperature indicator
7.0 Factory Test
7.1 All standard routine tests in accordance with latest issue of IS : 2026 shall be carried out on
each transformer.
7.2 All the type tests in accordance with latest issues of IS : 2026 shall be conducted on one
transformer of each rating.
7.3 In addition to all type and routine tests, following additional type tests shall also be carried
out on one transformer of each rating as per IS : 2026.
a) Measurement of zero sequence impedance
b) Short circuit test
c) Measurement of acoustic noise level. This shall conform to NEMA standard
publication TR-1.
d) Measurement of capacitance and tan delta of transformer winding.
e) Test on oil samples.
Sequence of testing shall be mutually agreed between Purchaser and Contractor after award.
7.4 All auxiliary equipment shall be tested as per the relevant IS Test Certificates shall be
submitted for bought out items.
7.5 High voltage withstand test shall be performed on auxiliary equipment and wiring after
complete assembly.
Volume-II (Section-F), LT Transformer 93
7.6 Tank Tests:
a) Routine Tests: As per CBIP Manual on Transformers
b) Type Tests:
i) Vacuum Tests: As per CBIP Manual on Transformers
ii) Pressure Test: As per CBIP Manual on Transformers
7.7 In addition to the above, the following checks should be carried out at manufacturer's works
before despatch for all transformers:
a) Check for interchangeability of components of similar transformers and for mounting
dimensions.
b) Check for proper packing and preservation of accessories like radiators, bushings
explosion vent, dehydrating breather, Buchholz relay, conservator etc.
c) Check for proper provision of bracings to arrest the movements of core and winding
assembly inside the tank.
d) Test for gas tightness and derivation of leakage rate. To ensure adequate reserve gas
capacity during transit and storage.
7.8 The Contractor shall submit a detailed inspection and testing programme for field activities,
covering areas right from the receipt of material stage upto commissioning stage as per IS
:1886 - Code of practice for installation and maintenance of transformers. The indicative
checks and tests are given below.
a) Physical checks on each transformer on receipt at site for any damage or short supply.
b) Tests on oil samples
c) Oil leakage test
d) Physical checks for colour of silica in breather
e) Check for oil level in breather housing, conservator tank, etc.
f) Check for correct operation of all protections and alarms.
g) Insulation Resistance Measurement for Main Winding, control wiring etc.
h) Continuously observe the transformer operation at no load for 24 hours.
8.0 Fittings
The following fittings shall be provided with each transformer covered under this
specification.
Volume-II (Section-F), LT Transformer 94
i) Conservator with drain plug and oil filling hole with blanking plate
ii) Plain oil Gauge
iii) Silica gel Breather
iv) Pressure Relief vent
v) Pocket on tank cover for Thermometer
vi) Valves
vii) Earthing Terminals
viii) Rating & Terminal Marking Plates
ix) Lifting Lugs
x) Rollers
xi) Air Release Plug
The fittings listed above are only indicative and any other fittings which generally are
required for satisfactory operation of transformer are deemed to be included.
9.0 Spare Parts
9.1 The list of spares for outdoor type transformers covered under this section shall be as
specified in mandatory Spares
9.2 In addition, the Bidder shall also recommend optional spare parts and maintenance
equipment necessary for three(3) years of successful operation of the equipment. The prices
of these shall be indicated in respective schedules and these shall not be considered for the
purpose of evaluation.
10.0 33 kV feeder Relay Panel for 630 KVA Transformer: The supply and installation of
auxiliary transformer should be complete with necessary switchgear and allied
equipments. Control and protection shall not be limited to the following:
i) Non-directional triple pole IDMT over current and earth fault relays with
instantaneous (high set) element – 2 nos. (2 O/C + 1 E/F). This can be a 3 element
relay also in one casing.
ii) Hand reset master trip relay for tripping commands for all protections – 1 no.
iii) Trip circuit supervision relay- 1 No
Volume-II (Section-F), LT Transformer 95
11.0 Technical Parameters
S.No. Description Parameters
a) Type Two Winding
b) Service Outdoor
c) Number of phases Three
d) Frequency 50 Hz
e) Type of cooling ONAN
f) Rating Ratio 250 kVA, 630 kVA and 800 kVA 11/0.433
kV 33/0.433 kVA
g) Impedance at 75OC with tolerance 0.05+10%
h) Duty Continuous
i) Overload As per IS:6600
j) Maximum Temp. rise over 50oC ambient
i) Oil (Temp. rise measurement by thermometer)
ii) Winding (Temp. rise measured by
resistance method)
50oC
55o C
k) Windings 33kV 630kVA
/250kVA
33 kV
800kVA
11kV 630kVA
/250kVA
0.433kV
i) System Apparent short circuit level (KA)
As per IS:2026 (Part-I)
ii) Winding connection Delta Delta Delta Star
iii) Vector Group Dyn1
iv) Insulation Uniform
v) Insulation level (KV) 36 52 11 0.433
a) Power frequency test level (KV
rms)
70 95 28 2
b) Basic impulse level (KV peak) 170 250 75 -
vi) Highest voltage (KV) for each 36 52 11 -
Volume-II (Section-F), LT Transformer 96
winding
l) Tap changer
i) Tap range +5% / -10% in steps of 2.5% on HV side
ii) Tap control Off circuit tap change switch
m) H.V. Bushings 800 KVA 630 KVA
11kV 33kV
i) Rated Voltage, KV 52 12 36
ii) Rated current, KV 100A
iii) Basic impulse Level (KV) 250 75 170
iv) Wet and dry power frequency withstand voltage (KV rms)
95 28 70
v) Minimum total Creepage distance
(mm)
31mm/kV
vi) Mounting Tank/Transformer body
n) L.V. and Neutral bushing
i) Rated Voltage (Volts) 1100 1100 1100
ii) Rated current (amps) 2000 1000 1000
o) Terminal details
i) High Voltage Suitable for 33kV/11kV cable or O/H Conductor
ii) Low Voltage phase and neutral Cable box
p) Minimum Clearance (mm) in AIR
33kV 630kVA/
250kVA
33kV 800kVA
11kV 630kVA/
250kVA
0.433kV
i) Phase to Phase 350 530 280 25
ii) Phase to Earth 320 480 140 25
Volume-II (Section-G), LT Switchgear 97
SECTION- (G)
TECHNICAL DETAILS OF LT SWITCHGEAR
1.1 SCOPE OF WORK
Scope of work under this section covers the provision of labour, tools, plants, materials and
performance of work necessary for the design, manufacture, quality assurance, quality
control, shop assembly, shop testing, delivery at site, site storage and preservation,
installation, commissioning, performance testing, acceptance testing, training of Employer’s
personnel, handing over to Employer of LT Switchgear system as per the specifications
hereunder, complete with all auxiliaries, accessories, spare parts and warranting a trouble
free safe operation of the installation.
1.2 CONSTRUCTIONAL DETAILS OF SWITCHBOARDS AND DISTRIBUTION
BOARDS
i) All boards shall be of metal enclosed, indoor floor mounted, compartmentalized construction
and freestanding type.
ii) All board frames, shall be fabricated using suitable mild steel structural sections or
pressed and shaped cold-rolled sheet steel of thickness not less than 2.0 mm. Frames shall
be enclosed in cold-rolled sheet steel of thickness not less than 1.6mm. Doors and
covers shall also be of cold rolled sheet steel of thickness not less than 1.6 mm.
Stiffeners shall be provided wherever necessary.
iii) All panel edges and cover/door edges shall be reinforced against distortion by rolling,
bending or by the addition of welded reinforcement members.
iv) The complete structures shall be rigid, self-supporting free from flaws, twists and bends. All
cut-outs be true in shape and devoid of sharp edges.
v) All boards shall be of dust and vermin proof construction and shall be provided with
a degree of protection of IP:42 as per IS 2147. Provision shall be made in all
compartments for providing IP: 42 degree of protection, when Circuit breaker or
module trolley, has been removed. All cut-outs shall be provided with neoprene/Synthetic
rubber gaskets.
vi) Provision of louvers on boards would not be preferred. However, louvers backed with
metal screen are acceptable on the busbar chambers where continuous busbar rating
exceeds 1000 Amps.
vii) All boards shall be uniform height not exceeding 2450 mm.
viii) Boards shall be easily extendible on both sides, by the addition of the vertical
Volume-II (Section-G), LT Switchgear 98
sections after removing the end covers.
ix) Boards shall be supplied with base frames made of structural steel sections, alongwith
all necessary mounting hardware required for welding the base frames to the insert plates.
x) All boards shall be divided into distinct vertical sections, each comprising of :
(a) A completely enclosed busbar compartment for running horizontal and vertical
busbars. Busbar chamber shall be completely enclosed with metallic portions.
Bolted covers shall be provided for access to horizontal and Vertical bus bars and all
joints for repair maintenance, which shall be feasible without disturbing feeder
compartment.
(b) Completely enclosed switchgear compartment(s) one for each circuit for housing
circuit breaker or MCCB or motor starter.
(c) A compartment or alley for power and control cables. Cable alley door shall
preferably be hinged. Cable alley shall have no exposed live parts, and shall have no
communication with busbar chamber. It shall be of at least 350mm width.
(d) A compartment for relays and other control devices associated with a circuit
breaker.
xi) A completely enclosed busbar compartment for running horizontal and vertical busbars.
Busbar chamber shall be completely enclosed with metallic portions. Bolted covers shall be
provided for access to horizontal and Vertical bus bars and all joints for repair maintenance,
which shall be feasible without disturbing feeder compartment.
xii) Completely enclosed switchgear compartment(s) one for each circuit for housing circuit
breaker or MCCB or motor starter.
xiii) A compartment or alley for power and control cables. Cable alley door shall preferably be
hinged. Cable alley shall have no exposed live parts, and shall have no communication with
busbar chamber. It shall be of at least 350mm width.
xiv) A compartment for relays and other control devices associated with a circuit breaker.
xv) Sheet steel barriers shall be provided between two adjacent vertical panels running to the
full height of the switchboard, except for the horizontal busbar compartment. Each
shipping section shall have full metal sheets at both ends for transport and storage.
xvi) All equipments associated with a single circuit except MCB circuits shall be housed in a
separate compartment of the vertical section. The Compartment shall be sheet steel
enclosed on all sides with the withdrawal units in position or removed. The front of the
compartment shall be provided with the hinged single leaf door, with locking facilities.
Volume-II (Section-G), LT Switchgear 99
xvii) In case of circuits controlled by MCBs, group of MCB feeders can be offered in
common compartment. In such case number of MCB feeder to be used in a common
compartment shall not exceed 4 (four) and front of MCB compartment, shall have a viewing
port of toughen glass sheet for viewing and sheet steel door of module shall be
lockable with star knob/panel key.
xviii) After isolation of power and control circuit connections it shall be possible to safely
carryout maintenance in a compartment with the busbar and adjacent circuit live.
Necessary shrouding arrangement shall be provided for this purpose over the cable
terminations located in cable alley.
xix) The minimum clearance in air between phases and between phase and earth for the
entire run of horizontal and vertical busbars, shall be 25mm.
xx) For all other components, the clearance between “two live parts”, “A live part and an
earthed part” and isolating distance shall be at least ten (10) mm throughout. Wherever
it is not possible to maintain these clearances, insulation shall be provided by sleeving
or barriers. However, for horizontal run of busbar minimum clearance of 25mm
should be maintained even if they are sleeved.
xxi) The temperature rise of horizontal & vertical busbars when carrying rated current along its
full run shall in no case exceed 55 Deg C, with silver plated joints and 40 Deg C with all
other type of joints over an outside ambient temperature of 50Deg C.
xxii) All single front boards shall be provided with removable bolted covers at the rear. The
covers shall be provided with danger labels.
xxiii) All identical circuit breakers and module chasis of same test size shall be fully
interchangeable without having to carryout modifications.
xxiv) All Circuit breaker boards shall be of Single Front type, with fully drawout circuit
breakers, which can be drawn out without having to unscrew any connections. The
circuit breakers shall be mounted on rollers and guides for smooth movement between
SERVICE, TEST and ISOLATED positions and for withdrawal from the Switchboard.
Testing of the breaker shall be possible in the TEST position.
xxv) Wherever two breaker compartments are provided in the same vertical section,
insulating barriers and shrouds shall be provided in the rear cable compartment to avoid
accidental touch with the live parts of one circuit when working on the other circuit.
xxvi) All disconnecting contacts for power circuits shall be of robust design and fully self
aligning. Fixed and moving contacts of the power draw out contact system shall be silver
plated. Both fixed and moving contacts shall be replaceable.
Volume-II (Section-G), LT Switchgear 100
xxvii) All AC & DC boards shall be of single Front type.
xxviii) All module shall be fixed type except air circuit breaker module, which shall be
drawout type.
xxix) The connections from busbars to the main switch shall be fully
insulated/shrouded, and securely bolted. The partition between the feeder compartment and
cable alley may be non-metallic and shall be such construction as to allow cable cores
with lugs to be easily inserted in the feeder compartment for termination.
xxx) All equipment and components shall be neatly arrangement and shall be easily accessible for
operation and maintenance. The internal layout of all modules shall be subject to OWNER
approval. Bidder shall submit dimensional drawings showing complete internal details of
Busbars and module components for each type and rating for approval.
xxxi) The tentative power and control cable entries shall be from bottom. However, Owner
reserves the right to alter the cable entries, if required, during detailed engineering, without
any additional commercial implications.
xxxii) Adaptor panels and dummy panels required to meet the various busbar arrangements
and layouts required shall be included in Bidder’s scope of work.
xxxiii) All sheet work shall be pre-treated, in tanks, in accordance with IS: 6005. Degreasing shall
be done by alkaline cleaning. Rust and scale shall be removed by pickling with acid. After
pickling the parts shall be washed in running water. Then these shall be rinsed in slightly
alkaline hot water and dried. The phosphate coating shall ‘Class-C’ as specified in IS: 6005.
The phosphated surfaces shall be rinsed and passivated prior to application of stoved lead
oxide primer coating after primer application, two coats of finishing synthetic enamel
paint on panels shall be applied, Electrostatic painting shall also be acceptable.
xxxiv) Finishing paint on panels shall be shade 631 of IS:5 unless required otherwise by the
OWNER. The inside shall be properly stoved. The paint thickness shall be coated by
peelable compound by spraying method to protect the finished surfaces from scratches
grease dirt and oily spots during testing, transportation, handling and erection.
1.3 DERATING OF EQUIPMENTS
i) The current ratings of all equipments at a reference ambient temperature of 50 DegC as per
relevant Indian Standards is to be derived by the Bidder.
ii) The Bidder shall indicate clearly the derating factors employed for each component
and furnish the basis for arriving at these derating duly considering the specified
ambient temperature of 50 DegC
Volume-II (Section-G), LT Switchgear 101
1.4 POWER BUS BARS AND INSULATORS
i) All AC Distribution Boards shall be provided with three phase buses and a neutral bus bars
and the DC Distribution Boards shall be provided with two busbars.
ii) Busbars and jumper connections shall be high conductivity aluminium/copper of adequate
size the bus bar size calculations shall be submitted for approval.
iii) The Cross-Section of the busbars shall be uniform throughout the length of Switchgear and
shall be adequately supported and braced to withstand the stresses due to the specified short
circuit currents.
iv) All busbars shall be adequately supported by Non-hygroscopic, non- combustible,
track resistant & high strength type Polyester fibre glass Moulded Insulators. Separate
supports shall be provided for each phase and neutral busbar. If a busbar support is provided
anti-tracking barriers shall be provided between the supports.
v) All busbars joints shall be provided with high tensile steel bolts. Belleville/spring washers
and nuts, so as to ensure good contacts at the joints. Non-silver plated Busbars joints
shall be thoroughly cleaned at the joint locations and suitable contact grease shall be
applied just before making a joint.
vi) All busbars shall be colour coded as per IS: 375.
vii) The Bidder shall furnish calculations alongwith the bid, establishing the adequacy of
busbar sizes for specified current ratings, on the basis of short circuit current and
temperature rise consideration at specified ambient temp.
1.5 EARTH BUS
i) A galvanised steel earthing shall be provided at the bottom of each panel and shall extend
throughout the length of each switchboard. It shall be welded/bolted to the frame work of
each panel and breaker earthing contact bar vertical bus shall be provided in each
vertical section which shall in turn be bolted/welded to main horizontal ground bus.
ii) The earth bus shall have sufficient cross-section to carry the momentary short circuit and
short time fault currents to earth without exceeding the allowable temperature rise.
iii) Suitable arrangements shall be provided at each end of the horizontal earth bus for bolting to
Owner’s earthing conductors. The horizontal earth bus shall project out the switchboard ends
and shall have predrilled holes for this connection. A joint spaced and taps to earth bus shall
be made through at least two bolts.
iv) All non-current metal work of the Switchboard shall be effectively bonded to the earth
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bus. Electrical conductivity of the whole switchgear enclosures frame work and the
truck shall be maintained even after painting.
v) The truck and breaker frame shall get earthed while the truck is being inserted in the
panel and positive earthing of the truck and breaker frame shall be maintained in all
positions. SERVICE & ISOLATED, as well as throughout the intermediate travel.
vi) Each module frame shall get engaged to the vertical earth bus, before the disconnecting
contacts on this module are engaged to the vertical busbar.
vii) All metallic cases of relays, instruments and other panel mounted equipments
shall be connected to earth by independent standard copper wires of size not less
than 2.5mm2. Insulation colour code of earthing wires shall be green. Earthing wires shall
be connected to terminals with suitable clamp connections and soldering is not acceptable.
Looping of earth connections which would result in loss of earth connection to the
devices when a device is removed is not acceptable. However, looping of earth connections
between equipment to provide alternative paths or earth bus is acceptable.
viii) VT and CT secondary neutral point earthing shall be at one place only, on the terminal
block. Such earthing shall be made through links so that earthing on one secondary circuit
shall be removed without disturbing the earthing of other circuit.
ix) All hinged doors shall be earthed through flexible earthing braid.
x) Caution nameplate ‘Caution-Live Terminals’ shall be provided at all points where the
terminals are like to remain live and isolation is possible only at remote end.
1.6 AIR CIRCUIT BREAKERS
i) Circuit breakers shall be three-pole air break horizontal drawout type and shall have
inherent fault making and breaking capacities as specified in “Technical Parameters”.
ii) Circuit breakers shall be mounted along with operating mechanism on a wheeled carriage.
Suitable guides shall be provided to minimize misalignment of the breaker.
iii) There shall be ‘Service’, ‘Test’ and ‘Fully withdrawn positions for the breakers. In
“Test’ position the circuit breaker shall be capable of being tested for operation
without energizing the power circuits i.e. the power contacts shall be disconnected
while Control circuits shall remain undisturbed. Locking facilities shall be
provided so as to prevent movement of the circuit breaker from the ‘SERVICE’,
‘TEST’ or FULLY WITHDRAWN’ position. It shall be possible to close the door in TEST
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position.
iv) All circuit breakers shall be provided with 4 NO and 4 NC potential free auxiliary contacts.
These contacts shall be addition to those required for internal mechanism of the
breaker. Separate limit switches each having required number of contacts shall be
provided in both ‘SERVICE & ‘TEST’ position of the breaker. All contacts shall be
rated for making continuously carrying and breaking 10 Amps at 240 V AC and 1
Amp (Inductive) at 220V DC.
v) Suitable mechanical indications shall be provided on all circuit breakers to show ‘OPEN’.
‘CLOSE’, ‘SERVICE’, TEST’ and ‘SPRING CHARGED’ positions.
vi) Main poles of the circuit breakers shall operate simultaneously in such a way that the
maximum difference between the instants of contacts touching during closing shall
not exceed half cycle of rated frequency.
vii) All circuit breakers shall be provided with the interlocks.
viii) Movement of a circuit breaker between SERVICE AND TEST positions shall not be
possible unless it is OPEN position. Attempted with drawl of a closed circuit breaker shall
trip the circuit breaker.
ix) Closing of a circuit breaker shall not be possible unless it is in SERVICE, TEST POSITION
or in FULLY WITHDRAWN POSITION.
x) Circuit breaker cubicles shall be provided with safety shutters operated automatically
by the movement of the circuit breaker carriage to cover the stationery isolated contacts
when the breaker is withdrawn. It shall however, be possible to open the shutters
intentionally, against spring pressure for testing purpose.
xi) A breaker of particular rating shall be prevented from insertion in a cubicle of a different
rating.
xii) Circuit breakers shall be provided with electrical anti-pumping and trip feature,even if
mechanical antipumping feature is provided.
xiii) Mechanical tripping shall be possible by means of front mounted RED‘TRIP’ push-
button. In case of electrically operated breakers these push buttons shall be shrouded to
prevent accidental operation.
xiv) Breaker controlled motors shall operate satisfactorily under the following conditions:-
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a) Direct on-line starting of Induction Motors rated 110kW to 220 kW with a locked rotor
current of seven times the rated current, and starting time of upto 30 seconds.
b) Breaking on-load, full load and locked motor currents of Induction Motors for rated 100
kW to 220kW.
xv) Means shall be provided to slowly close the circuit breaker in withdrawn position. If
required for inspection and setting of Contacts, in service position slow closing shall not be
possible.
xvi) Power operated mechanism shall be provided with a universal motor suitable for
operation 220V DC Control supply with voltage variation from 90% to 110% rated
voltage. Motor insulation shall be class ‘E’ or better.
xvii) The motor shall be such that it requires not more than 30 seconds for fully charging the
closing spring.
xviii) Once the closing springs are discharged, after the one closing operation of circuit breaker, it
shall automatically initiate, recharging of the spring.
xix) The mechanism shall be such that as long as power is available to the motor, a
continuous sequence of closing and opening operations shall be possible. After failure of
power supply at least one open-close open operation shall be possible.
xx) Provision shall be made for emergency manual charging and as soon as this manual
charging handle is coupled, the motor shall automatically get mechanically decoupled.
xxi) All circuit breakers shall be provided with closing and trip coils. The closing coils
shall operate correctly at all values of Voltage between 85% to 110% of rated control
voltage. The trip coil shall operate satisfactorily under all values of supply voltage between
70% to 110% of rated control voltage.
xxii) Provision for mechanical closing of the breaker only in ‘TEST’ and ‘WITHDRAWN’
positions shall be made.
1.7 PROTECTION CO-ORDINATION
It shall be the responsibility of the Contractor to fully co-ordinate the overload and
short circuit tripping of the circuit breakers with the upstream and downstream
circuit breakers/fuses/motor starters, to provide satisfactory discrimination.
1.8 MOULDED CASE CIRCUIT BREAKER (MCCB) and MCB
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i) MCCB shall in general conform to IS: 13947 Part-2, All MCCB shall be P2 duty.
ii) MCCB shall be flush mounted on the AC/DC distribution boards.
iii) MCCBs shall be provided with thermo-magnetic type release for Over current and short
circuit protection. The setting of the thermal release shall be adjustable between 75% to
100% of the rated current. The MCCB shall have breaking capacity not less than 20kA.
iv) MCCBs used for ACDB incomers and Bus coupler shall be equipped with stored energy
mechanism for electrical closing and tripping. All other MCCBs shall be manually operated.
The operating handle should give a clear trip indication.
v) Miniature circuit breaker (MCB) shall conform to IEC:898-1998 and IS:8828.
1.9 RELAYS
i) All relays and timers in protective circuits shall be flush mounted on panel front with
connections from the inside. They shall have transparent dust tight covers removable from
the front. All protective relays shall have a drawout construction for easy replacement from
the front. They shall either have built-up test facilities, or shall be provided with necessary
test blocks and test switches located immediately below each relay. The auxiliary
relays and timers may be furnished in non-drawout cases.
ii) All AC relays shall be suitable for operation, at 50 Hz with 110 Volts VT secondary and 1
amp or 5 Amp CT secondary.
iii) All protective relays and timers shall have at least two potentially free output
contacts. Relays shall have contacts as required for protection schemes. Contacts of relays
and timers shall be silver faced and shall have a spring action. Adequate number of
terminals shall be available on the relay cases for applicable relaying schemes.
iv) All protective relays auxiliary relays and timers shall be provided with hand reset
operation indicators (flags) and analysing the case of operation.
v) All relays shall withstand a test voltage of 2 KV (rms) for one minute.
vi) Motor starters shall be provided with three element, ambient temperature compensated, time
lagged, hand reset type overload relays with adjustable settings. The setting ranges shall
be properly selected to suit the motor ratings. These relays shall have a separate black
coloured hand reset push button mounted on compartment door and shall have at
least one changeover contact.
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vii) All fuse-protected contactors-controlled motors shall have phasing protection,
either as a distinct feature in the overload relays (by differential movement of bimetallic
strips), or as a separate device. The single phasing protection shall operate even with 80% of
the set current flowing in two of the phases.
1.10 CONTACTORS
i) Motor starter contactors shall be air break, electromagnetic type rated for uninterrupted duty
as per IS: 13947 (Part 4).
ii) Contactors shall be double break, non-gravity type and their main contacts shall be silver
faced.
iii) Direct on line starter contactors shall be utilisation category AC2. These contactors shall be
as IS: 13947 (Part 4).
iv) Each contactor shall be provided with two (2) normally open (NO) and two (2)
normally close (NC) auxiliary contacts.
v) Operating coils of contactors shall be of 240V AC Unless otherwise specified
elsewhere. The Contactors shall operate satisfactorily between 85% to 110% of the rated
voltage. The Contactor shall drop out at 70% of the rated voltage.
1.11 INSTRUMENT TRANSFORMERS
i) All current and voltage transformers shall be completely encapsulated cast resin insulated
type suitable for continuous operation at the temperature prevailing inside the
switchgear enclosure, when the switchgear is operating at its rated condition and
the outside ambient temperature is 50 DegC.
ii) All instrument transformers shall be able to withstand the thermal and mechanical
stresses resulting from the maximum short circuit and momentary current ratings of
the associated switchgear.
iii) All instrument transformers shall have clear indelible polarity markings. All secondary
terminals shall be wired to a separate terminal on an accessible terminal block where star-
point formation and earthing shall be done.
iv) Current transformers may be multi or single core type. All voltage transformers shall be
single phase type. The bus VTs shall be housed in a separate compartment.
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v) All VTs shall have readily accessible HRC current limiting fuses on both primary and
secondary sides.
1.12 INDICATING INSTRUMENTS
i) All indicating and integrating meters shall be flush mounted on panel front. The instruments
shall be of at least 96 mm square size with 90 degree scales, and shall have an
accuracy class of 2.5 or better. The covers and cases of instrument and meters shall provide a
dust and vermin proof construction.
ii) All instruments shall be compensated for temperature errors and factory calibrated to
directly read the primary quantities. Means shall be provided for zero adjustments without
removing or dismantling the instruments.
iii) All instruments shall have white dials with black numerals and lettering. Black knife edge
pointer with parallax free dials will be preferred.
iv) Ammeters provided on Motor feeders shall have a compressed scale at the upper current
region to cover the starting current.
v) Watt-hour meters shall be of 3 phase three element type, Maximum demand indicators
need not be provided.
1.13 CONTROL & SELECTOR SWITCHES
i) Control & Selector switches shall be of rotary type with escutcheon plates clearly marked to
show the function and positions. The switches shall be of sturdy construction suitable for
mounting on panel front. Switches with shrouding of live parts and sealing of contacts
against dust ingress be preferred.
ii) Circuit breaker selector switches for breaker controlled motor shall have three stay put
positions marked ‘Switchgear’, ‘Normal’ and ‘Trial’ respectively. They shall have two
contacts of each of the three positions and shall have black shade handles.
iii) Ammeter and voltmeter selector switches shall have four stay put position with adequate
number of contacts for three phase 4 wire system. These shall have oval handles Ammeter
selector switches shall have make before break type contacts to prevent open circuiting of
CT secondary’s.
iv) Contacts of the switches shall be spring assisted and shall be of suitable material to give a
long trouble free service.
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v) The contact ratings shall be at least the following:
a) Make and carry continuously 10 Amp.
b) Breaking current at 220V DC 1 Amp (Inductive)
c) Breaking current at 240V DC 5 Amp (at 0.3 pf lagging)
1.14 AIR BREAK SWITCHES
i) Air breaker switch shall be of the heavy duty, single throw group operated, load break, fault
make type complying with IS: 4064.
ii) The Bidder shall ensure that all switches are adequately rated so as to be fully protected by
the associated fuses during all abnormal operating conditions such as overload, locked
motor, short circuit etc.
iii) Switch operating handles shall be provided with padlocking facilities to lock them in ‘OFF’
position.
iv) Interlocks shall be provided such that it is possible to open the cubicle door only
when the switch is in ‘OFF’ position and to close the switch only when the door is
closed. However suitable means shall be provided to intentionally defeat the interlocks
explained above.
v) Switches and fuses for AC/DC control supply and heater supply wherever required shall be
mounted inside and cubicles.
1.15 PUSH BUTTONS
i) Push-buttons shall be of spring return, push to actuate type. Their contacts shall be rated to
make, continuously carry and break 10A at 240V and 0.5A (inductive) at 220V DC.
ii) All push-buttons shall have one normally open and one normally closed contact, unless
specified otherwise. The contact faces shall be of silver or silver alloy.
iii) All push-buttons shall be provided with integral escutcheon plates marked with its function.
iv) All push-buttons on panels shall be located in such a way that Red-push- buttons shall
always be to the left of green push-buttons.
1.16 INDICATING LAMPS
i) Indicating lamps shall be of the panel mounting cluster LED type. The lamps shall
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have escutcheon plates marked with its function, wherever necessary.
ii) Lamps shall be easily replaceable from the front of the cubicle.
iii) Indication lamps should be located just above the associated push buttons/control
switches.
iv) All indicating lamps shall be suitable for continuous operation at 90 to 110% of their rated
voltage.
1.17 FUSES
i) All fuses shall be of HRC cartridge fuse link type. Screw type fuses shall not be accepted.
Fuses for AC Circuits shall be of class 2 type, 20 kA (RMS) breaking current at 415
AC, and for DC circuits Class 1 type 5 kA breaking current.
ii) Fuses shall have visible operation indicators.
iii) Fuses shall be mounted on fuses carriers, which are mounted on fuse bases, wherever
it is not possible to mount fuses on carriers fuses shall be directly mounted on plug in
type of bases, In such cases one set of insulated fuse pulling handles shall be supplied
with each switchgear.
iv) Fuse rating shall be chosen by the Bidder depending upon the circuit requirements
and these shall be subject to approval of OWNER.
1.18 TERMINAL BLOCKS
i) Terminal blocks shall be of 1100 volts grade and have continuous rating to carry the
maximum expected current on the terminals. It shall be complete with insulating barriers,
clip-on-type/stud type terminals for Control Cables and identification strips.
Marking on terminal strip shall correspond to the terminal numbering on wiring on
diagrams. It shall be similar to ‘ELEMAX’ standard type terminals, cage clamp
type of Phoenix or WAGO or equivalent.
ii) Terminal blocks for CT and VT secondary leads shall be provided with test links
and isolating facilities. CT secondary leads shall be provided distributed on all
terminal circuiting and earthing facilities. It shall be similar to ‘Elem’, ‘CATD’ – Type.
iii) In all circuit breaker panels at least 10% spare terminals for external connections shall
be provided and these spare terminals shall be uniformly distributed on all terminal
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blocks. Space for adding another 10% spare terminals shall also be available.
iv) All terminals blocks shall be suitable for terminating on each side, two (2) nos. of 2.5mm
square size standard copper conductors.
v) All terminals shall be numbered for identification and grouped according to the function.
Engraved white-on-black labels shall be provided on the terminal blocks.
vi) Wherever duplication of a terminal block is necessary it shall be achieved by solid bonding
links.
vii) Terminal blocks shall be arranged with at least 100 mm clearance between two sets of
terminal block. The minimum clearance between the first row of terminal block and the
associated cable gland plate shall be 250 mm.
1.19 NAME PLATES AND LABELS
i) All switchgears AC/DC distribution boards shall be provided with prominent,
engraved identification plates. The module identification plate shall clearly give the feeder
number and feeder designation. For single front switchboards, similar panel and board
identification labels shall be provided at the rear also.
ii) All name plates shall be of non-rusting metal or 3-ply lamicoid with white engraved lettering
on black background. Inscriptions and lettering sizes shall be subject to OWNER approval.
iii) Suitable plastic sticker labels shall be provided for easy identification of al equipments,
located inside the panel/module. These labels shall be positioned so as to be
clearly inside visible and shall give the device number as mentioned in the module
wiring drawings.
1.20 SPACE HEATER
i) Space heater shall be provided in all the boards for preventing harmful moisture
condensation.
ii) The space heaters shall be suitable for continuous operation on 240V, AC, 50 Hz, single
phase supply, and shall be automatically controlled by thermostats. Necessary isolating
switches and fuses shall also be provided.
1.21 CONTROL AND SECONDARY WIRING
i) All switchboards shall be supplied completely wired internally upto the terminal blocks
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ready to receive Owner’s control cables.
ii) All inter cubicle and inter panel wiring and connections between panels of same switchboard
including all bus wiring for AC and DC supplies shall be provided by the bidder.
iii) All internal wiring shall be carried out with 1100V grade, single core, 1.5 square mm or
larger stranded copper wires having colour coded, PVC insulation. CT circuits shall be
wired with 2.5 square mm copper wires. Voltages and insulation shall be same as above.
iv) Extra-flexible wires shall be used for wiring to device mounted on moving parts such as
hinged doors.
v) All wiring shall be properly supported, neatly arranged, readily accessible and securely
connected to equipment terminals and terminals blocks.
1.22 POWER CABLES TERMINATION
i) Cable termination compartment and arrangement for power cables shall be suitable for
stranded aluminium conductor, armoured XLPE/PVC insulated and sheathed, single
core/three core, 1100V grade cables.
ii) All necessary cable terminating accessories such as Gland plates, supporting
clamps and brackets, power cable lugs, hardware etc., shall be provided by successful
bidder, suit the final cable sizes which would be advised later.
iii) The gland plate shall be removable type and shall cover the entire cable alley. Bidder shall
also ensure that sufficient space is provided for all cable glands. Gland plates shall be
factory-drilled according to the cable gland sizes and number which shall be informed to the
Contractor later. For all single core cables, gland plates shall be of non-magnetic Material.
1.22.1 TYPE TESTS
i) Type test reports of Panels (Switchgear and Control gear assemblies) as
per IS 8623 Part-I shall be submitted for the following tests before the
fabrication of switchgear is started :
(a) Verification of temperature rise limits
(b) Verification of the dielectric properties
(c) Verification of short circuit strength
(d) Verification of the continuity of the protective circuit
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(e) Verification of clearances and cree distances
(f) Verification of mechanical operation
(g) Verification of degree of protection
ii) Contractor shall submit type test reports for the following Switchgear and
Control gears before the fabrication of switchgear is started:
(a) Circuit breakers / MCCB as per IS 13947 Part-II
(b) Protective Relays as per IEC:60255 for the above equipments test
conducted once are acceptable (i.e. The requirement of test conducted
within last five years shall not be applicable).
1.24 ERECTION, TESTING AND COMMISSIONING
i) The Contractor shall unload, erect, install, test and put into commercial use all
electrical equipment included in this specification.
ii) Equipment shall be installed in a neat, workman like manner so that it is level, plumb, square
and properly aligned and oriented. Tolerance shall be as established in Contractor’s
drawings or as stipulated by Owner. No equipment shall be permanently bolted down to
foundations until the alignment has been checked and found acceptable by the Owner.
iii) Contractor shall furnish all supervision, labour tools equipment rigging materials,
bolts, wedges, anchors, concrete inserts etc. in proper time required to completely
install, test and commission the equipment.
iv) Manufacturer’s and Owner’s instructions and recommendations shall be correctly followed
in handling, setting, testing and commissioning of all equipment.
v) Contractor shall move all equipment into the respective room through the regular door or
openings specifically provided for this purpose. No part of the structure shall be utilized to
lift or erect any equipment without prior permission of Owner.
vi) All boards shall be installed in accordance with Indian Standards IS: 3072 and at Owner’s
instructions. All boards shall be installed on finished surfaces, concrete or steel stills.
Contractor shall be required to install and align any channel sills which form part of
foundations. In joining shipping sections of switchboards together adjacent housing of
panel sections or flanged throat sections shall be bolted together after alignment has
been complete. Power bus, enclosures ground and control splices of conventional nature
shall be cleaned and bolted together being drawn up with torque spanner of proper size or by
other approved means.
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vii) All boards shall be made completely vermin proof.
viii) Contractor shall take utmost care in holding instruments, relaying and other delicate
mechanism wherever the instruments and relays are supplied separately they shall
be mentioned only after the associated panels have been erected and aligned. The packing
materials employed for safe transit of instrument and relays shall be removed after ensuring
that panel have been completely installed and no further movement of the same should
be necessary. Any damage shall be immediately reported to Owner.
ix) Equipment furnished with finished coats of paint shall be touched by up Contractor if their
surface is specified or marred while handling.
x) After installation of panels, power and control wiring and connections, Contractor
shall perform operational tests on all switchboards, to verify proper operation of
switchboards/panels and correctness of all equipment in each and every respect. The cable
opening and cables entries for cables terminating to the panels shall be sealed with fire
sealing materials.
1.25 COMMISSIONING CHECK TESTS
i) The contractor shall carry out the following commissioning checks, in addition to the other
checks and tests recommended by the manufacturers:
A) General
(a) Check name plate details according to the specification.
(b) Check for physical damage.
(c) Check tightness of all bolts, clamps, joints connecting terminals.
(d) Check earth connections
(e) Check cleanliness of insulators and bushings
(f) Check all moving parts for proper lubrication
(g) Check settings of all the relays
B) Circuit Breakers
(a) Check alignment of breaker truck for free movement
(b) Check correct operation of shutters
(c) Check control wiring for correctness of connections, continuity and IR
values
(d) Manual operation of breaker completely assembled
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(e) Power closing/opening operation, manually and electrically
(f) Breaker closing and tripping time
(g) Trip free and anti-pumping operation
(h) IR values, minimum pick up voltage and resistance of coils
(i) Contact resistance
(j) Simultaneous closing of all the three phases
(k) Check electrical & mechanical interlocks provided
(l) Check on spring charging motor, correct operation of limit switches and
time of charging.
(m) All functional checks
C) Current Transformers
(a) Meggar between winding and winding terminals to body
(b) Polarity test
(c) Ratio identification checking of all ratios on all cores by primary injection
of current.
(d) Spare CT cores, if available, to be shorted and earthed.
D) Voltage Transformer
(a) Insulation resistance test
(b) Ratio test on all cores
(c) Polarity test
(d) Line connections as per connection diagram
E) Cubicle Wiring
(a) Check all switch developments
(b) Each wire shall be traced by continuity tests and it should be made sure that
the wiring is as per relevant drawing. All interconnections between
panels/equipment shall be similarly checked.
(c) All the wires shall be meggered to earth
(d) Functional checking of all control circuit e.g. closing, tripping control,
interlock, supervision and alarm circuit.
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F) Relays
(a) Check connections and wiring
(b) Megger all terminals to body
(c) Megger AC to DC terminals
(d) Check operating characteristics by secondary injection
(e) Check minimum pick up voltage of DC coils
(f) Check operation of electrical/mechanical targets
(g) Relays settings
(h) Check CT and VT connections with particular reference to their polarities
for directional relays wherever required.
G) Meters
(a) Check calibration by comparing it with a sub-standard.
(b) Megger all insulated portions.
(c) Check CT and VT connections with particulars reference to their polarities
for power type meters.
8.26 SPECIAL TOOLS AND TACKLES
i) The Bidder shall include in his proposal any special tools and tackles required
for erection, testing commissioning and maintenance of the equipments offered.
ii) The list of these special tools and tackles shall be given in the bid proposal sheets
along with their respective prices.
iii) The total price of the special tools and tackles shall be included in proposal
sheets.
8.26.1 EQUIPMENTS TO BE FURNISHED
i) Standard scheme of interconnection of switchboards and distribution boards
along with tentative feeder disposition for each board shall be provided by the
bidder for the approval of the Employer. Any other feeder required as per system
requirement for efficient and reliable operation shall be deemed to be included in
bidder’s scope.
ii) The Bill of Materials for each type of module shall be as under. These are minimum
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indicative requirement of the system. The necessary auxiliary relays, push buttons
and indicating lamps shall be provided as per scheme requirement. Any other item /
component required with in a module for efficient and reliable operation shall be
deemed to be included in bidder’s scope. The scheme shall have provision for
remote annunciation for the followings :
a. Station LT (415V) AC incomer supply unhealthy.
b. 220V DCDB U/V, O/V & Earth leakage relay operated.
c. 50V DCDB U/V & O/V relay operated.
d. DG set start
e. DG set protection
iii) Module Type AE (Electrically controlled circuit breaker for incoming and Bus
Coupler Circuit).
a. One (1) Triple pole air circuit breaker complete with all accessories and power
operated mechanism as specified.
b. Two (2) Neutral Link.
c. Three (3) Current Transformer for metering.
d. One (1) Ammeter with selector switch.
e. Three (3) Current Transformer for relaying.
f. One (1) Triple pole instantaneous over-current relay having the setting
range of 200- 800% or 500-2000% of CT secondary and adjustable definite
minimum time.
g. One (1) Instantaneous earth fault relay having and adjustable setting range
of 10-40% or 20-80% of CT secondary current and adjustable definite
minimum time. The earth fault relay shall be provided with a stabilizing
resistor.
iv) Module Type – M1 (Circuit Breaker Controlled Motor Feeder)
a. One (1) Triple pole Air Circuit Breaker complete with accessories, and power
operated mechanism as specified.
b. One (1) Three position 6 pole selector switch
c. ‘SWITCHGEAR / NORMAL / TRIAL’
d. Three (3) Current Transformer for metering.
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e. One (1) Ammeter with Ammeter Selector Switch.
f. Three (3) Current Transformer for relaying.
g. One (1) Triple pole instantaneous over-current relay for providing positive
sequence current protection in all the three phases. The relay setting range
shall be continuously adjustable between 200-800% or 400-1600% of CT
secondary rated current as required.
h. One (1) Double pole inverse definite minimum time over current relays
connected in R&B phases for over current protection of motor rated 110kw –
200kw. The relay shall have an adjustable setting range of 50%-200% of
CT Secondary current and time setting range of 0-30 Second. The relay
shall be CDGM-22 of EE or equivalent.
i. One (1) Single pole adjustable definite time delay relay for motor overload
alarm connected in Y-phase only. The relay shall have resetting ratio of not less
than 90%. The relay shall have continuously adjustable time delay range of 2.5
to 25 Sec.
j. One (1) Instantaneous earth fault relay having an adjustable setting range of 10-
40% or 20-80% of CT secondary current. The earth fault relay shall be provided
with a stabilizing resistor.
v) Module Type E
a. One (1) Four pole MCCB
vi) Module G-1 (VT Module with under Voltage Relay)
a. Three (3) 415/√3 / 110/√3 volts single phase voltage transformer star / star
connect with star point solidly earthed mounted on common draw out
chassis. Accuracy Class 0.5 for protection and metering with 50VA
Burden.
b. Six(6) HRC Fuses mounted on the above chassis. One (1)Four Position
voltmeter selector switch.
c. One (1) Voltmeter (0-500V)
d. One (1) Double pole instantaneous under voltage relays with continuous
variable setting range of 40-80% of 110 Volts.
e. One (1) Time delay pick up relay having a time setting range of 0.5
f. To 3 secs. With 3 ‘NO’. Self reset contacts, suitable for 220V DC.
Volume-II (Section-G), LT Switchgear 118
g. One (1) Auxiliary relay 220V DC with 2 No. self reset contacts.
h. Three (3) Indicating lamps with series resistor and colour lenses
vii) Module Type G-2
a. Three (3) HRC Fuse
b. One (1) Voltmeter (0-500V)
c. One (1) Voltmeter selector switch four position (R-Y, Y-B, B-R OFF).
d. Three (3) Indication lamps (Red, Blue & Yellow)
viii) Module Type H & H (BC) (Isolating Switch Controlled Incoming Circuit)
a. One (1) Four pole MCCB
b. One (1) Red Indicating lamp to indicate isolating switch closed position.
ix) Module Type S: (DC Metering and Protection Module)
a. One (1) Voltmeter 300-0-300V DC for 220V DC DB / Voltmeter 0-75V DC
for 50V DCDB
b. One (1) Three (3) position voltmeter selector switch
c. One (1) Instantaneous under voltage relay with 95% of 220V DC. The resetting
ratio of relay should not be more than 1.25. the relay shall be provided with a
series resistor and a push button across it for resetting (pick up) the relay
at about 105% of the drop out voltage.
d. One (1) Instantaneous over voltage relay with setting range of 110% of 220V
DC. The resetting ratio of relay should not be less than 0.8. the relay shall have
a push button in series for resetting the relay at about 95% of the
operating voltage.
e. One (1) Earth leakage relay only for 220V DC system having adjustable pick
up range between 3 to 7 milliamps the relay shall be suitable for 220V
DC/240V AC Auxiliary supply.
x) Module Type X
a. One (1) Double pole 250V MCB
xi) Module Type-DC (Incomer from Battery & Chargers)
a. One (1) Double pole 250V DC MCCB for incomer from Battery.
Volume-II (Section-G), LT Switchgear 119
b. One (1) DC ammeter with shunt and range of 90-0-400 Amps for 220V DC DB
and 90-0- 200 Amp. for 50V DC DB.
c. Two (2) Double pole 250V DC MCCB / MCB.
d. One (1) Double pole single throw 250V DC air Break switch connecting battery
& charger sections to DC DB.
xii) Module Type DG-1 (Electrically Controlled Circuit Breaker for Incomer
from DG Set)
a. One (1) Triple pole circuit breaker complete with all accessories and power
operated mechanism as specified.
b. One (1) Frequency meter.
c. One (1) Voltmeter with selector switch.
d. One (1) Remote/Local Selector switch.
e. Three (3) Current Transformer for Metering.
f. Six (6) Current Transformers for differential protection (out of this
g. Nos. will be supplied loose for mounting in DG set panel).
h. Three (3) Current Transformer for relaying.
i. One (1) Ammeter Selector Switch.
j. One (1) Ammeter
k. One (1) Wattmeter of range 0-300 KW
l. One (1)Three pole voltage controlled definite time delay relay having
current setting range of 50-200% of CT secondary current and adjustable time
delay 0.3 to 3 secs.
m. One (1) Watt hour meter with six (6) digits and minimum count of one (1) kwh.
n. One (1) Single pole definite time over current relay having a
continuous setting range of 50-200% of CT secondary current and a time
delay of 2.5-25 secs connected in CT of Y phase for overload alarm. The relay
shall have a setting ratio of not less than 90%.
o. One (1) Three pole differential protection relay having an operating current
setting range of 10-40% of generator full load current. The relay shall be
high impedance type, with necessary stabilizing resistors.
p. Two (2)Push Buttons for Remote starting & stopping of DG Set (Red,
Volume-II (Section-G), LT Switchgear 120
Green).
xiii) Module Type H1
a. One (1) Double pole DC Switch with pad locking facility in off position.
xiv) Module Type EL
a. One (1) Four pole MCCB
b. One (1) Contactor
c. Electronic Timer suitable for continuous operation, push button and selector
switch be as per scheme requirement.
8.27 PARAMETERS
A) POWER SUPPLY
S.No. i) AC System 3 phase, 4 wire, solidly earthed 1. Voltage 415 Volts, ± 10%
2. Frequency 50 Hz ± 5%
3. Combined variation + 10%
4. Fault Level 20 kA (rms)
ii) DC System 2 Wire, unearthed
1. System Voltage 220V ± 10%
2. Fault Level 4 kA
iii) Control Supply Voltage
1. Trip and closing 220 V DC Unearthed coils
2. Spring charging 220 V DC Unearthed
B) CUBICAL DATA
S.No. BUSBAR RATING
1. Continuous As specified
2. Short Time (1 Sec) 20kA (rms)
3. Momentary 45kA
4. Ambient Temperature 50Deg C
5. One Minute Power WithStand Voltage
Volume-II (Section-G), LT Switchgear 121
i) ii)
Power Circuit 2500V rms
Control Circuit 2500V rms
6. Cubicle Colour Finish
a) Interior Glossy White
b) Control Circuit Smoke Grey shade No. 692 of IS:5
C) CIRCUIT BREAKER
1. Type Air Break
2. No. Of poles 3
3. Voltage and Frequency 415 ±10%, 50 HZ ±5%
4. Rated Operating Duty As per IS
5. Symmetrical Interruption 20kA (RMS)
6. Short Circuit making Current 45kA (Peak) 7. Short time Withstand Current for
1Sec 20KA (RMS) for 1 Sec
8. Operating Mechanism Duration 20 kA (RMS) for 1 Sec
9. No. of auxiliary Contacts 4 NO & 4 NC contacts
10. Short Circuit breaking current
i) AC Component 20kA Rms
ii) DC Component As per IS:13947 Part 2
D) MOULDED CASE CIRCUIT BREAKER AC SYSTEM DC SYSTEM
1. No. Of poles 4 2
2. Voltage and Frequency 415 ±10%, 50 HZ ±5%
250V
3. Rated Operating Duty As per IS
4. Symmetrical Interrupting Current
20kA (RMS) 4kA
5. Short Circuit making Current
45kA (peak)
7. No. of auxiliary Contacts 2 NO & 2 NC 2 NO & 2 NC
8. Short Circuit breaking current
20kA Rms As per IS:13947
As per IS:13947
E) METERS
1. Accuracy Class 2.5
2. One Minute power frequency withstand test voltage (kV)
2.0
F) CURRENT TRANSFORMER
Volume-II (Section-G), LT Switchgear 122
1. Type Cast resin, Bar primary
2. Voltage class and frequency 650V, 50Hz
3. Class of Insulation E or better
4. Accuracy class metering CT Class 1, VA adequate for application, but not less than 7.5 VA
5. Accuracy class protection CT 5P 15, VA adequate for application, but not less than 7.5 VA
6. Accuracy class differential protection
PS, KPV = 300 V
7. Short time current rating (for CTs Associated with circuit breakers)
i) Current 20 kA (RMS)
ii) Duration One second
iii) Dynamic Rating 45 kA (Peak)
iv) One Minute Power WithStand Voltage 2.5 kV (rms)
G) VOLTAGE TRANSFORMER
1. Type Cast resin
2. Rated Voltage
i) Primary 415/√3 V
ii) Secondary 110/√3 V
3. Method of Connection
i) Primary Star
ii) Secondary Star
4. Rated Voltage Factor 1.1 continuous, 1.5 for seconds
5. Class of insulation E or better
6. One minute power frequency withstand voltage
2.5 KV (RMS)
7. Accuracy class 0.5, not less than 20 VA
H) RELAY
One minute power frequency withstand test Voltage 2 kV (rms)
1.29 AUTOMATIC CONTROL OF OUTDOOR LIGHTING
EL-type module of 415 V Main lighting distribution board and Emergency lighting
distribution board and shall be controlled by timer and contactor module to facilitate its
operation automatically.
Volume-II (Section-G), LT Switchgear 123
1.30 AUTOMATIC SUPPLY CHANGEOVER
i) Automatic changeover between Incomer I, Income II and DG set is to be carried out during
the failure of supply in one/or both the incomers. After the restoration of the supply, system
shall be restored to normal condition automatically. The requirement of changeover under
various conditions is as below:-
(a) Under normal conditions i.e. when supply is available in both the incomers,
incomers I&II of 415 V Main switchboard, ACDB shall be in closed condition and
Bus couplers and DG set breaker shall be in open condition.
(b) In case of failure of either of the sources, the incomer of that source shall trip
and Bus coupler shall get closed. On restoration of supply, normal conditions
described above are to be established automatically.
(c) In case of failure of supply in both the sources, both incomers, incomers of
ACDBs and ACDB Bus coupler shall trip and DG Set breaker switched on.
i) On restoration of one or both sources, DG Set breaker shall trip, DG set stopped and
conditions described in paragraph (a) & (b) shall be restored.
ii) To avoid unnecessary operation of switchgear for momentary disturbances all changeovers
from one state to another shall be intimated after a time delay, after the conditions
warranting such change has been detected.
Volume-II (Section-H), Power And Control Cables 124
SECTION- (H)
TECHNICAL DETAILS OF POWER AND CONTROL CABLES
1.1kV Control & Auxilliary Power Cables
1.0 SCOPE
This technical specification covers the requirement of design, manufacture, testing, packing
and dispatch of 1.1kV grade Auxiliary power and control cables (FRLS type). No deviation
from the requirements specified in various clauses of this specification shall be allowed.
1.1 TYPE OF CABLES
Sl No. Type of Control Cable
1 2C x 2.5 sq mm PVC/ Cu.
2 3C x 2.5 sq mm PVC/ Cu.
3 5C x 2.5 sq mm PVC/ Cu.
4 7C x 2.5 sq mm PVC/ Cu.
5 10C x 2.5 sq mm PVC/ Cu.
6 14C x 2.5 sq mm PVC/ Cu.
7 19C x 2.5 sq mm PVC/ Cu.
8 27C x 2.5 sq mm PVC/ Cu.
9 4 C x 4 sq mm PVC/ Cu.
10 4 C x 6 sq mm PVC/ Cu.
11 4 C x 10 sq mm PVC/ Cu.
12 1C x 630 sq mm XLPE/ Al.
13 1C x 400 sq mm XLPE/ Al.
14 1C x 500 sq mm XLPE/ Al.
15 3.5C x 240 sq mm XLPE/ Al.
16 3.5C x 300 sq mm XLPE/ Al.
17 3.5C x 400 sq mm XLPE/Al.
Volume-II (Section-H), Power And Control Cables 125
18 1C x 630 sq mm PVC / Al.
19 1C x 400 sq mm PVC/ Al.
20 3.5C x 400 sq mm PVC/Al.
21 3.5C x 300 sq mm PVC/Al.
22 1C x 185 sq mm PVC/ Al.
23 1C x 150 sq mm XLPE/ Al.
24 3.5C x 95 sq mm PVC/ Al.
25 3.5C x 70 sq mm PVC/ Al.
26 1C x 50 sq mm PVC/ Al.
27 3.5C x 35 sq mm PVC/ Al.
28 2C x 6 sq mm PVC/Al.
29 2C x 10 sq mm PVC/Al.
30 4C x 6 sq mm PVC/ Al.
31 4C x 10 sq mm PVC/ Al.
32 4C x 16 sq mm PVC/ Al.
33 4C x 25 sq mm PVC/ Al.
1.2 APPLICABLE STANDARDS
The auxiliary power and control cables shall conform to following latest Indian and
International standards and their amendments.
IS 1554 PVC insulated (heavy duty) electric cables -
(Part I) For working voltage up to and including 1100V
IS 7098 XLPE insulated PVC sheathed cables -
(Part I) For working voltage up to and including 1100V
IS 5831 PVC insulation and sheath of electric cables.
Volume-II (Section-H), Power And Control Cables 126
IS 8130 Conductors for insulated electric cables and flexible cords.
IS 3975 Low Carbon Galvanized Steel Wires, Formed Wires and Tapes
for Armouring of Cables - Specification
IS 10810 Method of tests for cables.
IEEE-383 Standard for type test of class IE electric cables, field splices, and
connections for nuclear power generating stations.
ASTM-D2843 Standard test method for density of smoke from burning or
decomposition of plastics.
ASTM-D2863 Standard test method for measuring minimum oxygen concentration
to support candle - like combustion of plastics (oxygen index).
IEC:60754 Test on gases evolved during combustion of electric cables
(Part-1 & 2)
IEC:60332 Tests on electric and optical fibre cables under fire conditions
(Part I to 3)
IS 3961 Recommended current rating for cables -
(Part II) PVC insulated and PVC sheathed heavy-duty cables.
IS 10418 Drums for electric cables.
SS 4241475 Swedish chimney test
1.3 SPECIFIC TECHNICAL REQUIREMENTS 1.3.0 OPERATIONAL REQUIREMENTS All cables shall be suitable for high ambient, high humid tropical Indian climatic
conditions. All cables shall be designed to withstand the mechanical, electrical and
thermal stresses under the foreseen steady state and transient/fault conditions, and
shall be suitable for the proposed method of installation.
Cables shall be derated for the site ambient and ground temperatures, grouping and
soil resistivity and cable-laying configuration. Cables shall be selected to limit
Volume-II (Section-H), Power And Control Cables 127
maximum voltage drop at equipment terminals during normal operation and starting
conditions well within permissible values. Voltage grade of cables shall be of
earthed grade when used in solidly earthed systems, and unearthed grade when used
in non-effectively earthed systems
1.3.1 DESIGN AND CONSTRUCTIONAL FEATURES 1.3.2 Parameters of the cables are as follows: ------------------------------------------------------------------------------------------------------
----- Particulars Aux Power cables Control cables ---------------------- XLPE PVC ------------------------------------------------------------------------------------------------------
----- a) Conductor i) Material Stranded Tinned Copper of Annealed Copper Aluminium as per IS 8130, Grade EC ii) Size As required, but 2.5 sq. mm minimum Min. 6 sq.mm Aluminium with minimum 7 strands or 2.5 sq mm for copper With minimum 7 strands iii) Shape Circular/ Circular/ Circular sector sector Shaped. Shaped b) Main Insulation i) Material XLPE PVC PVC ii) Continuous withstand 90 70 70 temperature (deg.C) iii) Short circuit withstand tem- 250 160 160 perature (deg.C) iv) Colour identi As per relevant codes and standards fication c) Inner Sheath All armoured cables shall have distinct extruded inner sheath
Volume-II (Section-H), Power And Control Cables 128
i) Material PVC PVC PVC ii) Colour Black Black Black d) Armour i) Material Aluminium wire for GS wire/formed
single core cable and wire as GS wire/formed wire per relevant IS. for multi core Min. coverage cables as per of 90%. relevant IS. Minimum Coverage of 90% ii) Breaking 95% of normal 95% of normal armour Load of armour Joint e) Outer sheath All power & control cable shall have extruded outer sheath. i) Material PVC PVC PVC (Polyethe- lene based Halogen free Material not Acceptable) ii) Colour Black Black Grey iii) Marking - Cable size & same as for Voltage grade Power Cables (by embossing) - Word “FRLS” @ 5m (by Embossing) - Sequential marking @1m
f) FRLS Oxygen Index: Min. 29 (As per ASTMD 2863)
Properties on Acid gas generation: Max. 20% (As per IEC754-I) Outer sheath Smoke density rating: 60% (As per ASTMD 2843) Temperature Index: Min 250oC g) Flammability Test on all As per IEC 332 Part-3 (Category B) & Swedish Chimney test
as per SS4241475 Types of cables h) Tolerance on +1.5mm for cable upto 30mm O.D. and +5% or 2mm
whichever is Outer Diameter less for cable above 30mm O.D.
(O.D.)
Volume-II (Section-H), Power And Control Cables 129
i) Minimum 12 x D for all multicore cables and 15 x D for single core cable Bending Radius 1.3.3 Core identification For cables having more than five (5) cores, each core shall be identified by number
marking. However, for cables upto five (5) cores, the same shall be by colour as per IS.
1.3.4 Armouring Cables buried direct in ground and cables in switchyard shall be armoured. Strip
armouring method (a) mentioned in Table 5, Page-6 of IS: 1554 (Part 1) - 1988 and Table 6, Page-6 of IS: 7098 (Part 1) - 1988 shall not be accepted for any of the cables.
1.3.5 Insulation & Sheath Insulation for PVC insulated aux. power & control cables shall be Type-A as per IS
1554 Part-1. Method of application shall be by extrusion and Sleeve extrusion is not permitted.
Insulation for XLPE insulated aux. power cables shall be as per IS 7098 Part-1. Inner sheath shall be PVC Type-ST1 as per IS 5831 for PVC power & PVC control
cables and Type-ST2 as per IS 5831 for XLPE power cables. Fillers are acceptable with material same as Inner sheath (Material of filler to be compatible with that of inner sheath). The method of application of inner sheath with fillers shall be Pressure/ Vacuum extrusion and without fillers shall be Pressure extrusion only.
Outer sheath for PVC insulated aux. power & control cables shall be PVC Extruded,
FRLS, Type ST-1 as per IS 5831 & Category C2 as per IS 1554 (Part-I) Outer sheath for XLPE insulated aux. power cables shall be PVC Extruded, FRLS,
Type ST-2 as per IS 5831 & Category C2 as per IS 7098 (Part-I)
1.4 CURRENT RATING FOR CONTROL and AUX. POWER CABLES
1.4.1 Normal current rating shall not be less than that covered by IS 3961.
1.4.2 PVC insulated cables shall be suitable for continuous conductor temperature of 70 C and
short circuit withstand temperature of 160 C. Tables giving de-rating factors for various
conditions of cable installation including the following, for all types of cables shall be
furnished -
- Variation in ambient air temperature.
Volume-II (Section-H), Power And Control Cables 130
- Variation in ground temperature.
- Depth of laying.
- Cables laid in the ground
- Cables laid in trench
- Cables laid in ducts
- Soil resistivity.
- Grouping of cables.
1.4.3 The value of short circuit withstand current ratings of all cables shall be indicated for a short
circuit for 1 second duration and should also specify the maximum temperature during short
circuit.
1.4.4 The following factors shall also be accounted for, while specifying the maximum short
circuit withstand of the cables.
1.4.4.1 Deformation of the insulation, due to thermo-mechanical forces produced by the short circuit
conditions, can reduce the effective thickness of insulation.
1.4.4.2 Conductor and core screens can be adversely affected with loss of screening effect. Likewise
the thermal properties of the outer sheath material can be the limitation.
1.4.4.3 It is essential that the accessories, which are used in the cable system with mechanical and/or
soldered connections, are suitable for the temperature adopted for the cables.
1.4.5 Formula for calculating short circuit current for different duration or curve showing short
time current v/s time for different sizes of cables shall be furnished by vendor.
1.5 CABLE DRUMS
1.5.1 Cables shall be supplied in non-returnable wooden cable drum and steel drums of heavy
construction. It shall be made of good quality wood, pressure impregnated against fungal and
insect attack. Wood preservative shall be applied to the entire drum. The ends of the each
length of cable shall be sealed before dispatch.
Volume-II (Section-H), Power And Control Cables 131
1.5.2 All Control and Power Cables shall be supplied in drum length of 1000m, unless otherwise
specified. For power cable with conductor cross sectional area 300sqmm and above may be
supplied in 500m drums. Each drum shall contain one continuous length of cable. Owner
shall have the option of rejecting cable drums with shorter lengths. The cable length per
drum is allowed a tolerance of +5%. The tolerance allowed on total quantity of each size is
+2%. Where the ordered quantity is not multiple of 1000/500 m and the incremental quantity
is very small, the same may be included in one of the drums. Otherwise, an additional length
for the incremental quantity will be supplied.
1.5.3 A layer of water proof paper shall be applied to the surface of the drums and over the outer
most cable layer.
1.5.4 A clear space of at least 40mm shall be left between the cables and the logging.
1.5.5 Each drum shall carry manufacturer’s name, purchaser’s name, address and contract number,
item number and type, size and length of the cable, net and gross weight stenciled on both
sides of drum. A tag containing the same information shall be attached to the leading end of
the cable. An arrow and suitable accompanying wordings shall be marked on one end of the
reel indicating the direction in which it should be rolled.
1.5.6 Packing shall be sturdy and adequate to protect the cables, from any injury due to
mishandling
or other conditions encountered during transportation, handling and storage. Both cable ends
shall be sealed with PVC/Rubber caps so as to eliminate ingress of water during
transportation and erection.
1.6 TESTS 1.06.00 All cables to be supplied shall conform to type tests as per relevant standards and
proven type.
1.06.01 All acceptance and routine tests shall be conducted as per approved QP of ultimate customer and relevant standards
1.06.02 The following type tests shall be carried out on one size each (to be selected by ultimate customer / BHEL) of LT control/LT PVC power/LT XLPE power of each voltage grade:
1.06.03 Conductor a) Annealing test : For copper conductor only
Volume-II (Section-H), Power And Control Cables 132
b) Tensile test : For Aluminium conductor only c) Wrapping test : For Aluminium conductor only d) Resistance test : For Al/Cu 1.06.04 Armour wires/formed wires a) Measurement of : Applicable for all types of material dimensions b) Tensile test : Applicable for all types of material c) Elongation test : Applicable for all types of material d) Torsion test : For round wire only e) Winding test : For formed wires only f) Resistance test : Applicable for all types of material g) Zinc coating test : For G. S. formed wires / wires only h) Wrapping test : For Aluminium wires only 1.06.05 For PVC / XLPE Insulation & PVC Sheath a) Test for thickness : Applicable for all types of material b) Tensile strength and : Applicable for all types of material Elongation test Before ageing and after ageing c) Ageing in air oven : Applicable for all types of material d) Loss of mass test : For PVC insulation & PVC sheath only e) Hot deformation test : For PVC insulation & PVC sheath only f) Heat shock test : For PVC insulation & PVC sheath only g) Shrinkage test : Applicable for all types of material h) Thermal stability test : For PVC insulation & PVC sheath only i) Hot set test : For XLPE insulation only j) Water absorption test : For XLPE insulation only k) Oxygen index test : For outer sheath only
Volume-II (Section-H), Power And Control Cables 133
l) Smoke density test : For outer sheath only m) Acid gas generation test : For outer sheath only 1.06.06 Completed Cables a) Flammability test as per : Applicable for all type of materials
IEC 332 part-III
b) Insulation resistance test (Volume resistivity method)
c) High voltage test
Volume-II (Section-I), Relay And Protection Panels 134
SECTION- (I)
TECHNICAL DETAILS OF RELAY AND PROTECTION PANELS
1. CONSTRUCTIONAL FEATURES
1.1. Simplex panel shall consist of a vertical front panel with equipment mounted thereon and having wiring
access from front for relay panels. Doors shall have handles with either built in locking facility or will be
provided with pad-lock.
1.2. Relay panels shall be of simplex type design as indicated. It is the responsibility of the Contractor to
ensure that the equipment specified and such unspecified complementary equipment required for
completeness of the protective/control schemes is properly accommodated in the panels without
congestion and if necessary, provide panels with larger dimensions. No price increase at a later date on this
account shall be allowed. However, the width of panels that are being offered to be placed in existing
switchyard control rooms, should be in conformity with the space availability in the control room.
1.3. Panels shall be completely metal enclosed and shall be dust, moisture and vermin proof. The enclosure
shall provide a degree of protection not less than IP-31 in accordance with IS:2147.
1.4. Panels shall be free standing, floor mounting type and shall comprise structural frames completely
enclosed with specially selected smooth finished, cold rolled sheet steel of thickness not less than 3 mm
for weight bearing members of the panels such as base frame, front sheet and door frames, and 2.0mm for
sides, door, top and bottom portions. There shall be sufficient reinforcement to provide level transportation
and installation.
1.5. All doors, removable covers and panels shall be gasketed all around with synthetic rubber gaskets
Neoprene/EPDM generally conforming with provision of IS 11149. However, XLPE gaskets can also be
used for fixing protective glass doors. Ventilating louvers, if provided shall have screens and filters. The
screens shall be made of either brass or GI wire mesh
1.6. Design, materials selection and workmanship shall be such as to result in neat appearance, inside and
outside with no welds, rivets or bolt head apparent from outside, with all exterior surfaces tune and
smooth.
1.7. Panels shall have base frame with smooth bearing surface, which shall be fixed on the embedded
foundation channels/insert plates. Anti vibration strips made of shock absorbing materials which shall be
supplied by the contractor, shall be placed between panel & base frame.
1.8. Cable entries to the panels shall be from the bottom. Cable gland plate fitted on the bottom of the panel
shall be connected to earthing of the panel/station through a flexible braided copper conductor rigidly.
Volume-II (Section-I), Relay And Protection Panels 135
1.9. Relay panels of modern modular construction would also be acceptable.
2.0 MOUNTING
2.1. All equipment on and in panels shall be mounted and completely wired to the terminal blocks ready for
external connections. The equipment on front of panel shall be mounted flush. No equipment shall be
mounted on the doors.
2.2. Equipment shall be mounted such that removal and replacement can be accomplished individually without
interruption of service to adjacent devices and are readily accessible without use of special tools. Terminal
marking on the equipment shall be clearly visible.
2.3. The Contractor shall carry out cut out, mounting and wiring of the free issue items supplied by others
which are to be mounted in his panel in accordance with the corresponding equipment manufacturer's
drawings. Cut outs if any, provided for future mounting of equipment shall be properly blanked off with
blanking plate.
2.4. The centre lines of switches, push buttons and indicating lamps shall be not less than 750mm from the
bottom of the panel. The centre lines of relays, meters and recorders shall be not less than 450mm from the
bottom of the panel
2.5. The centre lines of switches, push buttons and indicating lamps shall be matched to give a neat and
uniform appearance. Likewise the top lines of all meters, relays and recorders etc. shall be matched.
2.6. No equipment shall be mounted on the doors.
2.7. At existing station, panels shall be matched with other panels in the control room in respect of dimensions,
colour, appearance and arrangement of equipment (centre lines of switches, push buttons and other
equipment) on the front of the panel.
3.0 PANEL INTERNAL WIRING
3.1. Panels shall be supplied complete with interconnecting wiring provided between all electrical devices
mounted and wired in the panels and between the devices and terminal blocks for the devices to be
connected to equipment outside the panels. When panels are arranged to be located adjacent to each other
all inter panel wiring and connections between the panels shall be furnished and the wiring shall be carried
out internally
3.2. All wiring shall be carried out with 650V grade, single core, stranded copper conductor wires with PVC
insulation. The minimum size of the multi-stranded copper conductor used for internal wiring shall be as
follows:
Volume-II (Section-I), Relay And Protection Panels 136
• All circuits except current transformer circuits and voltage transfer circuits meant for energy metering -
one 1.5mm sq. per lead.
• All current transformer circuits one 2.5 sq.mm lead.
• Voltage transformer circuit (for energy meters): Two 2.5 mm sq.per lead.
3.3. All internal wiring shall be securely supported, neatly arranged, readily accessible and connected to
equipment terminals and terminal blocks. Wiring gutters & troughs shall be used for this purpose.
3.4. Auxiliary bus wiring for AC and DC supplies, voltage transformer circuits, annunciation circuits and other
common services shall be provided near the top of the panels running throughout the entire length of the
panels.
3.5. Wire termination shall be made with solderless crimping type and tinned copper lugs, which firmly grip
the conductor. Insulated sleeves shall be provided at all the wire terminations. Engraved core identification
plastic ferrules marked to correspond with panel wiring diagram shall be fitted at both ends of each wire.
Ferrules shall fit tightly on the wire and shall not fall off when the wire is disconnected from terminal
blocks. All wires directly connected to trip circuit breaker or device shall be distinguished by the addition
of red coloured unlettered ferrule.
3.6. Longitudinal troughs extending throughout the full length of the panel shall be preferred for inter panel
wiring. Inter-connections to adjacent panel shall be brought out to a separate set of terminal blocks located
near the slots of holes meant for taking the inter-connecting wires.
3.7. Contractor shall be solely responsible for the completeness and correctness of the internal wiring and for
the proper functioning of the connected equipments
4. 0 TERMINAL BLOCKS
4.1. All internal wiring to be connected to external equipment shall terminate on terminal blocks. Terminal
blocks shall be 650 V grade and have 10 Amps. continuous rating, moulded piece, complete with insulated
barriers, stud type terminals, washers, nuts and lock nuts. Markings on the terminal blocks shall
correspond to wire number and terminal numbers on the wiring diagrams. All terminal blocks shall have
shrouding with transparent unbreakable material.
4.2. Disconnecting type terminal blocks for current transformer and voltage transformer secondary leads shall
be provided. Also current transformer secondary leads shall be provided with short circuiting and earthing
facilities.
4.3. At least 20% spare terminals shall be provided on each panel and these spare terminals shall be uniformly
distributed on all terminal blocks.
Volume-II (Section-I), Relay And Protection Panels 137
4.4. Unless otherwise specified, terminal blocks shall be suitable for connecting the following conductors of
external cable on each side
• All CT & PT circuits: minimum of two of 2.5mm Sq. copper.
• AC/DC Power Supply Circuits : One of 6mm Sq. Aluminium.
• All other circuits: minimum of one of 2.5mm Sq. Copper.
4.5. There shall be a minimum clearance of 250mm between the first row of terminal blocks and the associated
cable gland plate or panel side wall. Also the clearance between two rows of terminal blocks edges shall be
minimum of 150mm.
4.6. Arrangement of the terminal block assemblies and the wiring channel within the enclosure shall be such
that a row of terminal blocks is run in parallel and close proximity along each side of the wiring-duct to
provide for convenient attachment of internal panel wiring. The side of the terminal block opposite the
wiring duct shall be reserved for the Owner's external cable connections. All adjacent terminal blocks shall
also share this field wiring corridor. All wiring shall be provided with adequate support inside the panels to
hold them firmly and to enable free and flexible termination without causing strain on terminals.
4.7. The number and sizes of the Owner's multi core incoming external cables will be furnished to the
Contractor after placement of the order. All necessary cable terminating accessories such as gland plates,
supporting clamps & brackets, wiring troughs and gutters etc. (except glands & lugs) for external cables
shall be included the scope of supply.
5.0 PAINTING
5.1. All sheet steel work shall be phosphated in accordance with the IS:6005 "Code of practice for phosphating
iron and steel".
5.2. Oil, grease, dirt and swarf shall be thoroughly removed by emulsion cleaning.
5.3. Rust and scale shall be removed by pickling with dilute acid followed by washing with running water
rinsing with a slightly alkaline hot water and drying.
5.4. After phosphating, thorough rinsing shall be carried out with clean water followed by final rinsing with
dilute dichromate solution and oven drying.
5.5. The phosphate coating shall be sealed with application of two coats of ready mixed, stoved type zinc
chromate primer. The first coat may be "flash dried" while the second coat shall be stoved.
5.6. After application of the primer, two coats of finishing synthetic enamel paint shall be applied, each coat
followed by stoving. The second finishing coat shall be applied after inspection of first coat of painting.
The exterior colour of paint shall be of a slightly different shade to enable inspection of the painting.
Volume-II (Section-I), Relay And Protection Panels 138
5.7. A small quantity of finished paint shall be supplied for minor touching up required at site after installation
of the panels.
5.8. In case the bidder proposes to follow any other established painting procedure like electrostatic painting ,
the procedure shall be submitted for OWNER's review and approval.
6.0 NAME PLATES AND MARKINGS
6.1. All equipment mounted on front and rear side as well as equipment mounted inside the panels shall be
provided with individual name plates with equipment designation engraved. Also on the top of each panel
on front as well as rear side, large and bold nameplates shall be provided for circuit/feeder designation.
6.2. All front mounted equipment shall also be provided at the rear with individual name plates engraved with
tag numbers corresponding to the one shown in the panel internal wiring to facilitate easy tracing of the
wiring.
6.3. All relays and other devices shall be clearly marked with manufacturer's name, manufacturer's type, serial
number and electrical rating data.
6.4. Name Plates shall be made of non-rusting metal or 3 ply lamicoid. Name plates shall be black with white
engraving lettering.
6.5. All the panels shall be provided with name plate mounted inside the panel bearing LOA No & Date, Name
of the Substation & feeder and reference drawing number.
7.0 MISCELLANEOUS ACCESSORIES
7.1. Plug Point: 240V, Single phase 50Hz, AC socket with switch suitable to accept 5 Amps and 15 Amps pin
round standard Indian plug, shall be provided in the interior of each cubicle with ON-OFF switch.
7.2. Interior Lighting: Each panel shall be provided with a fluorescent lighting fixture rated for 240 Volts,
single phase, 50 Hz supply for the interior illumination of the panel controlled by the respective panel door
switch. Adequate lighting shall also be provided for the corridor in Duplex panels.
7.3. Switches and Fuses: Each panel shall be provided with necessary arrangements for receiving, distributing
and isolating of DC and AC supplies for various control, signaling, lighting and space heater circuits. The
incoming and sub-circuits shall be separately provided with Fuses. Selection of the main and sub-circuit
Fuses rating shall be such as to ensure selective clearance of sub-circuit faults. Voltage transformer
circuits for relaying and metering shall be protected by fuses. All fuses shall be HRC cartridge type
conforming to IS: 13703 mounted on plug-in type fuse bases. The short time fuse rating of Fuses shall
be not less than 9 KA. Fuse carrier base shall have imprints of the fuse 'rating' and 'voltage'.
Volume-II (Section-I), Relay And Protection Panels 139
7.4. Space Heater: Each panel shall be provided with a thermostatically connected space heater rated for
240V, single phase , 50 Hz Ac supply for the internal heating of the panel to prevent condensation of
moisture. The fittings shall be complete with switch unit
8.0 EARTHING
8.1. All panels shall be equipped with an earth bus securely fixed. Location of earth bus shall ensure no
radiation interference for earth systems under various switching conditions of isolators and breakers. The
material and the sizes of the bus bar shall be at least 25 X 6 sq. mm perforated copper with threaded holes
at a gap of 50mm with a provision of bolts and nuts for connection with cable armours and mounted
equipment etc for effective earthing. When several panels are mounted adjoining each other, the earth bus
shall be made continuous and necessary connectors and clamps for this purpose shall be included in the
scope of supply of Contractor. Provision shall be made for extending the earth bus bars to future adjoining
panels on either side.
8.2. Provision shall be made on each bus bar of the end panels for connecting Substation earthing grid.
Necessary terminal clamps and connectors for this purpose shall be included in the scope of supply of
Contractor.
8.3. All metallic cases of relays, instruments and other panel mounted equipment including gland plate, shall be
connected to the earth bus by copper wires of size not less than 2.5 sq. mm. The colour code of earthing
wires shall be green.
8.4. Looping of earth connections which would result in loss of earth connection to other devices when the
loop is broken, shall not be permitted. Earthing may be done in such a manner that no circulating current
shall flow in the panel.
8.5. VT and CT secondary neutral or common lead shall be earthed at one place only at the terminal blocks
where they enter the panel. Such earthing shall be made through links so that earthing may be removed
from one group without disturbing continuity of earthing system for other groups.
8.6. An electrostatic discharge point shall be provided in each panel connected to earth bus via 1 Mega Ohm
resistor.
9.0 RELAYS
9.1. All relays shall conform to the requirements of IS:3231/IEC-60255/IEC 61000 or other applicable
standards. Relays shall be suitable for flush or semi-flush mounting on the front with connections from the
rear.
9.2. All protective relays shall be of numerical type and communication protocol shall be as per IEC 61850.
Further, the test levels of EMI as indicated in IEC 61850 shall be applicable to these relays.
Volume-II (Section-I), Relay And Protection Panels 140
9.3. All protective relays shall be in draw out or plug-in type/modular cases with proper testing facilities.
Necessary test plugs/test handles shall be supplied loose and shall be included in contractor's scope of
supply.
9.4. All AC operated relays shall be suitable for operation at 50 Hz. AC Voltage operated relays shall be
suitable for 110 Volts VT secondary and current operated relays for 1 amp CT secondary. All DC operated
relays and timers shall be designed for the DC voltage specified, and shall operate satisfactorily between
80% and 110% of rated voltage. Voltage operated relays shall have adequate thermal capacity for
continuous operation.
9.5. The protective relays shall be suitable for efficient and reliable operation of the protection scheme
described in the specification. Necessary auxiliary relays and timers required for interlocking schemes for
multiplying of contacts suiting contact duties of protective relays and monitoring of control supplies and
circuits, lockout relay monitoring circuits etc. also required for the complete protection schemes described
in the specification shall be provided. All protective relays shall be provided with at least two pairs of
potential free isolated output contacts. Auxiliary relays and timers shall have pairs of contacts as required
to complete the scheme; contacts shall be silver faced with spring action. Relay case shall have adequate
number of terminals for making potential free external connections to the relay coils and contacts,
including spare contacts.
9.6. Timers shall be of solid state type. Time delay in terms of milliseconds obtained by the external capacitor
resistor combination is not preferred and shall be avoided .
9.7. No control relay which shall trip the power circuit breaker when the relay is de-energised shall be
employed in the circuits.
9.8. Provision shall be made for easy isolation of trip circuits of each relay for the purpose of testing and
maintenance.
9.9. Auxiliary seal-in-units provided on the protective relays shall preferably be of shunt reinforcement type. If
series relays are used the following shall be strictly ensured:
(a) The operating time of the series seal-in-unit shall be sufficiently shorter than that of the trip coil or
trip relay in series with which it operates to ensure definite operation of the flag indicator of the
relay.
(b) Seal-in-unit shall obtain adequate current for operation when one or more relays operate
simultaneously.
(c) Impedance of the seal-in-unit shall be small enough to permit satisfactory operation of the trip
coil on trip relays when the D.C. Supply Voltage is minimum.
Volume-II (Section-I), Relay And Protection Panels 141
(d) Trip-circuit seal-in is required for all trip outputs, irrespective of the magnitude of the interrupted
current. The trip-circuit seal-in logic shall not only seal-in the trip output(s),but also the relevant
initiation signals to other scheme functions, (e.g. initiate signals to the circuit-breaker failure
function, reclosing function etc.), and the alarm output signals.
(e) Two methods of seal-in are required, one based on the measurement of AC current, catering for
those circumstances for which the interrupted current is above a set threshold, and one based on a
fixed time duration, catering for those circumstances for which the interrupted current is small
(below the set threshold).
(f) For the current seal-in method, the seal-in shall be maintained until the circuit breaker opens, at
which time the seal-in shall reset and the seal-in method shall not now revert to the fixed time
duration method. For this seal-in method, the seal-in shall be maintained for the set time duration.
For the line protection schemes, this time duration shall be independently settable for single- and
three-pole tripping.
(g) Seal-in by way of current or by way of the fixed duration timer shall occur irrespective of whether
the trip command originates from within the main protection device itself (from any of the internal
protection functions), or from an external device with its trip output routed through the main
protection device for tripping. Trip-circuit seal-in shall not take place under sub-harmonic
conditions (e.g. reactor ring down).
9.10. All protective relays and alarm relays shall be provided with one extra isolated pair of contacts wired to
terminals exclusively for future use.
9.11. The setting ranges of the relays offered, if different from the ones specified shall also be acceptable if they
meet the functional requirements.
9.12. Any alternative/additional protections or relays considered necessary for providing complete effective and
reliable protection shall also be offered separately. The acceptance of this alternative/ additional equipment
shall lie with the Owner.
9.13. The bidder shall include in his bid a list of installations where the relays quoted have been in satisfactory
operation.
9.14. All relays and their drawings shall have phase indications as R-Red, Y-yellow, B-blue
9.15. For numerical relays, the scope shall include the following:
a) Necessary software and hardware to up/down load the data to/from the relay from/to the personal
computer installed in the substation. However, the supply of PC is not covered under this clause.
Volume-II (Section-I), Relay And Protection Panels 142
b) The relay shall have suitable communication facility for future connectivity to SCADA. The relay
shall be capable of supporting IEC 870-5-103 and 61850 protocol.
c) In case of line protection and transformer/reactor differential protection, the features like fault recorder
and event logging function as available including available as optional feature in these relays shall
be supplied and activated at no extra cost to the owner. Also necessary software/hardware for
automatic uploading to station HMI/DR work station (as applicable) shall be supplied. It is to be
clearly understood that these shall be in addition to fault locator and event logger functions as
specified at clause no. 19.
10. TRANSMISSION LINE PROTECTION
10.1. All relays shall be suitable for series compensated line.
10.2. The line protection relays are required to protect the line and clear the faults on line within shortest
possible time with reliability, selectivity and full sensitivity to all type of faults on lines. The general
concept is to have two main protections having equal performance requirement specially in respect of time
as called Main-I and Main-II for 765kV, 400KV and 220KV transmission lines and Main and back up
protection for 132 KV transmission lines.
10.3. The Transmission system for which the line protection equipment are required is shown in the Table. The
length of lines for 765,400 kV are also indicated there.
10.4. The maximum fault current could be as high as 40 kA but the minimum fault current could be as low as
20% of rated current of CT secondary. The starting & measuring relays characteristics should be
satisfactory under these extremely varying conditions.
10.5. The protective relays shall be suitable for use with capacitor voltage transformers having non-electronic
damping and transient response as per IEC.
10.6. Fault Recorder, Distance to fault Locator and Over voltage relay (stage -1) functions if offered as an
integral part of line protection relay, shall be acceptable provided these meet the technical requirements as
specified in the respective clauses.
10.7. Auto reclose relay function if offered as an integral part of line distance protection relay, shall be
acceptable for 220kV and 132 KV lines only provided the auto reclose relay feature meets the technical
requirements as specified in the respective clause.
10.8. The following protections shall be provided for each of the Transmission lines:
For 765 KV,400 KV & 220KV
Main-I: Numerical distance protection scheme
Volume-II (Section-I), Relay And Protection Panels 143
Main-II: Numerical distance protection scheme of a make different from that of Main –I
For 132KV
Main: Numerical distance protection scheme
Back up : Directional Over current and Earth fault Protection
10.9. Further back up Over current and Earth fault protection shall be provided instead of Main -II protection
scheme for 220KV lines to match with requirements at the remote ends.
10.10. The detailed description of the above line protections is given here under.
10.10.1. Main-I and Main-II Numerical Distance Protection scheme:
(a) Shall have continuous self monitoring and diagnostic feature.
(b) Shall be non-switched type with separate measurements for all phase to phase and phase to
ground faults
(c) Shall have stepped time-distance characteristics and three independent zones (zone 1, zone-2 and
zone-3)
(d) Shall have mho or quadrilateral or other suitably shaped characteristics for zone-1 , zone-2 and
zone- 3.
(e) Shall have following maximum operating time (including trip relay time , if any) under given set
of conditions and with CVT being used on line (with all filters included) .
(i) For 765 KV,400 KV & 220 KV lines:
Source to Impedance ratio 4 15
Relay setting (Ohms) (10 or 20) and 2 2
Fault Locations 50 50
(as % of relay setting)
Fault resistance (Ohms) 0 0
Maximum operating time 40 for all faults 45 for 3 ph. Faults & 60 for all
(Milliseconds ) other faults
(ii) for 132 KV lines :
A relaxation of 5 ms in above timings is allowed for 132 KV lines.
Volume-II (Section-I), Relay And Protection Panels 144
(f) The relay shall have an adjustable characteristics angle setting range of 30 -85 degree or shall have
independent resistance(R ) and reactance (X) setting.
(g) shall have two independent continuously variable time setting range of 0-3 seconds for zone-2 and
0-5 seconds for zone-3.
(h) shall have resetting time of less than 55 milli-seconds (including the resetting time of trip relays)
(i) shall have facilities for offset features with adjustable 10-20% of Zone-3 setting.
(j) shall have variable residual compensation.
(k) shall have memory circuits with defined characteristics in all three phases to ensure correct
operation during close-up 3 phase faults and other adverse conditions and shall operate
instantaneously when circuit breaker is closed to zero-volt 3 phase fault
(l) shall have weak end in-feed feature
(m) shall be suitable for single & three phase tripping. However relays offered for 132 kV lines
provided with mechanically ganged circuit breakers single pole tripping need not to be provided.
(n) shall have a continuous current rating of two times of rated current. The voltage circuit shall be
capable of operation at 1.2 times rated voltage. The relay shall also be capable of carrying a high
short time current of 70 times rated current without damage for a period of 1 sec.
(o) shall be provided with necessary self reset type trip duty contacts for completion of the scheme
(Minimum number of these trip duty contacts shall be four per phase) either through built in or
through separate high speed trip relays . Making capacity of these trip contacts shall be 30 amp for
0.2 seconds with an inductive load of L/R > 10 mill seconds. If separate high speed trip relays are
used , the operating time of the same shall not be more than 10 milliseconds
(p) shall be suitable for use in permissive under reach / over reach /blocking communication mode.
(q) shall have suitable number of potential free contacts for Carrier aided Tripping, Auto reclosing,
CB failure, Disturbance recorder & Data acquisition system.
(r) include power swing blocking protection which shall
• have suitable setting range to encircle the distance protection described above.
• block tripping during power swing conditions.
• release blocking in the event of actual fault
(s) include fuse failure protection which shall monitor all the three fuses of C.V.T. and associated
cable against open circuit.
Volume-II (Section-I), Relay And Protection Panels 145
• inhibit trip circuits on operation and initiate annunciation.
• have an operating time less than 7 milliseconds
• remain inoperative for system earth faults
(t) include a directional back up Inverse Definite Minimum Time (IDMT ) earth fault relay with normal
inverse characteristics as per IEC 60255-3 as a built in feature or as a separate unit for 400 KV and 220KV
transmission lines
(u) In case the numerical distance relay is not having the built in feature as per above clause (t), the same can
be supplied as an independent relay
(v) Must have a current reversal guard feature.
10.10.2. Back-up Directional Over Current and Earth fault protection scheme
(a) shall have three over current and one earth fault element(s) which shall be either independent or
composite unit
(b) shall be of Numerical type
(c) shall include necessary VT fuse failure relays for alarm purposes.
(d) shall
• have IDMT characteristic with a definite minimum time of 3.0 seconds at 10 times setting
• have a variable setting range of 50-200% of rated current
• have a characteristic angle of 30/45 degree lead
• include hand reset flag indicators or LEDs .
(e) shall
• have IDMT characteristic with a definite minimum time of 3.0 seconds at 10 times setting
• have a variable setting range of 20-80% of rated current
• have a characteristic angle of 45/60 degree lag
• include hand reset flag indicators or LEDs
• include necessary separate interposing voltage transformers or have internal feature in the
relay for open delta voltage to the relay.
10.10.3. All trip relays used in transmission line protection scheme shall be of self/electrical reset type
depending on application requirement.
Volume-II (Section-I), Relay And Protection Panels 146
11.0 Circuit Breaker Protection : This shall include following function:
11.1. AUTO RECLOSING function shall be separate from Main-I and Main-II protection However, Auto-
reclose as in built function of bay controller unit (BCU) provided for sub-station automation is
acceptable. The AUTO RECLOSE shall
(a) have single phase and three phase reclosing facilities.
(b) have a continuously variable single phase dead time range of 0.1-2 seconds.
(c) have a continuously variable three phase dead time range of 0.1-2 seconds.
(d) have a continuously variable reclaim time range of 5-300 seconds.
(e) incorporate a four-position selector switch/ from which single phase/three phase/single and three
phase auto reclosure and non-auto reclosure mode can beselected. Alternatively, the mode of auto
reclosing can be selected through programming.
(f) have facilities for selecting check synchronising or dead line charging features. It shall be possible
at any time to change the required feature by reconnection of links.
(g) be of single shot type.
(h) have priority circuit to closing of both circuit breakers in case one and half breaker arrangements
to allow sequential closing of breakers
(i) include check synchronising relay which shall
• have a time setting continuously variable between 0.5-5 seconds. with a facility of
additional 10 seconds.
• have a response time within 200 milli seconds with the timer disconnected.
• have a phase angle setting not exceeding 35 degree
• have a voltage difference setting not exceeding 10%
• include dead line charging relay which shall
• have two sets of relays and each set shall be able to monitor the three phase voltage where
one set shall be connected to the line CVTs with a fixed setting of 20% of rated voltage
and the other set shall be connected to the bus CVTs with a fixed setting of 80% of rated
voltage.
• incorporate necessary auxiliary relays and timers to give comprehensive scheme.
Volume-II (Section-I), Relay And Protection Panels 147
11.2. LOCAL BREAKER BACK-UP PROTECTION SCHEME shall
(a) be triple pole type
(b) have an operating time of less than 15 milli seconds
(c) have a resetting time of less than 15 milli seconds
(d) have three over current elements
(e) be arranged to get individual initiation from the corresponding phase of main protections of line
for each over current element. However, common three phase initiation is acceptable for other
protections and transformer /reactor equipment protections
(f) have a setting range of 20-80% of rated current
(g) have a continuous thermal withstand two times rated current irrespective of the setting
(h) have a timer with continuously adjustable setting range of 0.1-1 seconds
(i) have necessary auxiliary relays to make a comprehensive scheme.
11.3. TRIP CIRCUIT SUPERVISION RELAY
(a) The relay shall be capable of monitoring the healthiness of each 'phase' trip-coil and associated
circuit of circuit breaker during 'ON' and 'OFF' conditions.
(b) The relay shall have adequate contacts for providing connection to alarm and event logger.
(c) The relay shall have time delay on drop-off of not less than 200 milli seconds and be provided
with operation indications for each phase.
12. LINE OVER VOLTAGE PROTECTION RELAY shall
(a) monitor all three phases
(b) have two independent stages and stage- 1 & II relay are acceptable as built in with line distance
relays Main I & II respectively .
(c) have an adjustable setting range of 100-170% of rated voltage with an adjustable time delay range
of 1 to 60 seconds for the first stage.
(d) have an adjustable setting range of 100-170% of rated voltage with a time delay of 100-200 mill
seconds for the second stage.
(e) be tuned to power frequency
Volume-II (Section-I), Relay And Protection Panels 148
(f) provided with separate operation indicators (flag target) for each stage relays.
(g) have a drop-off to pick-up ratio greater than 95%.
(h) provide separate out-put contacts for each 'Phase' and stage for breaker trip relays, event logger
and other scheme requirements.
13. REACTOR PROTECTION
13.1. Numerical Differential Protection shall
(a) Be triple pole type
(b) Have operation time less than 25 milli-seconds at 5 times setting.
(c) Be tuned to system frequency
(d) Have current setting range of 10 to 40% of 1 Amp. Or a suitable voltage setting range.
(e) Be high impedance / biased differential type .
(f) Be stable for all external faults
13.2. Restricted earth fault protection Relay shall
(a) Be single pole and numerical type
(b) Be of current/voltage operated high impedance type
(c) Have a current setting of 10-40% of 1 Amp./have a suitable voltage setting range.
(d) Be tuned to system frequency.
(e) Have a suitable non-linear resistor to limit the peak voltage to 1000 Volts.
13.3. Numerical Back up impedance protection Relay shall
(a) Be triple pole type, with faulty phase identification/ indication
(b) Be single step polarised 'mho' distance/ impedance relay suitable for measuring phase to ground
and phase to phase faults.
(c) Have adequate ohmic setting range to cover at least 60 % of the impedance of the reactor and
shall be continuously variable.
(d) Have an adjustable characteristic angle of 30-80 degree.
(e) Have a definite time delay relay with a continuously adjustable setting range of 0.2- 2.0 seconds.
Volume-II (Section-I), Relay And Protection Panels 149
(f) Include VT failure relay which shall block the tripping during VT fuse failure condition.
14. TRANSFORMER PROTECTION
14.1. Numerical Transformer differential protection scheme shall
(a) Be triple pole type, with faulty phase identification/ indication
(b) Have an operating time not greater than 30 milli seconds at 5 times the rated current .
(c) Have three instantaneous high set over-current units
(d) Have an adjustable bias setting range of 20-50%
(e) Be suitable for rated current of 1 Amp.
(f) Have second harmonic or other inrush proof features and also should be stable under normal over
fluxing conditions. Magnetising inrush proof feature shall not be achieved through any intentional
time delay e.g use of timers to block relay operation or using disc operated relays
(g) Have an operating current setting of 15% or less (h) include necessary separate interposing
current transformers for angle and ratio correction or have internal feature in the relay to take care
of the angle & ratio correction
(h) Have a fault recording feature to record graphic form of instantaneous values of following
analogue channels during faults and disturbances for the pre fault and post fault period:
• Current in all three windings in nine analogue channels in case of 400kV class and above
transformers or 6 analogue channels for lower voltage transformers and
• Voltage in one channel
The disturbance recorder shall have the facility to record the following external digital channel
signals apart from the digital signals pertaining to differential relay.
1. REF protection operated
2. HV breaker status (Main and tie)
3. IV breaker status
4. Bucholz /OLTC Bucholz alarm / trip
Volume-II (Section-I), Relay And Protection Panels 150
5. WTI/OTI/PRD alarm/trip of transformer
Necessary hardware and software for automatic up-loading the data captured by disturbance recorder to
the personal computer (DR Work Station) available in the substation shall be included in the scope.
14.2. Over fluxing protection Relays shall
(a) Operate on the principle of Voltage to frequency ratio and shall be phase to phase connected
(b) Have inverse time characteristics, matching with transformer over fluxing withstand capability
curve.
(c) Provide an independent 'alarm' with the time delay continuously adjustable between 0.1 to 6.0
seconds at values of 'v/f' between 100% to 130% of rated values
(d) Tripping time shall be governed by 'v/f' Vs. time characteristics of the relay
(e) Have a set of characteristics for Various time multiplier settings. The maximum operating time of
the relay shall not exceed 3 seconds and 1.5 seconds at 'v/f' values of 1.4 and 1.5 times, the rated
values, respectively.
(f) Have an accuracy of operating time, better than ±10%.
(g) Have a resetting ratio of 95 % or better.
(h) Be acceptable as a built in feature of protection IEDs provided for transformer protection
14.3. Numerical Restricted Earth Fault Protection shall
(a) Be single pole type
(b) Be of current/voltage operated high impedance type
(c) Have a current setting range of 10-40% of 1 Amp./ have a suitable voltage setting range.
(d) Be tuned to the system frequency
14.4. Numerical Back-up Over Current and Earth fault protection scheme with high set feature
(a) Shall have three over current and one earth fault element(s) which shall be either independent or
composite unit(s).
(b) The scheme shall include necessary VT fuse failure relays for alarm purposes
(c) Over current relay shall
• Have directional IDMT characteristic with a definite minimum time of 3.0 seconds at 10 times
setting and have a variable setting range of 50-200% of rated current
Volume-II (Section-I), Relay And Protection Panels 151
• Have low transient, over reach high set instantaneous unit of continuously variable setting range
500-2000 % of rated current
• Have a characteristic angle of 30/45 degree lead
• Include hand reset flag indicators or LEDs.
(d) Earth fault relay shall
• Have directional IDMT characteristic with a definite minimum time of 3.0 seconds at 10 times
setting and have a variable setting range of 20-80% of rated current
• Have low transient, over reach high set instantaneous unit of continuously variable setting range
200-800 % of rated current
• Have a characteristic angle of 45/60 degree lag
• Include hand reset flag indicators or LEDs
• Include necessary separate interposing voltage transformers or have internal feature in the relay for
open delta voltage to the relay
14.5. Transformer Overload Protection Relay shall
(a) Be of single pole type
(b) Be of definite time over-current type
(c) Have one set of over-current relay element, with continuously adjustable setting range of 50-200%
of rated current
(d) Have one adjustable time delay relay for alarm having setting range of 1 to 10.0 seconds,
continuously.
(e) Have a drop-off/pick-up ratio greater than 95%.
(f) Be acceptable as built in feature of numerical transformer differential relay
14.6. Transformer Neutral Current relay for 765/400 KV transformer.
(a) Have directional IDMT characteristic with a definite minimum time of 3.0 seconds at 10 times setting and
have a variable setting range of 20-80% of rated current
(b) Have low transient, over reach high set instantaneous unit of continuously variable setting range 200-800
% of rated current
Volume-II (Section-I), Relay And Protection Panels 152
15. TEE PROTECTION DIFFERENTIAL RELAYS
15.1.1. TEE-1 differential protection relays shall
(a) Be triple pole type
(b) Have an operating time less than 30 milliseconds at 5 times the rated current.
(c) Have three instantaneous high set over current units
(d) Have an adjustable bias setting range of 20-50%
(e) Have an operating current setting of 15% of 1 Amp or less
15.1.2. TEE-2 Differential relay shall
(a) Be triple pole type
(b) Have operating time less than 25 milliseconds at 5 times setting
(c) Be tuned to system frequency
(d) Have current setting range of 20 to 80% of 1 Amp
(e) Be voltage operated, high impedance type
(f) Be stable for all external faults
(g) Be provided with suitable non linear resistors across the relay to limit the peak voltage to 1000
volts
16. TRIPPING RELAY
High Speed Tripping Relay shall
(a) Be instantaneous (operating time not to exceed 10 milli-seconds).
(b) Reset within 20 milli seconds
(c) Be D.C. operated
(d) Have adequate contacts to meet the requirement of scheme, other functions like auto-reclose
relay, LBB relay as well as cater to associated equipment like event logger, Disturbance recorder,
fault Locator, etc.
(e) Be provided with operation indicators for each element/coil.
Volume-II (Section-I), Relay And Protection Panels 153
17. DC SUPPLY SUPERIVISION RELAY
(a) The relay shall be capable of monitoring the failure of D.C. supply to which, it is connected.
(b) It shall have adequate potential free contacts to meet the scheme requirement.
(c) The relay shall have a 'time delay on drop-off' of not less than 100 milli seconds and be provided
with operation indicator/flag.
18. BUS BAR PROTECTION
18.1 Redundant (1+1) numerical Bus Bar protection scheme for each bus system (Bus1 +Bus2+Transfer Bus
wherever applicable) for 400kV and 765kV shall be provided. The scheme shall be engineered so as to
ensure that operation of any one out of two schemes connected to main faulty bus shall result in tripping of
the same.
18.2 Single busbar protection scheme shall be provided for each main and transfer bus for 220KV and 132 KV
voltage levels
18.3 Each Bus Bar protection scheme shall
(a) Have maximum operating time up to trip impulse to trip relay for all types of faults of 25 milli
seconds at 5 times setting value.
(b) Operate selectively for each bus bar
(c) Give hundred percent security up to 40 KA fault level up to 40 KA for fault level for 400KV and
220KV and 31.5 KA for 132 KV
(d) Incorporate continuous supervision for CT secondary against any possible open circuit and if it
occurs, shall render the relevant zone of protection inoperative and initiate an alarm
(e) Not give false operation during normal load flow in bus bars.
(f) Incorporate clear zone indication.
(g) Be of phase segregated and triple pole type
(h) Provide independent zones of protection (including transfer bus if any). If the bus section is
provided then each side of bus section shall have separate set of bus bar protection schemes
(i) Include individual high speed electrically reset tripping relays for each feeder.
However, in case of distributed Bus bar protection, individual trip relay shall not be required if
bay unit is having trip duty contacts for breaker tripping.
(j) Be transient free in operation
Volume-II (Section-I), Relay And Protection Panels 154
(k) Include continuous D.C. supplies supervision.
(l) Not cause tripping for the differential current below the load current of heaviest loaded feeder.
Bidder shall submit application check for the same.
(m) Shall include necessary C.T. switching relays wherever C.T. switching is involved and have 'CT'
selection incomplete alarm
(n) Include protection 'IN/OUT' switch for each zone
(o) Shall include trip relays, CT switching relays(if applicable) , auxiliary CTs (if applicable) as well
as additional power supply modules, input modules etc. as may be required to provide a Bus-bar
protection scheme for the complete bus arrangement i.e. for all the bay or breakers under this
specification as per the Single line diagram for new substations. However for extension of bus bar
protection scheme in existing substations, scope shall be limited to the bay or breakers covered
under this specification. Suitable panels (if required) to mount these are also included in the scope
of the work. 18.4 Built-in Local Breaker Backup protection feature as a part of bus bar protection
scheme shall also be acceptable.
18.5 At existing substations, Bus-bar protection scheme with independent zones for each bus, will be available.
All necessary co-ordination for 'AC' and 'DC' interconnections between existing schemes (Panels) and the
bays proposed under the scope of this contract shall be fully covered by the bidder. Any auxiliary relay,
trip relay, flag relay and multi tap auxiliary CTs (in case of biased differential protection) required to
facilitate the operation of the bays covered under this contract shall be fully covered in the scope of the
bidder..
(a) The test terminal blocks (TTB) to be provided shall be fully enclosed with removable covers and made of
moulded, non-inflammable plastic material with boxes and barriers moulded integrally. All terminals shall
be clearly marked with identification numbers or letters to facilitate connection to external wiring.
Terminal block shall have shorting, disconnecting and testing facilities for CT circuits.
19.0 FAULT RECORDER
19.1 The fault recorder shall be provided for transmission line and the fault recorder in-built feature of line
distance relay is also acceptable provided the requirements of following clauses are met
19.2 Fault recorder shall be microprocessor based and shall be used to record the graphic form of instantaneous
values of voltage and current in all three phases, open delta voltage & neutral current, open or closed
position of relay contacts and breakers during the system disturbances.
19.3 The Fault recorder shall consist of individual acquisition units, one for each feeder and an Evaluation unit
which is common for the entire Substation. Whenever, more than one acquisition units are connected to an
Volume-II (Section-I), Relay And Protection Panels 155
Evaluation unit, necessary hardware and software shall also be supplied for on line transfer of data from all
acquisition units to Evaluation unit. The acquisition unit is connected with evaluation unit being supplied
as described in section sub-station automation through bus conforming to IEC 61850.
In case of extension sub-station, one set of evaluation software shall be supplied and loaded in existing
fault recorder evaluation unit. Automatic uploading of disturbance files from acquisition unit to evaluation
unit shall be done through existing station bus only conforming to IEC 61850. Necessary
configuration/updation shall be in the scope of the contractor.
19.4 Fault recorder shall have atleast 8 analogue and 16 digital channels for each feeder.
19.5 Acquisition units shall acquire the Disturbance data for the pre fault and post fault period and transfer them
to Evaluation unit automatically to store in the hard disk. The acquisition units shall be located in the
protection panels of the respective feeders.
19.6 The acquisition unit shall be suitable for inputs from current transformers with 1A rated secondary and
capacitive voltage transformers with 63.5V (phase to neutral voltage) rated secondary. Any device
required for processing of input signals in order to make the signals compatible to the Fault recorder
equipment shall form an integral part of it. However, such processing of input signals shall in no way
distort its waveform.
19.7 The equipment shall be carefully screened, shielded, earthed and protected as may be required for its safe
functioning. Also, the Fault recorder shall have stable software, reliable hardware, simplicity of
maintenance and immunity from the effects of the hostile environment of EHV switchyard which are
prone to various interference signals typically from large switching transients.
19.8 The evaluation unit hardware shall be as described in clause no. 4.0 of section substation automation.
19.9 Necessary software for transferring the data automatically from local evaluation unit to a remote station
and receiving the same at the remote station through owner’s PLCC/VSAT/LEASED LINE shall be
provided.
19.10 Evaluation software shall be provided for the analysis and evaluation of the recorded data made available
in the PC under DOS/WINDOWS environment. The Software features shall include repositioning of
analog and digital signals, selection and amplification of time and amplitude scales of each analog and
digital channel, calculation of MAX/MIN frequency, phase difference values, recording of MAX/MIN
values etc. of analog channel, group of signal to be drawn on the same axis etc, listing and numbering of
all analog and digital channels and current, voltage, frequency and phase difference values at the time of
fault/tripping. Also, the software should be capable of carrying out Fourier /Harmonic analysis of the
Volume-II (Section-I), Relay And Protection Panels 156
current and voltage wave forms. The Disturbance records shall also be available in COMTRADE format (
IEEE standard- Common Format for Transient data Exchange for Power System )
19.11 The Evaluation unit shall be connected to the printer to obtain the graphic form of disturbances whenever
desired by the operator.
19.12 Fault recorder acquisition units shall be suitable to operate from 220V DC or 110V DC as available at sub-
station Evaluation unit along with the printer shall normally be connected to 230V, single phase AC
supply. In case of failure of AC supply, Evaluation unit and printer shall be switched automatically to the
station DC through Inverter of adequate capacity which shall form a part of Distance recorder system. The
inverter of adequate capacity shall be provided to cater the requirement specified in section sub-station
automation clause no. 8.0 and DR evaluation unit.
19.13 The acquisition unit shall have the following features
(a) Facility shall exist to alarm operator in case of any internal faults in the acquisition units such as power
supply fail, processor / memory fail etc and same shall be wired to annunciation system.
(b) The frequency response shall be 5 Hz on lower side and 250 Hz or better on upper side.
(c) Scan rate shall be 1000 Hz/channel or better.
(d) Pre-fault time shall not be less than 100 milliseconds and the post fault time shall not be less than 2
seconds (adjustable). If another system fault occurs during one post-fault run time, the recorder shall also
be able to record the same. However, the total memory of acquisition unit shall not be less than 5.0
seconds
(e) The open delta voltage and neutral current shall be derived either through software or externally by
providing necessary auxiliary transformers.
(f) The acquisition unit shall be typically used to record the following digital channels:
1 Main CB R phase open
2 Main CB Y phase open
3 Main CB B phase open
4 Main-1 carrier received
5 Main-1 protection operated
6 Main/Tie /TBC Auto reclosed operated
Volume-II (Section-I), Relay And Protection Panels 157
7 Over Voltage -Stage-1 /2 operated
8 Reactor / Stub/TEE-1/2/UF protection operated
9 Direct Trip received
10 Main-2 carrier received
11 Main- 2/ Back Up protection operated
12 Bus bar protection operated
13 LBB operated of main /tie/TBC circuit breaker
14 Tie/TBC CB R phase open
15 Tie/TBC CB Y phase open
16 Tie/TBC CB B phase open
(g) In case the Fault recorder is in-built part of line distance protection, above digital channels may be
interfaced either externally or internally.
(h) Any digital signal can be programmed to act as trigger for the acquisition unit. Analog channels should
have programmable threshold levels for triggers and selection for over or under levels should be possible.
19.14 The printer shall be compatible with the desktop PC and shall use Plain paper. The print out shall contain
the Feeder identity, Date and time (in hour, minute and second up to 100th of a second), identity of trigger
source and Graphic form of analogue and digital signals of all the channels. Two packets of paper (500
sheets in each packet) suitable forprinter shall be supplied.
19.15 Each Fault recorder shall have its own time generator and the clock of the time generator shall be such that
the drift is limited to ±0.5 seconds/day, if allowed to run without synchronisation. Further, Fault recorder
shall have facility to synchronise its time generator from Time Synchronisation Equipment having output
of following types
• Voltage signal : (0-5V continuously settable, with 50m Sec. minimum pulse duration)
• Potential free contact (Minimum pulse duration of 50 m Sec.)
• IRIG-B
• RS232C
The recorder shall give annunciation in case of absence of synchronising within a specified time.
Volume-II (Section-I), Relay And Protection Panels 158
19.16 Substations where Time Synchronisation Equipment is not available, time generator of any one of the
Fault recorders can be taken as master and time generators of other Fault recorders and Event loggers in
that station shall be synchronised to follow the master.
20.0 DISTURBANCE RECORDING ( for 765 KV FEEDERS ONLY)
A separate numerical disturbance recording function shall be provided. The following requirements shall
be met:
20.1 The disturbance recorder shall record the analogue values form of the instantaneous values of voltage and
current in all three phases, the open delta voltage and the neutral current. The open or closed position of
relay contacts and circuit breakers during system disturbances shall also be recorded.
20.2 The disturbance recorder shall comprise distributed individual acquisition units, one for each feeder and an
evaluation unit which is common for the entire substation. The acquisition units shall acquire the
disturbance data for the pre-fault, fault and post-fault periods and transfer them to the evaluation unit
automatically for storage on a mass storage device. The acquisition unit shall be suitable for inputs from
current transformers with 1 A rated secondaries and capacitive voltage transformers with 63.5 V (phase-
toneutral voltage) rated secondaries.
20.3 The acquisition units shall have the following features:
(a) A facility to alert the operator in the case of any internal faults (such as power supply fail,
processor/memory fail etc.) in any of the acquisition units and this alarm shall be wired to the station
annunciation system.
(b) The pre-fault time shall not be less than 200 milliseconds and the post fault time shall not be less than 2
seconds (adjustable). If another system disturbance occurs during a post-fault run time, the recorder shall
also be able to record this subsequent disturbance. The scan rate should be selectable in the range from
1000 Hz to 5000 Hz.
(c) The open delta voltage and neutral current shall be derived either through software or externally by
providing necessary auxiliary transformers.
(d) The acquisition unit shall be typically used to record the following digital channels:
1. Main circuit-breaker R-phase open
2. Main circuit-breaker Y-phase open
3. Main circuit-breaker B-phase open
4. Main 1 carrier received
Volume-II (Section-I), Relay And Protection Panels 159
5. Main 1 protection operated
6. Main/Tie auto-reclose operated
7. Overvoltage stage 1/2 operated
8. Reactor/Stub-1/2 protection operated
9. Direct trip received
10. Main 2 carrier received
11. Main 2 protection operated
12. Busbar protection operated
13. Breaker failure protection of main/tie circuit-breaker operated
14. Tie circuit-breaker R-phase open
15. Tie circuit-breaker Y-phase open
16. Tie circuit-breaker B-phase open
20.4 The necessary hardware and software shall also be supplied for the on-line transfer of data from all
acquisition units to the evaluation unit. The disturbance recording system shall be capable of handling the
full complement of feeders in the substation.
20.5 The disturbance recording equipment shall be screened, shielded, earthed and protected as may be required
for its safe and proper functioning. Also, the disturbance recorder shall have stable software, reliable
hardware, simplicity of maintenance and immunity from the effects of the hostile environment of a 765 kV
EHV switchyard which is prone to numerous interference signals such as large switching transients.
20.6 The evaluation unit shall comprise all the necessary hardware and software for the proper evaluation of
disturbances. The hardware would typically consist of a desktop personal computer (including a large high
resolution colour monitor, mouse and keyboard) and a high-speed colour printer. The desktop PC shall
have Pentium P4 processor or better and shall have a clock speed of 1600 MHz or better. The mass storage
capacity of PC shall not be less than 32 GB and the RAM capacity shall not be less than 1 GB. The
evaluation software required for the analysis and evaluation of the recorded data shall run on the PC under
Microsoft Windows environment. The software features shall provide:
• clear and unambiguous display of all channels;
• the ability to reposition the analog and digital traces;
• recording of maximum/minimum values etc. of the analog channels;
Volume-II (Section-I), Relay And Protection Panels 160
• calculation of maximum/minimum frequency and phase difference values;
• grouping of signals for drawing on the same axis;
• listing and identification of all analog and digital channels as well as and current, voltage,
frequency and phase difference values at the time of fault/tripping;
• the capability of carrying out Fourier/Harmonic analysis of the current and voltage waveforms;
and,
• the availability of the disturbance records in COMTRADE format.
20.7 The evaluation unit shall be permanently connected to the printer so as to obtain the graphic display of
disturbances whenever desired by the operator. The printer shall be compatible with the desktop PC and
shall use plain paper. The print out shall contain the feeder identity, date and time (in hour, minute and
second up to 100th of a second), identity of the trigger source and graphic representation of the analog and
digital signals of all the channels.
20.8 The disturbance recorder acquisition units shall be suitable to operate from the station DC. The evaluation
unit along and the printer shall normally be connected to the 230 V, single phase AC supply. In the case of
a failure of the AC supply, the evaluation unit and printer shall be automatically switched to the station DC
through an inverter of adequate capacity and which shall form part of disturbance recording system.
20.9 The disturbance recorder shall be capable of being triggered by the following user specified quantities:
(a) external start, both software and hardware
(b) cross triggering of groups of channels, either software or hardware or both
(c) binary channel (NO and NC contacts)
(d) overvoltage and undervoltage
(e) overcurrent
(f) negative sequence voltage
(g) zero sequence voltage
(h) rate of change, voltage or current
(i) overfrequency or underfrequency
(j) logical or Boolean expressions, programmable
(k) power swing
(l) rate of change of active or reactive power
Volume-II (Section-I), Relay And Protection Panels 161
20.10 The disturbance recorder shall have its own time generator and the clock of the time generator shall be
such that the drift is limited to less than ± 0.5 seconds per day, if allowed to run without synchronisation.
Further, the disturbance recorder shall have the facility to synchronise its time generator from the station
Time Synchronisation Equipment using IRIG-B. The recorder shall give an alarm in the case of the
absence of the synchronising pulse for a pre-determined time.
21.0 DISTANCE TO FAULT LOCATOR
a) be electronic or microprocessor based type.
b) be 'On-line' type
c) be suitable for breaker operating time of 2 cycles
d) have built-in display unit
e) the display shall be directly in percent of line length or kilometres without requiring any further
calculations
f) have an accuracy of 3% or better for the typical conditions defined for operating timings
measurement of distance relays .
g) The above accuracy should not be impaired under the following conditions:
• presence of remote end infeed
• predominant D.C. component in fault current
• high fault arc resistance
• severe CVT transients
h) shall have mutual zero sequence compensation unit if fault locator is to be used on double circuit
transmission line.
i) built in feature of line distance relay is acceptable provided the requirements of above clauses are
met.
22.0 TIME SYNCHRONISATION EQUPMENT
22.1 The Time synchronisation equipment shall receive the co-ordinated Universal Time (UTC) transmitted
through Geo Positioning Satellite System (GPS) and synchronise equipments to the Indian Standard Time
in a substation.
22.2 Time synchronisation equipment shall include antenna, all special cables and processing equipment etc.
Volume-II (Section-I), Relay And Protection Panels 162
22.3 It shall be compatible for synchronisation of Event Loggers, Disturbance recorders and SCADA at a
substation through individual port or through Ethernet realised through optic fibre bus.
22.4 Equipment shall operate up to the ambient temperature of 50 degree centigrade and 80%
humidity.
22.5 The synchronisation equipment shall have 2 micro second accuracy. Equipment shall give real time
corresponding to IST (taking into consideration all factors like voltage, & temperature variations,
propagation & processing delays etc).
22.6 Equipment shall meet the requirement of IEC 60255 for storage & operation.
22.7 The system shall be able to track the satellites to ensure no interruption of synchronisation signal.
22.8 The output signal from each port shall be programmable at site for either one hour, half hour, minute or
second pulse, as per requirement.
22.9 The equipment offered shall have six (6) output ports. Various combinations of output ports shall be
selected by the customer, during detailed engineering, from the following :
• Potential free contact (Minimum pulse duration of 50 milli Seconds.)
• IRIG-B
• RS232C
• SNTP Port
22.10 The equipment shall have a periodic time correction facility of one second periodicity.
22.11 Time synchronisation equipment shall be suitable to operate from 220V DC or 110V DC as available at
Substation.
22.12 Equipment shall have real time digital display in hour, minute, second (24 hour mode) & have a separate
time display unit to be mounted on the top of control panels having display size of approx. 100 mm height.
23.0 RELAY TEST KIT
23.1 One relay test kit shall comprise of the following equipment as detailed here under
3 sets Relay tools kits.
2 nos. Test plugs
1 no. Special type test plugs for using with modular type cases (if applicable)
Volume-II (Section-I), Relay And Protection Panels 163
24.0 TYPE TESTS
24.1 The reports for following type tests shall be submitted by the bidder for the Protective relays, Fault locator
and Disturbance recorder
a) Insulation tests as per IEC 60255-5
b) High frequency disturbance test as per IEC 60255-4 (Appendix -E) 61000-4 –Class IV (Not
applicable for electromechanical relays)
c) Fast transient test as per IEC 1000-4, Level IV (Not applicable for electromechanical relays)
d) Relay characteristics, performance and accuracy test as per IEC 60255
• Steady state Characteristics and operating time
• Dynamic Characteristics and operating time for distance protection relays and current
differential protection relays
• For Disturbance recorder, only performance tests are intended under this item.
• Conformance test as per IEC 61850-10.
e) Tests for thermal and mechanical requirements as per IEC 60255-6
f) Tests for rated burden as per IEC 60255-6
g) Contact performance test as per IEC 60255-0-20 (not applicable for Distance to fault locator and
Disturbance recorder)
In case there is a change either in version or in model (Except firmware) of the relay, the
contractor has to submit the type test reports for the offered revision/model.
24.2 Steady state & Dynamic characteristics test reports on the distance protection relays, as type test, shall be
based on test programme specified in Appendix A on simulator/network analyser/PTL. Alternatively, the
files generated using Electromagnetic transient Programme (EMTP) can also be used for carrying out the
above tests. Single source dynamic tests on transformer differential relay shall be/ should have been
conducted based on general guidelines specified in CIGRE committee 34 report on Evaluation of
characteristics and performance of Power system protection relays and protective systems.
25.0 CONFIGURATION OF RELAY AND PROTECTION PANELS
The following is the general criteria for the selection of the equipments to be provided in each type of
panel. However contractor can optimise the requirement of panels by suitably clubbing the feeder
protection and CB relay panels. But the Main-I and Main-I protection cannot be provided in single panel.
Volume-II (Section-I), Relay And Protection Panels 164
The Line Protection panel for transmission lines shall consist of following protection features/schemes
S.NO.
DESCRIPTION 765/400kV 220 kV 132 kV
1. Main-1 Numerical Distance protectionscheme
1 Set 1 Set 1 Set
2. Main-2 Numerical Distance protection scheme
1 Set 1 Set NIL
3. Over Voltage Protection Scheme 1 Set NIL NIL 4. Fault Recorder 1 Set 1 Set NIL 5. Disturbance Recorder* 1 Set NIL NIL 6. Distance to fault Locator 1 Set 1 Set 1 Set 7. 3 phase Trip Relays Lot Lot Lot 8. Flag relays , carrier receive relays,
aux. Relays timers etc as per scheme requirements
2 Nos. 2 Nos. 1 Nos.
9. Under Voltage protection relay for isolator/earth switch
2 Nos. 2 Nos. 2 Nos.
10. Cutout and wiring with TTB for Owner supplied energy meter
1 Set 1 Set 1 Set
11. Directional back up Overcurrent and E/F protection scheme
NIL NIL 1 Set
‘*’ Applicable for 765kV Lines Only
In a substation where 400kV and 220 KV lines are under the scope of the contract , bidder is required to give identical Main 1 and main 2 distance protection scheme for both voltage levels TRANSFORMER PROTECTION PANEL The protection panel for Auto transformer/Transformer shall consists of the following features/schemes.
S.No. Description HV Side MV/LV Side
1. Transformer Differential Protection scheme 1 Nos. NIL
2. Restricted Earth fault protection scheme 1 Nos. 1 Nos.@
@ Not applicable for autotransformer
3. Directional back up O/C and E/F relay with non directional high set feature 1 Set 1 set
4. Over Fluxing Protection scheme 1 Nos. 1 Nos.$
$ applicable only for 400/220kV X’former & 765/400 Transformer5. Overload protection scheme 1 Nos.
6. Three phase trip relays 2 Nos. 2 Nos.
Volume-II (Section-I), Relay And Protection Panels 165
REACTOR PROTECTION PANEL
The protection panel for Reactor shall consist of the following protection features/schemes:
No. Description Qty.
1. Reactor Differential Protection scheme 1 no.
2. Restricted Earth fault Protection scheme 1 no.
3. Reactor back up impedance protection scheme 1 set
4. Three phase trip relays(Only for Bus Reactor) 2 nos.
5. CVT selection relay as per scheme requirement Lot
6. Teed protection relay (only for 765kV bus reactor ) 1 no.
BREAKER RELAY PANEL The breaker relay panel shall comprise of the following
S.NO. Description With A/R With out A/R 1. Breaker failure Protection Scheme 1 No. 1 No. 2. DC supply Supervision relay 1 No. 1 No. 3. Trip Circuit supervision relays# 1 No. 1 No. 4. Autoreclose scheme with check synchronizing and
dead line charging relay 1 No. NIL
5. Flag relays, aux. relays, timers, trip relays as per scheme requirements
Lot Lot
# Trip supervision relays shall be 2 numbers for each 132KV Circuit breaker.
Note: Equipment/relays to be provided for CB relay panel may be accommodated in the panels to be provided for Transmission Line/Transformer/Reactor as applicable.
Capacitor Bank Protection: As specified in Capacitor Bank (Section-L), Clause No.4
LT Transformer Protection: As specified in LT Transformer (Section-F), Clause No.10.
PLCC and SDH both systems are available for protection and standby and these should be taken into
account by the bidder for control and protection.
7. CVT selection relays as per scheme requirement Lot Lot
8. Cutout and wiring with TTB for Owner supplied energy meter 1 Set 1 set
9. Transformer Neutral Current relay for 765/400 KV transformer. 1 Set 1 set
Volume-II (Section-I), Relay And Protection Panels 166
26.0 ERECTION AND MAINTENANCE TOOL EQUIPMENTS
All special testing equipment required for the installation and maintenance of the apparatus
instruments devices shall be furnished in relevant schedule
27.0 TROPICALISATION
Control room will be normally air-cooled/air- conditioned. All equipments shall however be suitable
for installation in a tropical monsoon area having hot, humid climate and dry and dusty seasons with
ambient conditions specified in the specification. All control wiring, equipment and accessories shall
be protected against fungus growth, condensation, vermin and other harmful effects due to tropical
environment.
28.0 MONITORING, CONTROL & PROTECTION FOR AUXILIARY TRANSFORMER:
Suitable monitoring, control (operation of associated circuit breaker & isolator) and protection for
630/800/1000KVA transformer, connected to tertiary winding of auto transformer for the purpose of
auxiliary supply shall be provided by the contractor. Over current and open delta protection is
required to be provided for the auxiliary transformer. These protection and control shall be also be
acceptable as built in feature either in the bay controller to be provided for the auxiliary system or in
the control & protection IEDs to be provided for autotransformer.
Volume-II (Section-I), Relay And Protection Panels 167
APPENDIX-A Test program for distance relays
General Comments:
1. The fault inception angles are referred to R- N voltage for all types of faults
2. The fault inception angle is zero degree unless otherwise specified
3. Where not stated specifically, the fault resistance (Rf) shall be zero or minimum as possible
in simulator
4. Single pole circuit breakers are to be used
5. The power flow in double source test is 500 MW
Details of fault cases to be done:
S.No. Description 1. Dynamic Accuracy for zone 1 2. Operating time for zone 1 at SIR=4 3. Operating time for zone II and zone III 4. Switch on to fault feature 5. Operation during current reversal 6. Directional sensitivity 7. Limit for fault resistance 8. Operation at evolving faults 9. Fault locator function, in case the same is offered as built in feature
10. Operation at simultaneous fault
Volume-II (Section-J), Substation Automation System 168
SECTION- (J)
TECHNICAL DETAILS OF SUBSTATION AUTOMATION SYSTEM
1.0 GENERAL
1.1. The substation automation system shall be offered from a manufacturer who must have
designed, manufactured, tested, installed and commissioned substation automation system
which must be in satisfactory operation on 220kV system or higher for at least 2 (Two)
years as on the date of bid opening.
1.2. The Substation Automation System (SAS) shall be installed to control and monitor all the
sub-station equipment from remote control centre (RCC) as well as from local control
centre.
The SAS shall contain the following main functional parts:
Bay control Intelligence Electronic Devices (IED s) for control and monitoring.
Station Human Machine Interface (HMI)
Redundant managed switched Ethernet Local Area Network communication
infrastructure with hot standby.
Gateway for remote control via industrial grade hardware (to RCC) through
IEC60870-5-101 protocol.
Gateway for remote supervisory control (to RSCC), the gateway should be able
to communicate with RSCC on IEC 60870-5-101 protocol. The specific
protocol to be implemented is enclosed as Appendix-I. For Northern Region –I
& II, Eastern Region I & II and North Eastern Region interoperability profile
shall be as per AREVA inter operability profile and for other regions it shall
be as per GE’s interoperability profile. It shall be the bidder’s
responsibility to integrate his offered system with existing RSCC system for
exchange of desired data. The requirement of IO point shall be worked out by
the bidder as per criterion enclosed as Appendix-II for data exchange with
RLDCs.
Remote HMI.
Peripheral equipment like printers, display units, key boards, Mouse etc.
1.3. It shall enable local station control via a PC by means of human machine interface (HMI)
and control software package, which shall contain an extensive range of supervisory
control and data acquisition (SCADA) functions.
Volume-II (Section-J), Substation Automation System 169
1.4. It shall include communication gateway, intelligent electronic devices (IED) for bay
control and inter IED communication infrastructure.
1.5. The communication gateway shall facilitate the information flow with remote control
centres. The bay level intelligent electronic devices (IED) for protection and control
shall provide the direct connection to the switchgear without the need of interposing
components and perform control, protection, and monitoring functions.
2. System design
2.1 General system design
The Substation Automation System (SAS) shall be suitable for operation and monitoring
of the complete substation including future extensions.
The systems shall be of the state-of-the art suitable for operation under electrical
environment present in Extra high voltage substations, follow the latest engineering
practice, ensure long-term compatibility requirements and continuity of equipment supply
and the safety of the operating staff. The o f f e red SAS shall support remote control
and monitoring from Remote Control centres via gateways.
The system shall be designed such that personnel without any background
knowledge in Microprocessor-based technology are able to operate the system. The operator
interface shall be intuitive such that operating personnel shall be able to operate the
system easily after having received some basic training.
The system shall incorporate the control, monitoring and protection functions
specified, self-monitoring, signalling and testing facilities, measuring as well as
memory functions, event recording and evaluationof disturbance records.
Maintenance, modification or extension of components may not cause a shutdown of the
whole substation automation system. Self-monitoring of components, modules and
communication shall be incorporated to increase the availability and the reliability of
the equipment and minimize maintenance.
Bidder shall offer the Bay level unit (a bay comprises of one circuit breaker and
associated disconnector, earth switches and instrument transformer), bay mimic along
with relay and protection panels and PLCC panels housed in air-conditioned
Switchyard Panel Room suitably located in switchyard and Station HMI in
Control Room building for overall optimisation in respect of cabling and control
room building..
2.2 System architecture
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The SAS shall be based on a decentralized architecture and on a concept of bay-oriented,
distributed intelligence.
Functions shall be decentralized, object-oriented and located as close as possible to the
process. The main process information of the station shall be stored in distributed databases.
The typical SAS architecture shall be structured in two levels, i.e. in a station and a bay level.
At bay level, the IEDs shall provide all bay level functions regarding control,
monitoring and protection, inputs for status indication and outputs for commands. The IEDs
should be directly connected to the switchgear without any need for additional interposition
or transducers.
Each bay control IED shall be independent from each other and its functioning shall
not be affected by any fault occurring in any of the other bay control units of the station.
The data exchange between the electronic devices on bay and station level shall take
place via the communication infrastructure. This shall be realized using fibre-optic cables,
thereby guaranteeing disturbance free communication. The fibre optic cables shall be run
in G.I conduit pipes. Data exchange is to be realised using IEC 61850 protocol with
a redundant managed switched Ethernet communication infrastructure
The communication shall be made in fault tolerant ring in redundant mode, excluding
the links between individual bay IEDs to switch wherein the redundant connections are not
envisaged, such that failure of one setof fiber shall not affect the normal operation of the
SAS. However failure of fiber shall be alarmed in SAS. Each fiber optic cable shall have
four (4)spare fibers At station level, the entire station shall be controlled and supervised
from the station HMI. It shall also be possible to control and monitor the bay from the
bay level equipment at all times.
Clear control priorities shall prevent operation of a single switch at the same time from
more than one of the various control levels, i.e. RCC, station HMI, bay level or
apparatus level. The priority shall always be on the lowest enabled control level.
The station level contains the station-oriented functions, which cannot be realized at bay
level, e.g. alarm list or event list related to the entire substation, gateway for the
communication with remote control centres.
The GPS time synchronizing signal (as specified in the section relay & protection) for the
synchronization of the entire system shall be provided.
The SAS shall contain the functional parts as described in para 1.2 above.
2.3 FUNCTIONAL REQUIREMENTS
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The high-voltage apparatus within the station shall be operated from different places:
Remote control centres
Station HMI.
Local Bay controller IED (in the bays)
Operation shall be possible by only one operator at a time.
The operation shall depend on the conditions of other functions, such as interlocking,
synchro check, etc. (see description in ”Bay level control functions”).
2.3.1 Select-before-execute
For security reasons the command is always to be given in two stages: selection of the
object and command for operation under all mode of operation except emergency
operation. Final execution shall take place only when selection and command are actuated.
2.3.2 Command supervision
Bay/station interlocking and blocking
Software Interlocking is to be provided to ensure that inadvertent incorrect operation
of switchgear causing damage and accidents in case of false operation does not take place.
In addition to software interlocking hardwired interlocking are to be provided for:
a) Bus Earth switch Interlocking
b) Transfer Bus interlocking (if applicable)
It shall be a simple layout, easy to test and simple to handle when upgrading the station
with future bays. For software interlocking the bidder shall describe the scenario while
an IED of another bay is switched off or fails.
A software interlock override function shall be provided which can be enabled to bypass the
interlocking function.
2.3.3 Run Time Command cancellation
Command execution timer (configurable)must be available for each control level connection.
If the control action is not completed within a specified time, the command should get
cancelled.
2.3.4 Self-supervision
Continuous self-supervision function with self-diagnostic feature shall be included.
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2.3.5 User configuration
The monitoring, controlling and configuration of all input and output logical signals
and binary inputs and relay outputs for all built-in functions and signals shall be
possible both locally and remotely.
It shall also be possible to interconnect and derive input and output signals, logic
functions, using built-In functions, complex voltage and currents, additional logics
(AND-gates, OR gates and timers). (Multi- activation of these additional functions should
be possible).
The Functional requirement shall be divided into following levels:
a. Bay (a bay comprises of one circuit breaker and associated disconnector, earth
switches and instrument transformer) Level Functions
b. System Level Functions
3.1. Bay level functions
In a decentralized architecture the functionality shall be as close to the process as possible.
In this respect, the following functions can be allocated at bay level:
Bay control functions including data collection functionality in bay control/protection unit.
Bay protection functions
Separate IEDs shall be provided for bay control function and bay protection function.
3.1.1. Bay control functions
3.1.1.1. Overview
Functions
Control mode selection
Select-before-execute principle
Command supervision:
o Interlocking and blocking
o Double command
Synchrocheck, voltage selection
Run Time Command cancellation
Transformer tap changer control (Raise and lower of tap ) (for power transformer
bays)
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Operation counters for circuit breakers and pumps
Hydraulic pump/ Air compressor runtime supervision
Operating pressure supervision through digital contacts only
Breaker position indication per phase
Alarm annunciation
Measurement display
Local HMI (local guided, emergency mode)
Interface to the station HMI.
Data storage for at least 200 events
Extension possibilities with additional I/O's inside the unit or via fibre- optic
communication and process bus
3.1.1.2. Control mode selection
Bay level Operation:
As soon as the operator receives the operation access at bay level the operation is normally
performed via bay control IED. During normal operation bay control unit allows the safe
operation of all switching devices via the bay control IED.
EMERGENCY Operation
It shall be possible to close or open the selected Circuit Breaker with ON or OFF push buttons
even during the outage of bay IED.
REMOTE mode
Control authority in this mode is given to a higher level (Remote Control Centre)
and the installation can be controlled only remotely. Control operation from lower
levels shall not be possible in this operating mode.
3.1.1.3. Synchronism and energizing check
The synchronism and energizing check functions shall be bay-oriented and distributed to the
bay control and/or protection devices. These features are:
Settable voltage, phase angle, and frequency difference.
Energizing for dead line - live bus, live line - dead bus or dead line–dead bus with no
synchro-check function.
Synchronizing between live line and live bus with synchro-check
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function
Voltage selection
The voltages relevant for the Synchro check functions are dependent on the station
topology, i.e. On the positions of the circuit breakers and/or the isolators. The correct
voltage for synchronizing and energizing is derived from the auxiliary switches of the
circuit breakers, the isolator, and earthing switch and shall be selected automatically by the
bay control and protection IEDs.
3.1.1.4. Transformer tap changer control
Raise and lower operation of OLTC taps of transformer shall be facilitated through Bay
controller IED.
3.1.2. Bay protection functions0
3.1.2.1. General
The protection functions are independent of bay control function. The protection shall be
provided by separate protection IEDs (numerical relays) and other protection devices as per
section Relay & Protection. IEDs, shall be connected to the communication infrastructure
for data sharing and meet the real-time communication requirements for automatic
functions. The data presentation and the configuration of the various IEDs shall be
compatible with the overall system communication and data exchange requirements.
Event and disturbance recording function
Each IED should contain an event recorder capable of storing at least 200 time-tagged
events. The disturbance recorder function shall be as per detailed in section C&R
3.1.2.2. Bay Monitoring Function:
Analogue inputs for voltage and current measurements shall be connected directly to
the voltage transformers (VT) and the current transformers (CT) without intermediate
transducers. The values of active power (W), reactive power (VAR), frequency (Hz), and
the rms values for voltage (U) and current (I) shall be calculated in the Bay
control/protection unit.
3.2. System level functions
3.2.1. Status supervision
The position of each switchgear, e.g. circuit breaker, isolator, earthing switch, transformer
tap changer etc., shall be supervised continuously. Every detected change of position shall
be immediately displayed in the single-line diagram on the station HMI screen, recorded in
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the event list and a hard copy printout shall be produced. Alarms shall be initiated in the
case of spontaneous position changes.
The switchgear positions shall be indicated by two auxiliary switches, normally closed
(NC) and normally open (NO), which shall give ambivalent signals. An alarm
shall be initiated if these position indications are inconsistent or if the time
required for operating mechanism to change position exceeds a predefined limit.
The SAS shall also monitor the status of sub-station auxiliaries. The status and control of
auxiliaries shall be done through separate one or more IED and all alarm and analogue
values shall be monitored and recoded through this IED.
3.2.2. Measurements
The analogue values acquired/calculated in bay control/protection unit shall be displayed
locally on the station HMI and in the control centre. The abnormal values must be
discarded. The analogue values shall be updated every 2 seconds.
Threshold limit values shall be selectable for alarm indications.
3.2.3. Event and alarm handling
Events and alarms are generated either by the switchgear, by the control IEDs, or by the
station level unit. They shall be recorded in an event list in the station HMI. Alarms shall be
recorded in a separate alarm list and appear on the screen. All, or a freely selectable group
of events and alarms shall also be printed out on an event printer. The alarms and events
shall be time-tagged with a time resolution of 1 ms.
3.2.4. Station HMI
3.2.4.1. Substation HMI Operation:
On the HMI the object has to be selected first. In case of a blocking or interlocking
conditions are not met, the selection shall not be possible and an appropriate alarm
annunciation shall occur. If a selection is valid the position indication will show the
possible direction, and the appropriate control execution button shall be pressed in order to
close or open the corresponding object.
Control operation from other places (e.g. REMOTE) shall not be possible in this operating
mode.
3.2.4.2. Presentation and dialogues
General
The operator station HMI shall be a redundant with hot standby and shall provide basic
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functions for supervision and control of the substation. The operator shall give commands
to the switchgear on the screen via mouse clicks.
The HMI shall give the operator access to alarms and events displayed on the screen.
Aside from these lists on the screen, there shall be a printout of alarms or events in an
event log.
An acoustic alarm shall indicate abnormalities, and all unacknowledged alarms shall be
accessible from any screen selected by the operator.
The following standard pictures shall be available from the HMI:
Single-line diagram showing the switchgear status and measured values
Control dialogues with interlocking or blocking information details. This control
dialogue shall tell the operator whether the device operation is permitted or blocked.
Measurement dialogues
Alarm list, station / bay-oriented
Event list, station / bay-oriented
System status
3.2.4.3. HMI design principles
Consistent design principles shall be adopted with the HMI concerning labels, colors,
dialogues and fonts. Non-valid selections shall be dimmed out.
The object status shall be indicated using different status colors for:
Selected object under command
Selected on the screen
Not updated, obsolete values, not in use or not sampled
Alarm or faulty state
Warning or blocked
Update blocked or manually updated
Control blocked
Normal state
3.2.4.4. Process status displays and command procedures
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The process status of the substation in terms of actual values of currents, voltages,
frequency, active and reactive powers as well as the positions of circuit breakers, isolators
and transformer tap-changers shall be displayed in the station single-line diagram.
In order to ensure a high degree of security against undesired operation, a "select-before-
execute" command procedure shall be provided. After the "selection" of a switch, the
operator shall be able to recognize the selected device on the screen, and all other switchgear
shall be blocked. As communication between control centre and device to be controlled is
established, the operator shall be prompted to confirm the control action and only then final
execute command shall be accepted. After the “execution” of the command the operated
switching symbol shall flash until the switch has reached its new position.
The operator shall be in a position to execute a command only, if the switch is not
blocked and if no interlocking condition is going to be violated. The interlocking
statements shall be checked by the interlocking scheme implemented at bay and station level.
After command execution the operator shall receive a confirmation that the new switching
position has been reached or an indication that the switching procedure was unsuccessful
with the indication of the reason for non-functioning.
3.2.4.5. System supervision & display
The SAS system shall be comprehensively self-monitored such that faults are immediately
indicated to the operator, possibly before they develop into serious situations. Such faults are
recorded as a faulty status in a system supervision display. This display shall cover the status
of the entire substation including all switchgear, IEDs, communication infrastructure and
remote communication links, and printers at the station level, etc.
3.2.4.6. Event list
The event list shall contain events that are important for the control and monitoring of the
substation.
The event and associated time (with1 ms resolution) of its occurrence has to be displayed
for each event.
The operator shall be able to call up the chronological event list on the monitor at any time
for the whole substation or sections of it.
A printout of each display shall be possible on the hard copy printer.
The events shall be registered in a chronological event list in which the type of event and its
time of occurrence are specified. It shall be possible to store all events in the computer
for at least one month. The information shall be obtainable also from a printed event log.
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The chronological event list shall contain:
Position changes of circuit breakers, isolators and earthing devices
Indication of protective relay operations
Fault signals from the switchgear
Indication when analogue measured values exceed upper and lower limits.
Suitable provision shall be made in the system to define two level of alarm on either
side of the value or which shall be user defined for each measurands.
Loss of communication.
Filters for selection of a certain type or group of events shall be available. The
filters shall be designed to enable viewing of events grouped per:
Date and time
Bay
Device
Function e.g. trips, protection operations etc.
Alarm class
3.2.4.7. Alarm list
Faults and errors occurring in the substation shall be listed in an alarm list and shall be
immediately transmitted to the control centre. The alarm list shall substitute a
conventional alarm tableau, and shall constitute an evaluation of all station alarms. It
shall contain unacknowledged alarms and persisting faults. The date and time of
occurrence shall be indicated.
The alarm list shall consist of a summary display of the present alarm situation. Each
alarm shall be reported on one line that contains:
The date and time of the alarm
The name of the alarming object
A descriptive text
The acknowledgement state.
Whenever an alarm condition occurs, the alarm condition must be shown on the alarm list
and must be displayed in a flashing state along with an audible alarm. After
acknowledgement of the alarm, it should appear in a steady (i.e. not flashing) state and the
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audible alarm shall stop. The alarm should disappear only if the alarm condition has
physically cleared and the operator has reset the alarm with a reset command. The state of
the alarms shall be shown in the alarm list (Unacknowledged and persistent,
Unacknowledged and cleared, Acknowledged and persistent).
Filters for selection of a certain type or group of alarms shall be available as for events.
3.2.4.8. Object picture
When selecting an object such as a circuit breaker or isolator in the single-line diagram,
the associated bay picture shall be presented first. In the selected object picture, all attributes
like
Type of blocking
Authority
Local / remote control
RSCC / SAS control
Errors
shall be displayed.
3.2.4.9. Control dialogues
The operator shall give commands to the system by means of mouse click located on the
single-line diagram. Data entry is performed with the keyboard. Dedicated control
dialogues for controlling at least the following devices shall be available:
Breaker and disconnector
Transformer tap-changer
3.2.5. User-authority levels
It shall be possible to restrict activation of the process pictures of each object (bays,
apparatus...) within a certain user authorization group. Each user shall then be given
access rights to each group of objects, e.g.:
Display only
Normal operation (e.g. open/close of switchgear)
Restricted operation (e.g. by-passed interlocking)
System administrator
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For maintenance and engineering purposes of the station HMI, the following authorization levels
shall be available:
No engineering allowed
Engineering/configuration allowed
Entire system management allowed
The access rights shall be defined by passwords assigned during the log-in procedure. Only
the system administrator shall be able to add/remove users and change access rights.
3.2.6. Reports
The reports shall provide time-related follow-ups of measured and calculated values. The data
displayed shall comprise:
Trend reports:
Day (mean, peak)
Month (mean, peak)
Semi-annual (mean, peak)
Year (mean, peak)
Historical reports of selected analogue Values:
Day (at 15 minutes interval)
Week
Month
Year
It shall be possible to select displayed values from the database in the process display on-line.
Scrolling between e.g. days shall be possible. Unsure values shall be indicated. It shall be possible
to select the time period for which the specific data are kept in the memory.
Following printouts shall be available from the printer and shall be printed on demand:
i. Daily voltage and frequency curves depicting time on X-axis and the appropriate parameters
on the Y-axis. The time duration of the curve is 24 hours.
ii. Weekly trend curves for real and derived analogue values.
iii. Printouts of the maximum and minimum values and frequency of occurrence and duration of
maximum and minimum values for each analogue parameter for each circuit in 24 hr period.
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iv. Provision shall be made for logging information about breaker status like number of
operation with date and time indications along with the current vale it interrupts (in
both condition i.e. manual opening and fault tripping)
v. Equipment operation details shift wise and during 24 hours.
vi. Printout on adjustable time period as well as on demand for MW, MVAR, Current, Voltage
on each feeder and transformer as well as Tap Positions, temperature and status of pumps
and fans for transformers.
vii. Printout on adjustable time period as well as on demand system frequency and average
frequency.
viii. Reports in specified formats which shall be handed over to successful bidder. The
bidder has to develop these reports. The reports are limited to the formats for which data is
available in the SAS database.
3.2.7. Trend display (historical data)
It shall be possible to illustrate all types of process data as trends - input and output data,
binary and analogue data. The trends shall be displayed in graphical form as column
or curve diagrams with a maximum of 10 trends per screen. Adjustable time span and
scaling ranges must be provided. It shall be possible to change the type of value logging
(direct, mean, sum, or difference) on-line in the window. It shall also be possible to change
the update intervals on-line in the picture as well as the selection of threshold values for alarming
purposes.
3.2.8. Automatic disturbance file transfer
All recorded data from the IEDs with integrated disturbance recorder as well as dedicated
disturbance recording systems shall be automatically uploaded (event triggered or once per
day) to a dedicated computer and be stored on the hard disc.
3.2.9. Disturbance analysis
The PC-based work station shall have necessary software to evaluate all the required information
for proper fault analysis.
3.2.10. IED parameter setting
It shall be possible to access all protection and control IEDs for reading the parameters
(settings) from the station HMI or from a dedicated monitoring computer. The setting
of parameters or the activation of parameter sets shall only be allowed after entering a
password.
3.2.11. Automatic sequences
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The available automatic sequences in the system should be listed and described, (e.g.
sequences related to the bus transfer). It must be possible to initiate pre-defined
automatic sequences by the operator and also define new automatic sequences.
3.3. Gateway
3.3.1 Communication Interface
The Substation Automation System shall have the capability to support simultaneous
communications with multiple independent remote master stations,
The Substation Automation System shall have communication ports as follows:
(a) Two ports for Remote Control Centre
(b) Two ports for Regional System Coordination Centre (RSCC)
The communication interface to the SAS shall allow scanning and control of defined points
within the substation automation system independently for each control centre. The
substation automation system shall simultaneously respond to independent scans and
commands from employer's control centres (RCC & RSCC). The substation automation
system shall support the use of a different communication data exchange rate (bits per
second), scanning cycle, and/or communication protocol to each remote control centre.
Also, each control centre’s data scan and control commands may be different for different
data points within the substation automation system's database.
3.3.2 Remote Control Centre Communication Interface
Employer will supply communication channels between the Substation Automation
System and the remote control centre. The communication channels provided by
Employer will consist either of power line carrier, microwave, optical fiber, VSAT or
leased line , the details of which shall be provided during detailed Engineering .
3.3.3 Interface equipment:
The Contractor shall provide interface equipment for communicating between
Substation Automation system and Remote control centre and between Substation
Automation system and Regional System Coordination Centre (RSCC).
In case of PLCC communication any modem supplied shall not require manual
equalization and shall include self-test features such as manual mark/space keying,
analogue loop-back, and digital loop-back. The modems shall provide for convenient
adjustment of output level and receive sensitivity. The modem should be stand alone
complete in all respects including power supply to interface the SAS with communication
channel. The configuration of tones and speed shall be programmable and maintained in
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non-volatile memory in the modem. All necessary hardware and software shall also be
in the scope of bidder except the communication link along with communication equipment
between substation control room and Remote Control Centre.
3.3.4 Communication Protocol
The communication protocol for gateway to control centre must be open protocol and shall
support IEC 60870-5-101 and IEC 61850 for all levels of communication for sub-station
automation such as Bay to station HMI, gateway to remote station etc..
4.0 System hardware:
4.1 Redundant Station HMI, Remote HMI and Disturbance Recorder Work station:
The contractor shall provide redundant station HMI in hot standby mode. The servers used in
these work stations shall be of industrial grade.
It shall be capable to perform all functions for entire substation including future
requirements as indicated in the SLD. It shall use industrial grade components. Processor
and RAM shall be selected in such a manner that during normal operation not more than
30% capacity of processing and memory are used. Supplier shall demonstrate these
features.
The capacity of hard disk shall be selected such that the following requirement should
occupy less than 50% of disk space:
1. Storage of all analogue data (at 15 Minutes interval)and digital data including
alarm , event and trend data for thirty(30) days,
2. Storage of all necessary software,
3. 20GB space for OWNER'S use.
Supplier shall demonstrate that the capacity of hard disk is sufficient to meet the above
requirement.
4.1.1 HMI (Human Machine Interface)
The VDU shall show overview diagrams (Single Line Diagrams) and complete details
of the switchgear with a color display. All event and alarm annunciation shall be selectable
in the form of lists. Operation shall be by a user friendly function keyboard and a cursor
positioning device. The user interface shall be based on WINDOWS concepts with
graphics & facility for panning, scrolling, zooming, decluttering etc.
4.1.2 Visual Display Units/TFT's (Thin Film Technology)
The display units shall have high resolution and reflection protected picture screen.
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High stability of the picture geometry shall be ensured. The screen shall be at least 21"
diagonally in size and capable of colour graphic displays.
The display shall accommodate resolution of 1280 X 1024 pixels.
4.1.3 Printer
It shall be robust & suitable for operation with a minimum of 132 characters per line.
The printing operation shall be quiet with a noise level of less than 45 dB suitable for location
in the control room. Printer shall accept and print all ASCII characters via master control
computer unit interface.
The printer shall have in built testing facility. Failure of the printer shall be indicated in the
Station HMI. The printer shall have an off line mode selector switch to enable safe
maintenance. The maintenance should be simple with provisions for ease of change of print
head, ribbon changing, paper insertion etc.
All reports and graphics prints shall be printed on laser printer. One dot matrix printer shall
be exclusively used for hourly log printing. All printers shall be continuously online.
4.1.4 Mass Storage Unit
The mass storage unit shall be built-in to the Station HMI. All operational measured values
and indications shall be stored in a mass-storage unit in form of DVD RW The unit
should support at least Read (48X), Write(24X), and Re-Write (10X) operations, with
Multi-Session capability. It should support ISO9660, Rockridge and Joliet File systems. It
should support formatting and use under the operating system provided for Station HMI.
The monthly back up of data shall be taken on disc. The facility of back up of data shall be
inherent in the software.
4.1.5 Switched Ethernet Communication Infrastructure:
The bidder shall provide the redundant switched optical Ethernet communication
infrastructure for SAS One switch shall be provided to connect all IEDs in one diameter
of each 765 and 400kV yard and for two bays of 220kV yard to communication
infrastructure. Each switch shall have at least two spare ports for connecting bay level IEDs
and one spare port for connecting station bus.
4.2 Bay level unit
The bay unit shall use industrial grade components. The bay level unit, based on
microprocessor technology, shall use numerical techniques for the calculation and
evaluation of externally input analogue signals. They shall incorporate select-before-
operate control principles as safety measures for operation via the HMI. They shall
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perform all bay related functions, such as control commands, bay interlocking, data
acquisition, data storage, event recording and shall provide inputs for status indication and
outputs for commands. They shall be directly connected to the switchgear. The bay unit
shall acquire and process all data for the bay (Equipment status, fault indications,
measured values, alarms etc.) and transmit these to the other devices in sub-station
automation system. In addition, this shall receive the operation commands from station
HMI and control centre. The bay unit shall have the capability to store all the data for at
least 24 hours.
One no. Bay level unit shall be provided for supervision and control of each 765, 400
and 220 kV bay (a bay comprises of one circuit breaker and associated disconnector, earth
switches and instrument transformer). The Bay level unit shall be equipped with
analogue and binary inputs/outputs for handling the control, status monitoring and analogue
measurement functions. All bay level interlocks are to be incorporated in the Bay level unit
so as to permit control from the Bay level unit/ local bay mimic panel, with all bay
interlocks in place, during maintenance and commissioning or in case of contingencies
when the Station HMI is out of service.
The bay control unit to be provided for the bays shall be preferably installed
in the CB relay panel/feeder protection panel for respective bay. Further in
case of one and half breaker schemes, the BCU for Tie CB shall be provided in Tie
CB relay panel. The tie CB relay panel shall also house the Ethernet switch(es) to
be provided for the diameter. The bay control unit for future bay shall be installed
in a separate panel.
The Bay level unit shall meet the requirements for withstanding electromagnetic
interference according to relevant parts of IEC 61850. Failure of any single component within
the equipment shall neither cause unwanted operation nor lead to a complete system
breakdown.
4.2.1 Input/ Output (I/O) modules
The I/O modules shall form a part of the bay level unit and shall provide coupling to the
substation equipment. The I/O modules shall acquire all switchgear information (i.e. data
coming directly from the switchgear or from switchgear interlocking devices) and
transmit commands for operation of the switchgear. The measured values of voltage and
current shall be from the secondaries of instrument transformers. The digital inputs shall
be acquired by exception with 1 ms resolution. Contact bouncing in digital inputs shall
not be assumed as change of state
4.3 Switchyard Panel Room:
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The switchyard panel room shall be constructed to house Bay level units, bay mimic, relay
and protection panels, PLCC panels etc. one each for a diameter in 765/400kVsub-station
and for two bays in 220kV Level. In case of incomplete diameter the switchyard panel
room shall have necessary space for accommodating the future bay IEDs. The layout of
equipment/panel shall be subject to Owner’s approval. The switchyard panel room shall be
provided with necessary illuminations, fire alarm system with at least two detectors
with necessary power supply if required and it shall be wired to SAS. The detailed
constructional requirement of switchyard panel room is detailed in section civil of
technical specification and air conditioning requirement of switchyard panel room shall
be as detailed in section Air conditioning system of technical specification. The air
conditioner provided in switchyard panel room shall be monitored from substation
automation system.
4.4 Extendibility in future
Offered substation automation system shall be suitable for extension in future for additional
bays. During such requirement, all the drawings and configurations, alarm/event list etc.
displayed shall be designed in such a manner that its extension shall be easily performed
by the employer. During such event, normal operation of the existing substation shall be
unaffected and system shall not require a shutdown. The contractor shall provide all
necessary software tools along with source codes to perform addition of bays in future and
complete integration with SAS by the user. These software tools shall be able to
configure IED, add additional analogue variable, alarm list, event list, modify
interlocking logics etc. for additional bays/equipment which shall be added in future.
5.0 Software structure
The software package shall be structured according to the SAS architecture and
strictly divided in various levels. Necessary firewall shall be provided at suitable points
in software to protect the system. An extension of the station shall be possible with
lowest possible efforts. Maintenance, modification or an extension of components of any
feeder may not force a shut-down of the parts of the system which are not affected by
the system adaptation.
5.1.1 Station level software
5.1.1.1 Human-machine interface (HMI)
The base HMI software package for the operator station shall include the main SAS
functions and it shall be independent of project specific hardware version and
operating system. It shall further include tools for picture editing, engineering and system
configuration. The system shall be easy to use, to maintain, and to adapt according to
Volume-II (Section-J), Substation Automation System 187
specific user requirements. Systems shall contain a library with standard functions and
applications.
5.1.2 Bay level software
5.1.1.1 System software
The system software shall be structured in various levels. This software shall be placed in
a non-volatile memory. The lowest level shall assure system performance and contain
basic functions, which shall not be accessible by the application and maintenance
engineer for modifications. The system shall support the generation of typical control
macros and a process database for user specific data storage. In case of restoration of links
after failure, the software along with hardware shall be capable of automatically
synchronizing with the remaining system without any manual interface. This shall
be demonstrated by contractor during integrated system test.
5.1.1.2 Application software
In order to ensure robust quality and reliable software functions, the main part of the
application software shall consist of standard software modules built as functional block
elements. The functional blocks shall be documented and thoroughly tested. They form part of
a library. The application software within the control/protection devices shall be programmed
in a functional block language.
5.1.1.3 Network Management System:
The contractor shall provide network management system software for following management
functions:
a. Configuration Management
b. Fault Management
c. Performance Monitoring
This system shall be used for management of communication devices and other IEDs in
the system. This NMS can be loaded in DR work- station and shall be easy to use, user
friendly and menu based. The NMS shall monitor all the devices in the SAS and report if
there is any fault in the monitored devices. The NMS shall
(a) Maintain performance, resource usage, and error statistics for all managed links
and devices and present this information via displays, periodic reports and on
demand reports.
(b) Maintain a graphical display of SAS connectivity and device status.
Volume-II (Section-J), Substation Automation System 188
(c) Issue alarms when error conditions occurs
(d) Provide facility to add and delete addresses and links
5.1.1.4 The contractor shall provide each software in two copies in CD to load into the system in
case of any problem related with Hardware/Communication etc.
6.0 TESTS
The substation automation system offered by the bidder shall be subjected to
following tests to establish compliance with IEC 61850 for EHV sub-station equipment
installed in sheltered area in the outdoor switchyard and specified ambient conditions:
6.1 Type Tests:
6.1.1 Control IEDs and Communication Equipment:
a. Power Input:
i. Auxiliary voltage
ii. Current Circuits
iii. Voltage Circuits
iv. Indications
b. Accuracy Tests:
i. Operational Measured values
ii. Currents
iii. Voltages
iv. Time resolution
c. Insulation Tests:
i. Dielectric Tests
ii. Impulse Voltage withstand Test
d. Influencing Quantities
i. Limits of operation
ii. Permissible ripples
iii. Interruption of input voltage
e. Electromagnetic Compatibility Test:
i. 1 MHZ. burst disturbance test
Volume-II (Section-J), Substation Automation System 189
ii. Electrostatic Discharge Test
iii. Radiated Electromagnetic Field Disturbance Test
iv. Electrical Fast transient Disturbance Test
v. Conducted Disturbances Tests induced by Radio Frequency Field
vi. Magnetic Field Test
vii. Emission (Radio interference level) Test.
viii. Conducted Interference Test
f. Function Tests:
i. Indication
ii. Commands
iii. Measured value Acquisition
iv. Display Indications
g. Environmental tests:
i. Cold Temperature
ii. Dry Heat
iii. Wet heat
iv. Humidity (Damp heat Cycle)
v. Vibration
vi. Bump
vii. Shock
6.2 Factory Acceptance Tests:
The supplier shall submit a test specification for factory acceptance test(FAT) and
commissioning tests of the station automation system for approval. For the individual
bay level IED’s applicable type test certificates shall be submitted.
The manufacturing and configuration phase of the SAS shall be concluded by the
factory acceptance test (FAT). The purpose is to ensure that the Contractor has interpreted the
specified requirements correctly and that the FAT includes checking to the degree required
by the user. The general philosophy shall be to deliver a system to site only after it has
been thoroughly tested and its specified performance has been verified, as far as site
conditions can be simulated in a test lab. During FAT the entire Sub-station Automation
Volume-II (Section-J), Substation Automation System 190
System including complete control and protection system to be supplied under present scope
shall be tested for complete functionality and configuration in factory itself. The extensive
testing shall be carried out during FAT. The purpose of Factory Acceptance Testing
is to ensure trouble free installation at site. No major configuration setting of system is
envisaged at site.
If the complete system consists of parts from various suppliers or some parts are already
installed on site, the FAT shall be limited to sub-system tests. In such a case, the complete
system test shall be performed on site together with the site acceptance test (SAT).
6.2.1 Hardware Integration Tests:
The hardware integration test shall be performed on the specified systems to be used for Factory
tests when the hardware has been installed in the factory. The operation of each item shall be
verified as an integral part of system. Applicable hardware diagnostics shall be used to verify
that each hardware component is completely operational and assembled into a
configuration capable of supporting software integration and factory testing of the
system. The equipment expansion capability shall also be verified during the hardware
integration tests. The vendor specifically demonstrates how to add a device in future in
SAS during FAT. The device shall be from a different manufacturer than the SAS supplier.
6.2.2 Integrated System Tests:
Integrated system tests shall verify the stability of the hardware and the software. During
the tests all functions shall run concurrently and all equipment shall operate a
continuous 100 Hours period. The integrated system test shall ensure the SAS is free of
improper interactions between software and hardware while the system is operating as a
whole.
6.3 Site Acceptance Tests:
The site acceptance tests (SAT) shall completely verify all the features of SAS hardware
and software. The bidder shall submit the detailed SAT procedure and SAT procedure
shall be read in conjunction with the specification.
7.0 SYSTEM OPERATION
7.1 Substation Operation
7.1.1 NORMAL OPERATION
Operation of the system by the operator from the remote RCC or at the substation shall
take place via industry standard HMI(Human Machine interface) subsystem consisting
of graphic colour VDU, a standard keyboard and a cursor positioning device (mouse).
Volume-II (Section-J), Substation Automation System 191
The coloured screen shall be divided into 3 fields :
i) Message field with display of present time and date
ii) Display field for single line diagrams
iii) Navigation bar with alarm/condition indication
For display of alarm annunciation, lists of events etc a separate HMI View node. shall be provided.
All operations shall be performed with mouse and/or a minimum number of function keys and
cursor keys. The function keys shall have different meanings depending on the operation. The
operator shall see the relevant meanings as function tests displayed in the command field (i.e.
operator prompting). For control actions, the switchgear (i.e. circuit breaker etc.) requested shall be
selectable on the display by means of the cursor keys. The switching element selected shall then
appear on the background that shall be flashing in a different color. The operator prompting
shall distinguish between:-
- Prompting of indications e.g. fault indications in the switchgear, and
- prompting of operational sequences e.g. execution of switching operations
The summary information displayed in the message field shall give a rapid display of
alarm/message of the system in which a fault has occurred and alarm annunciation lists in
which the fault is described more fully.
Each operational sequence shall be divided into single operation steps which are initiated by
means of the function keys/WINDOW command by mouse. Operator prompting shall be designed
in such a manner that only the permissible keys are available in the command field related to the
specific operation step. Only those switching elements shall be accessed for which control actions
are possible. If the operation step is rejected by the system, the operator prompting shall be
supported by additional comments in the message field. The operation status shall be reset to the
corresponding preceding step in the operation sequence by pressing one of the function keys. All
operations shall be verified. Incorrect operations shall be indicated by comments in the message
field and must not be executed.
The offer shall include a comprehensive description of the system. The above operation shall
also be possible via WINDOWS based system by mouse.
8.0 POWER SUPPLY
Power for the substation automation system shall be derived from substation 220V DC
system. Inverter of suitable capacity shall be provided for station HMI disturbance recorder
evaluation unit and its peripheral devices e.g. printer etc. In the event of Power failure, necessary
safeguard software shall be built for proper shutdown.
Volume-II (Section-J), Substation Automation System 192
9.0 DOCUMENTATION
The following documents shall be submitted for employer’s approval during detailed engineering:
(a) System Architecture Drawing
(b) Hardware Specification
(c) Functional Design Document
(d) Clear procedure describing how to add an IED/bay/diameter in future covering
all major suppliers.
The following documentation to be provided for the system in the course of the project shall be
consistent, CAD supported, and of similar look/feel. All CAD drawings to be provide in “dxf”
format.
List of Drawings
Substation automation system architecture
Block Diagram
Guaranteed technical parameters, Functional Design Specification and Guaranteed
availability and reliability
Calculation for power supply dimensioning
I/O Signal lists
Schematic diagrams
List of Apparatus
List of Labels
Logic Diagram (hardware & software )
Switchyard Panel Room layout drawing
Control Room Lay-out
Test Specification for Factory Acceptance Test (FAT)
Product Manuals
Assembly Drawing
Operator’s Manual
Complete documentation of implemented protocols between various elements
Listing of software and loadable in CD ROM
Volume-II (Section-J), Substation Automation System 193
Other documents as may be required during detailed engineering
10.0 TRAINING, SUPPORT SERVICES, MAINTENANCE AND SPARES
10.1 Training
Contractor personnel who are experienced instructors and who speak understandable English
shall conduct training. The contractor shall arrange on its own cost all hardware
training platform required for successful training and understanding in India. The
Contractor shall provide all necessary training material. Each trainee shall receive
individual copies of all technical manuals and all other documents used for training. These
materials shall be sent to Employer at least two months before the scheduled commencement
of the particular training course. Class materials, including the documents sent before the
training courses as well as class handouts, shall become the property of Employer.
Employer reserves the right to copy such materials, but for in-house training and use only.
Hands-on training shall utilize equipment identical to that being supplied to Employer.
For all training courses, the travel (e.g., airfare) and per-diem expenses will be borne by the bidder.
The schedule, location, and detailed contents of each course will be finalized during
Employer and Contractor discussions.
10.2 Computer System Hardware Course
A computer system hardware course shall be offered, but at the system level only. The
training course shall be designed to give Employer hardware personnel sufficient
knowledge of the overall design and operation of the system so that they can
correct obvious problems, configure the hardware, perform preventive maintenance, run
diagnostic programs, and communicate with contract maintenance personnel. The
following subjects shall be covered:
(a) System Hardware Overview: Configuration of the system hardware.
(b) Equipment Maintenance: Basic theory of operation, maintenance techniques and
diagnostic procedures for each element of the computer system, e.g., processors,
auxiliary memories, LANs, routers and printers. Configuration of all the hardware
equipments.
(c) System Expansion: Techniques and procedures to expand and add equipment
such as loggers, monitors, and communication channels.
(d) System Maintenance: Theory of operation and maintenance of the redundant
hardware configuration, failover hardware, configuration control panels, and
failover switches. Maintenance of protective devices and power supplies.
Volume-II (Section-J), Substation Automation System 194
(e) Subsystem Maintenance: Theory of design and operation, maintenance
techniques and practices, diagnostic procedures, and (where applicable) expansion
techniques and procedures. Classes shall include hands-on training for the specific
subsystems that are part of Employer's equipment or part of similarly designed and
configured subsystems. All interfaces to the computing equipment shall be taught in
detail.
(f) Operational Training: Practical training on preventive and corrective maintenance
of all equipment, including use of special tools and instruments. This training
shall be provided on Employer equipment, or on similarly configured systems.
10.3 Computer System Software Course
The Contractor shall provide a computer system software course that covers the following
subjects:
(a) System Programming: Including all applicable programming languages and all stand-
alone service and utility packages provided with the system. An introduction to software
architecture, Effect of tuning parameters (OS software, Network software,
database software etc.) on the performance of the system.
(b) Operating System: Including the user aspects of the operating system, such as program
loading and integrating procedures; scheduling, management, service, and utility
functions; and system expansion techniques and procedures
(c) System Initialization and Failover: Including design, theory of operation, and practice
(d) Diagnostics: Including the execution of diagnostic procedures and the interpretation of
diagnostic outputs,
(e) Software Documentation: Orientation in the organization and use of system software
documentation.
(f) Hands-on Training: One week, with allocated computer time for trainee
performance of unstructured exercises and with the course instructor available for
assistance as necessary.
10.4 Application Software Course
The Contractor shall provide a comprehensive application software courses covering
all applications including the database and display building course. The training shall
include:
(a) Overview: Block diagrams of the application software and data flows. Programming
standards and program interface conventions.
Volume-II (Section-J), Substation Automation System 195
(b) Application Functions: Functional capabilities, design, and major algorithms.
Associated maintenance and expansion techniques.
(c) Software Development: Techniques and conventions to be used for the preparation
and integration of new software functions.
(d) Software Generation: Generation of application software from source code and
associated software configuration control procedures.
(e) Software Documentation: Orientation in the organization and use of functional and
detailed design documentation and of programmer and user manuals.
(f) Hands-on Training: One week, with allocated computer time for trainee performance
of unstructured exercises and with the course instructor available for assistance as
necessary.
10.5 Requirement of training:
The contractor shall provide training for Owner personnel comprehensively covering
following courses.
S. No. Name of Course
1 Computer System Hardware
2 Computer System Software
3 Application Software
11.0 Maintenance
11.1 Maintenance Responsibility during the Guaranteed Availability Period.
During Guaranteed Availability Period, the Contractor shall take continual actions to ensure
the guaranteed availability and shall make available all the necessary resources such as
specialist personnel, spare parts, tools, test devices etc. for replacement or repair of all
defective parts and shall have prime responsibility for keeping the system operational.
During guarantee period as specified in tender document, contractor shall arrange
bi-monthly visit of their representative to site to review the performance of system and
in case any defect/shortcoming etc. is observed during the period, the same shall be
set right by the contractor within 15 days.
12.0 RELIABILITY AND AVAILABILITY
The SAS shall be designed so that the failure of any single component, processor, or
device shall not render the system unavailable. The SAS shall be designed to satisfy the
very high demands for reliability and availability concerning:
Volume-II (Section-J), Substation Automation System 196
Mechanical and electrical design
Security against electrical interference (EMI)
High quality components and boards
Modular, well-tested hardware
Thoroughly developed and tested modular software
Easy-to-understand programming language for application programming
Detailed graphical documentation and application software
Built-in supervision and diagnostic functions
Security
− Experience of security requirements
− Process know-how
− Select before execute at operation
− Process status representation as double indications
Distributed solution
Independent units connected to the local area network
Back-up functions
Panel design appropriate to the harsh electrical environment and ambient
conditions
Panel grounding immune against transient ground potential rise
Outage terms
1) Outage
The state in which substation automation system or a unit of SAS is unavailable for
Normal Operation as defined in the clause 7.1 due to an event directly related to the
SAS or unit of SAS. In the event, the owner has taken any equipment/ system
other than Sub-station Automation System for schedule/forced maintenance, the
consequent outage to SAS shall not be considered as outage for the purpose of
availability.
2) Actual outage duration (AOD)
The time elapsed in hours between the start and the end of an outage. The time shall be
counted to the nearest 1/4th of an hour. Time less than 1/4th of an hour shall be counted
Volume-II (Section-J), Substation Automation System 197
as having duration of 1/4th of an hour.
3) Period Hours (PH)
The number of hours in the reporting period. In a full year the period hour are 8760h
(8784h for a leap year).
4)Actual Outage hours (AOH)
The sum of actual outage duration within the reporting period
AOH = ∑ AOD
5) Availability:
Each SAS shall have a total availability of 99.98 % i.e. the ratio of total time duration minus the
actual outage duration to total time duration.
12.1 Guarantees Required
The availability for the complete SAS shall be guaranteed by the Contractor. Bidder shall
include in their offer the detailed calculation for the availability. The contractor shall
demonstrate their availability guaranteed by conducting the availability test on the total
sub-station automation system as a whole after commissioning of total Sub-station
Automation system. The test shall verify the reliability and integrity of all sub-systems.
Under these conditions the test shall establish an overall availability of 99.98%. After the
lapse of 1000 Hours of cumulative test time, test records shall be examined to
determine the conformance with availability criterion. In case of any outage during the
availability test, the contractor shall rectify the problem and after rectification, the 1000
Hours period start after such rectification. If test object has not been met the test shall
continue until the specified availability is achieved.
The contractor has to establish the availability in a maximum period of three months from the
date of commencement of the availability test.
After the satisfactory conclusion of test both contractor and employer shall mutually
agree to the test results and if these results satisfy the availability criterion, the test is
considered to be completed successfully. After that the system shall be taken over by the
employer and then the guarantee period shall start.
13.0 Spares
13.1 Consumables:
All consumables such as paper, cartridges shall be supplied by the contractor till the SAS is taken
over by the owner.
Volume-II (Section-J), Substation Automation System 198
13.2 Availability Spares:
the bidder is required to list the spares, which may be required for ensuring the guaranteed
availability during the guaranteed availability period. The final list of spares shall form part of
scope of supply and accordingly the price thereof shall be quoted by the bidder and shall be
considered in the evaluation of the bids. During the guaranteed availability period, the spare
parts supplied by the Contractor shall be made available to the Contractor for usage subject to
replenishment at the earliest. Thus, at the end of availability period the inventory of spares with
the Employer shall be fully replenished by the Contractor. However, any additional spares
required to meet the availability of the system (which are not a part of the above spares supplied
by the Contractor) would have to be supplied immediately by the Contractor free of cost to the
Employer.
14.0 LIST OF EQUIPMENTS
Quantity of equipments shall be decided by bidder in order to achieve guaranteed reliability
and availability as declared by bidder.
i) Station HMI
ii) Redundant Station HMI (in Hot-stand by mode)
iii) Bay level units along with bay mimic
iv) Bay Level Unit for Auxiliary system (as per requirement)
v) Disturbance Recorder Work Station(Maintenance HMI)
vi) Colour Laser Printer – 1 No. (For Reports & Disturbance records)
vii) Dot matrix printers - (one each for Alarms and log sheets)
viii) All interface equipment for gateway to RCC and RSCC
ix) Communication infrastructure between Bay level units, Station
HMI, Printers, gateways, redundant LAN etc. as required
x) Remote workstation including HMI and along with one printer
xi) Modems as per requirement.
xii) Any other equipment as necessary.
Annexure-I
List of Analogue and Digital inputs
Basic Monitoring requirements are:
Volume-II (Section-J), Substation Automation System 199
- Switchgear status indication
- Measurements (U, I, P, Q, f)
- Event
- Alarm
- Winding temperature of transformers & reactors
- Ambient temperature
- Status and display of 415V LT system, 220V & 48V DC system
- Status of display of Fire protection system and Air conditioning system.
- Acquisition of all counters in PLCC panels through potential free contacts from PLCC or
independently by counting the receive/send commands
- Acquisition of alarm and fault record from protection relays
- Disturbance records
- Monitoring the state of batteries by displaying DC voltage, charging current and
load current etc.
- Tap-position of Transformer
List of Inputs
The list of input for typical bays is as below:-
Analogue inputs
i) For line Current R phase
Y phase
B phase
Voltage R-Y phase
Y-B phase
B-R phase
ii) For transformer/reactor
Current R phase
Y phase
Volume-II (Section-J), Substation Automation System 200
B phase
WTI (for transformer and reactor)
Tap position(for transformer only)
iii) For TBC and bus coupler
Current R phase
Y phase
B phase
iv) Common
a) Voltage for Bus-I, Bus-II and Transfer bus wherever applicable
Voltage R-Y phase
Y-B phase
B-R phase
b) Frequency for Bus-I and Bus-II
c) Ambient temperature (switchyard)
d) Switchyard Panel Room Temperature.
e) LT system
i) Voltage R-Y, Y-B, B-R of Main Switch Board section-I
ii) Voltage R-Y, Y-B, B-R of Main Switch Board section-II
iii) Voltage R-Y, Y-B, B-R of Diesel Generator
iv) Current from LT transformer-I
v) Current from LT transformer-II
vi) Current from Diesel Generator
vii) Voltage of 220V DCDB-I
viii) Voltage of 220V DCDB-II
ix) Current from 220V Battery set-I
x) Current from 220V Battery set-II
xi) Current from 220V Battery charger-I
xii) Current from 220V Battery charger-I
Volume-II (Section-J), Substation Automation System 201
xiii) Voltage of 48V DCDB-I
xiv) Voltage of 48V DCDB-II
xv) Current from 48V Battery set-I
xvi) Current from 48V Battery set-II
xvii) Current from 48V Battery charger-I
xviii) Current from 48V Battery charger-I
Digital Inputs
The list of input for various bays/SYSTEM is as follows:
1. Line bays
i) Status of each pole of CB.
ii) Status of Isolator, Earth switch
iii) CB trouble
iv) CB operation/closing lockout
v) Pole discrepancy ptd
vi) Trip coil faulty v
ii) LBB optd
viii) Bus bar protn trip relay optd
ix) Main bkr auto recloser operated
x) Tie/transfer auto recloser operated
xi) A/r lockout
xii) Tie/transfer bkr a/r lockout
xiii) Direct trip-I/II sent
xiv) Direct trip-I/II received
xv) Main I/II blocking
xvi) Main I/II-Inter trip send
xvii) Main I/II-Inter trip received
xviii) O/V STAGE – I operated
xix) O/V STAGE – II operated
Volume-II (Section-J), Substation Automation System 202
xx) FAULT LOCATOR FAULTY
xxi) MAIN-I/II CVT FUSE FAIL
xxii) MAIN-I PROTN TRIP
xxiii) MAIN-II PROTN TRIP
xxiv) MAIN-I PSB ALARM
xxv) MAIN-I SOTF TRIP
xxvi) MAIN-I R-PH TRIP
xxvii) MAIN-I Y-PH TRIP
xxviii) MAIN-I B-PH TRIP
xxix) MAIN-I START
xxx) MAIN-I/II Carrier aided trip
xxxi) MAIN-I/II fault in reverse direction
xxxii) MAIN-I/II ZONE-2 TRIP
xxxiii) MAIN-I/II ZONE-3 TRIP
xxxiv) MAIN-I/II weak end infeed optd
xxxv) MAIN-II PSB alarm
xxxvi) MAIN-II SOTF TRIP
xxxvii) MAIN-II R-PH TRIP
xxxviii) MAIN-II Y-PH TRIP
xxxix) MAIN-II B-PH TRIP
xl) MAIN-II start
xli) MAIN-II aided trip
xlii) MAIN-I/II fault in reverse direction
xliii) Back-up o/c optd
xliv) Back-up e/f optd
xlv) 220V DC-I/II source fail
xlvi) SPEECH CHANNEL FAIL
xlvii) PLCC Protection Channel-I FAIL
Volume-II (Section-J), Substation Automation System 203
xlviii) PLCC Protection Channel-II FAIL
2. Transformer bays
i) Status of each pole of CB, Isolator, Earth switch
ii) CB trouble
iii) CB operation/closing lockout
iv) Pole discrepancy optd
v) Trip coil faulty
vi) LBB optd
vii) Bus bar protn trip relay optd
viii) REF OPTD
ix) DIF OPTD
x) OVERFLUX ALARM (MV)
xi) OVERFLUX TRIP (MV)
xii) OVERFLUX ALARM (HV)
xiii) OVERFLUX TRIP (HV)
xiv) HV BUS CVT ½ FUSE FAIL
xv) MV BUS CVT ½ FUSE FAIL
xvi) OTI ALARM/TRIP
xvii) PRD OPTD
xviii) OVERLOAD ALARM
xix) BUCHOLZ TRIP
xx) BUCHOLZ ALARM
xxi) OLTC BUCHOLZ ALARM
xxii) OLTC BUCHOLZ TRIP
3. Transformer bays
i) Status of each pole of CB, Isolator, Earth switch
ii) CB trouble
iii) CB operation/closing lockout
Volume-II (Section-J), Substation Automation System 204
iv) Pole discrepancy optd
v) Trip coil faulty
vi) LBB optd
vii) Bus bar protn trip relay optd viii) REF OPTD
ix) DIF OPTD
x) HV BUS CVT ½ FUSE FAIL
xi) OTI ALARM/TRIP
xii) PRD OPTD
xiii) BUCHOLZ TRIP
xiv) BUCHOLZ ALARM
xv) OIL LOW ALARM
xvi) Back-up impedance relay
xvii) 220v DC-I/II source fail
xviii) GR-A PROTN OPTD
xix) GR-B PROTN OPTD
4. Line/Bus Reactor bays (as applicable):
i) Status of each pole of CB, Isolator, Earth switch
ii) CB trouble
iii) CB operation/closing lockout
iv) Pole discrepancy optd
v) Trip coil faulty
vi) LBB optd
vii) Bus bar protn trip relay optd
viii) REF OPTD
ix) DIF OPTD
x) Line/ BUS CVT ½ FUSE FAIL
xi) OTI ALARM/TRIP
xii) PRD OPTD
Volume-II (Section-J), Substation Automation System 205
xiii) BUCHOLZ TRIP
xiv) BUCHOLZ ALARM
xv) OIL LOW ALARM
xvi) Back-up impedance relay
xvii) 220V DC-I/II source fail
xviii) GR-A PROTN OPTD
xix) GR-B PROTN OPTD
5. Bus bar Protection
i) Bus bar main-I trip
ii) Bus bar main-II trip
iii) Bus bar zone-I CT open
iv) Bus bar zone-II CT open
v) Bus transfer CT sup. Optd
vi) Bus transfer bus bar protn optd
vii) Bus protection relay fail
6. Auxillary System
i) Incomer-1 On/Off
ii) Incomer-II On/Off
iii) 415V Bus-I/II U/V
iv) 415V Bus Coupler breaker On/Off
v) DG ser brk On/Off
vi) Alarm/Trip signals as listed in section: DG set
vii) LT transformer-I Bunchholz Alarm & Trip
viii) LT transformer-II Bunchholz Alarm & Trip
ix) LT transformer –I WTI alarm & trip
x) LT transformer –I OTI alarm & trip
xi) LT transformer –II OTI alarm & trip
xii) PLCC exchange fail
Volume-II (Section-J), Substation Automation System 206
xiii) Time sync.Signal absent
xiv) Alarm/trip signals as listed in section: Battery and Battery charger
xv) 220V DC-I earth fault
xvi) 220V DC-II earth fault
xvii) Alarm/trip ignals as listed in section: fire Protection System
7. Switchyard Panel Room:
i) AC Compressor 1 ON/OFF
ii) AC Compressor 2 ON/OFF
iii) Fire detection 1 ON/OFF
iv) Fire detection 2 ON/OFF
v) Switchyard Panel Room Temperature High Alarm
The exact number and description of digital inputs shall be as per details engineering
requirement apart from the above mentioned digital inputs, minimum of 200 inputs
shall be kept for Owner use in future.
Volume-II (Section-K), SDH And PLCC 207
SECTION- (K)
TECHNICAL DETAILS OF SDH & PLCC
SDH
SDH: Synchronous Digital Hierarchy (SDH) Fiber Optic System is to be installed &
commissioned at all the 400kV sub-station by the contractor. The network architecture to be
implemented shall be of ring topology with adequate transmission and synchronization
protection scheme to achieve operational requirement.
The minimum configuration for OPGW equipment shall be as follows:-
SDH equipment shall be of STM-4 capacity with 63E-1(alternative 252E-1) channels.
a. Provision for extending SDH to 220kV system shall also be made by the contractor.
b. The SDH system shall be used for data transfer and standby protection.
PLCC
1.0 GENERAL
1.1 All the PLCC equipment covered under the package shall conform to the requirements of the
latest edition of the relevant IEC/IS Specifications or equivalent National Standards,
2.0 LOCATION OF EQUIPMENT
2.1 The PLCC Equipment and Line traps as specified shall be installed at the respective ends of
the transmission lines. The Contractor shall be responsible for coordinating the equipment
supplied by him with the already existing carrier equipment at the respective sub-stations.
Contractor shall also be responsible for collecting all the necessary information/data from
the respective substations/ concerned State Electricity Boards for the installation of the
equipment.
3.0 GENERAL REQUIREMENT
a) In case of LILO Lines, PLCC cabinets from existing sub-station shall be shifted and
commissioned by contractor in one bay of LILO at new sub-station. Further 4 nos. digital
PLCC cabinets (Programmable to analogue as well as digital) alongwith associated
equipments such as wave trap, LMU, HF cable etc. shall be procured by contractor. Out of
these 4 cabinets 2 nos. digital PLCC cabinets shall be commissioned at existing sub-station
and other 2 nos. in 2nd bay of LILO line at new sub-station.
b) Both end digital PLCC cabinets alongwith associated equipments shall be procured and
commissioned by contractor.
Volume-II (Section-K), SDH And PLCC 208
c) PLCC cabinets on 220kV & below network shall be provided by UPPTCL ( not in scope of
this package ). However, contractor has to provide the space for PLCC cabinets and
associated equipments in control room and switchyard respectively for the same.
d) 2 digital channels will be required for Main-I and Main-II protection and IIIrd Channel for
Data Transfer.
e) For line details see Table I
4.0 FREQUENCY PLANNING
4.1 For planning frequency and output power of carrier terminals Bidders may plan for a
minimum receive signal to noise ratio of 25 dB for the speech channels without companders.
The noise power in 2.1 kHz band (300-2400 Hz) may be taken as -13 dBm referred to the
coupling point of the H.T. line. An additional minus two and a half dB may be assumed for
psophometric factor. As far as coupling loss (phase to phase) is concerned the Bidders may
assume the same as 6dB at one coupling end for evaluating SNR. For protection channels the
minimum SNR shall not be less than 15 dB under adverse weather. A safety margin of 9 dB
shall be taken over and above these SNR values in order to cater for variations in line
attenuation from the computed value as inhand reserve. Frequency and output power of PLC
terminals for protection shall be planned such that the protection signal is received with full
reliability even when one of the phase is earthed or is on open circuit on the line side causing
an additional minimum loss of 6 dB.
The Bidder shall indicate the noise power in the bandwidth used for protection signaling and
shall submit the SNR calculations for speech as well as protection channels on all the line
section given in at the proposed frequencies. Sample calculations for SNR requirement and
power allocation over different channels must be furnished alongwith the bid. Maximum
permissible line attenuation shall be clearly brought out in these calculations. Further, Bidder
shall submit details of frequency planning done (including computer studies carried out and
facilities available) for PLCC links on EHV lines in the past in the relevant schedule of
DRS. Bidder must enclose one copy of computer study result done in the past along with the
Bid.
4.2 Successful Bidder shall be fully responsible for the coordination required with concerned
State Electricity Boards for finalising the frequency plan.
4.3 The frequency plan will be referred to wireless Adviser/DOP Department for clearance and
in case any change in the Contractor’s recommended carrier frequency and power output is
proposed by these authorities, the Contractor shall have to modify his proposal accordingly.
Change of power output shall, however, not involve repeater stations.
Volume-II (Section-K), SDH And PLCC 209
5.0 PROPOSED ARRANGEMENT
5.1 The power line carrier communication equipment required by the Owner is to provide
primarily efficient, secure and reliable information link for carrier aided distance protection
and direct tripping of remote-end breaker and also for speech communication between
765/400/220 kV sub-stations. It shall include separate carrier terminals of multipurpose type
for speech and protection purposes. All carrier terminals including those for protection shall
be suitable for point to point speech communication also.
5.2 For security reasons each 400/220kV transmission line shall be protected by
Main-I and Main-II protections as given below:
Main-I Numerical Distance protection with permissive inter-tripping.
Main-II Distance protection of a different measuring technique than that of
relay under Main I.
5.3 The requirement of carrier information on each link covered under this specification is as
below:
a) One protection channel for Main-I and another for Main-II distance protection
schemes. Further these channels will also be used as main and back-up channel for
direct circuit breaker inter-tripping for 400kV lines.
In case of 400kV/220kV lines, speech and data channel can also be used for protection
wherever possible.
b) One speech channel with a facility to superimpose data signals upto 1200Baud.
However, the number of channels for protection signaling , speech and data
communication for SAS and Load dispatch centre shall be as per the BOQ given in
price schedule.
5.4 The equipment for protection signals shall have high degree of reliability and speed. It shall
be guaranteed to function reliably in the presence of noise impulse caused by isolator or
breaker operation. The equipment shall be suitable for direct tripping of remote end breaker
for fault in unswitched 400 kV Shunt Reactor & Operation of Buchholz relays of reactor etc.
It shall also be possible to effect direct tripping of breaker at one end when the other end
breaker opens out either manually or by relays such as Bus fault relay etc.
5.5 The time intervals between receipt of a trip command on the transmit side, its transmission
over the carrier link, reception at the far end and giving command to the trip relays at the
distant end shall not exceed 20 mS. for permissive intertripping and 30 m sec. for direct
inter-tripping even for the longest line section.
Volume-II (Section-K), SDH And PLCC 210
The above timings are inclusive of operating time for auxiliary relays and interposing relays,
if any, included in the PLCC equipment.
5.6 The requirement of protection signaling channel is such that security against incorrect
signals being received shall be at least two to three orders higher than reliability against a
signal not being received.
5.7 For reasons of security and reliability, phase to phase coupling for 400 kV D/C & 220kV
D/C lines shall be employed. Inter-circuit coupling shall be used for 220 D/C lines. Double
differential coupling shall also be considered for double circuit lines. Bidders must furnish
detailed write-up on methods of coupling and recommend suitable coupling mode for
double-circuit lines alongwith the bids. Coupling mode shall, however, be fully confirmed
by Contractor after conducting detailed computer study taking into account the
transpositions of 400 kV lines for optimum coupling mode over these line sections.
The coupling arrangement shall be fully optimized by the Contractor after conducting
detailed study of every line section individually, taking into account the temperature
variations, transpositions, earth resistivity, conductor configuration, carrier channels
requirements, security and reliability criteria and other relevant details. The line attenuation
shall be calculated for complete range of frequencies. The earth resistivity data, existing
frequency networks and other relevant details of each line will be furnished to the Contractor
for carrying out the computer studies and frequency planning. The Contractor shall complete
the computer studies wherever required and submit the frequency plan and optimum
coupling details within a period of one month from the date of receipt of above data.
5.8 The 400 kV transmission lines may be transposed. The transmission tower configuration and
conductor details shall be forwarded after the award to enable the contractor to make his
own computer study assessment of the carrier path based on wave propagation over
transposed lines with each transposition point acting as “Modal Converter”.
5.9 The parameters of the equipment quoted shall be such that the mode of wave propagation on
400 kV power line (with transpositions indicated) shall not impose any limitation on the
efficient and reliable performance of information link from protection or communication
point of view.
5.10 The Contractor shall have to check and prove through the results of his computer studies that
attenuation due to transpositions in the EHV lines is within limits and the offered equipment
will perform satisfactorily.
5.11 The Bidder shall submit curves illustrating ‘incorrect tripping’ and “Failure to trip”
probability plotted against corona noise level, in the presence of impulse noise due to
switching of isolator and circuit breaker etc. Details of field tests and laboratory tests for
Volume-II (Section-K), SDH And PLCC 211
successful operation of his equipment, under such adverse conditions shall be furnished by
the Bidder. These are to be related to end-to-end signaling and shall take into account the
type of communication link e.g. account shall be taken of transpositions in the phase to
phase coupled H.T. line. Details of field tests and laboratory tests for successful operation of
the equipment under the above circumstances shall be submitted by the Bidder illustrating
the above parameters.
7.0 LINE TRAP
7.1 Line trap shall be broad band tuned for its entire carrier frequency range. Resistive
component of impedance of the line trap within its carrier frequency blocking range shall not
be less than 450 ohms for 400 kV system and 570 ohms for 220kV systems.
7.2 Line trap shall be provided with a protective device in the form of surge arrestors which
shall be designed and arranged such that neither significant alteration in its protective
function nor physical damage shall result from either temperature rise or the magnetic field
of the main coil at continuous rated current or rated short time current. The protective device
shall neither enter into operation nor remain in operation, following transient actuation by
the power frequency voltage developed across the line trap by the rated short time current.
The lightning arrestor shall be station class current limiting active gap type. Its rated
discharge current shall be 10 kA. Coordination, however, shall be done by taking 20 kA at
8/20 micro-sec. discharge current into account. Bidder has to furnish full justification in case
the use of gap-less metal oxide arrestor is recommended by them.
7.3 The lightning arrestor provided with the line trap of each rating shall fully comply with the
requirements of IS: 3070 Part-I/IEC-60099-I Part-I. It shall conform to type tests as
applicable and type test certificate for the same shall be submitted by the Bidder.
7.4 The lightning arrestor provided with the line trap shall be subject to routine and acceptance
tests as per IEC-60099-1 (Part-I).
7.5 The line trap on 400 kV line shall show no visual corona discharge at a voltage of 320 KV
(rms) power frequency falling voltage.
Suitable corona rings may be incorporated in the line trap. Radio interference voltage for
420kV shall not exceed 1000 micro volts at 266kV (rms.
7.6 Line trap shall be equipped with the bird barriers.
7.7 Line trap shall conform to IEC 60353 (latest) fulfilling all the technical requirements. The
rated short time current for 1 Second shall be 31.5/40/50 kA as per requirement. The mH
rating shall be 0.25/0.5/1.0 mH depending on frequency plan.
Volume-II (Section-K), SDH And PLCC 212
7.8 The Bidder shall indicate continuous current rating of the line trap at 65 deg. C ambient.
7.9 Reports for the following type tests on each type of line trap shall be submitted:
1. Measurement of Inductance of the main coil.
2. Measurement of temperature rise.
3. Insulation test.
4. Short time current test.
5. Corona Extinction Voltage test (procedure for this shall be mutually agreed ).
6. Radio Interference Voltage measurement test (procedure for this shall be mutually
agreed ).
7.10 The Bidder must enclose with his bid the reports of type and routine tests conducted on
similar equipment earlier as per IEC-60353.
7.11 Welding
All the welding included in the manufacture of line traps shall be performed by personnel
and procedure qualified in accordance with ASME-IX and all the critical welds shall be
subject to NDT as applicable.
7.12 Line Trap Mounting
7.12.1 The Line Trap shall be suitable for outdoor pedestal or suspension mounting and
shall be mechanically strong enough to withstand the stresses due to maximum wind
pressure of 260 kg/square meter.
7.12.2 For pedestal mounting, each line trap shall be mounted on a tripod structure formed
by three insulator stacks arranged in a triangular form. All the accessories and
hardware, mounting stool including bolts for fixing the line trap on insulators shall
be of non-magnetic material and shall be supplied by the Contractor.
7.12.3 For suspension mounting, Contractor shall be required to coordinate the mounting
arrangement with the existing arrangement. Non-magnetic suspension hook/link of
adequate length and tensile strength to provide necessary magnetic clearance
between the line trap and suspension hardware shall be supplied by the Contractor.
7.13 Terminal Connectors
7.13.1 The line traps shall be suitable for connecting to 4" IPS Aluminium tube or 3" IPS
Al. tube or ACSR single/twin/Quad bundle conductor with horizontal or vertical
takeoff. Necessary connector shall be supplied by the Contractor.
Volume-II (Section-K), SDH And PLCC 213
7.13.2 Terminal Connectors shall conform to IS:5561.
7.13.3 No part of clamp or connector (including hardware) shall be of magnetic material.
7.13.4 Clamps and connectors shall be designed corona controlled. Visual Corona
extinction voltage shall not be less than 320kV (rms) for 420kV respectively. All
nuts and bolts shall be suitably shrouded.
7.13.5 Radio interference Voltage for 420/245 kV shall not exceed 1000 microvolts at
266/156 kV (rms) respectively.
7.13.6 Clamps/connectors shall be designed for the same current ratings as line trap and
temperature rise shall not exceed 35 deg. C over 50 deg. C ambient. No current
carrying part shall be less than 10 mm thick.
7.13.7 Clamps/connectors shall conform to type test as per IS: 5561. Type Test reports
shall also be submitted for following additional type tests :
a) Visual Corona Extinction Test
b) Radio Interference Voltage Measurement
7.13.8 Bidders are required to submit alongwith their bid typical drawings clearly
indicating the above mentioned features of the line traps, line trap mounting
arrangement and terminal connectors. For suspension mounted line traps, Bidder
shall submit drawings showing single point as well as multipoint (normally 3 point)
suspension arrangements.
8.0 COUPLING DEVICE
8.1 The coupling devices shall be interposed between the capacitor voltage transformer and
coaxial line to the PLC transmitter /receiver and in conjunction with the capacitor voltage
transformer shall ensure:
a) Efficient transmission of carrier frequency signals between the carrier frequency
connection and the power line.
b) Safety of personnel and protection of the low voltage parts and installation, against the
effects of power frequency voltage and transient over voltages.
8.2 The coupling device, in conjunction with the CVT shall from an electric filter of band pass
type:
a) It shall match characteristic impedance of H.T. line to impedance of the carrier
frequency connection.
Volume-II (Section-K), SDH And PLCC 214
b) Galvanic isolation between primary and secondary terminals of the coupling device shall
be performed by the above mentioned transformer.
c) Power frequency currents derived by the CVT may be drained to the earth by a separate
inductance termed drain coil of suitable rating.
d) Voltage surges coming from the power line at the terminals of the coupling device shall
be limited by a non-linear surge arrestor of suitable rating in the primary side.
Requirement of a gas type voltage arrestor in secondary side of the coupling device
shall have to be fully justified, but in any case the input circuit of PLC. equipment shall
have protective devices in the form of zener diodes and surge suppressers.
The surge arrester shall have power frequency spark over voltage coordinated with the
equipment ahead of it.
e) For direct and efficient earthing of its primary terminals, the coupling device shall be
equipped with an earthing switch. The Earth Switch shall be available for earthing of
CVT-HT terminals, when the coupling filter units are removed from circuit for
maintenance/ replacement. The design shall take due regard of requirements for safety
in accordance with the Indian Electricity Rules.
8.3 Two numbers ‘phase to earth’ type coupling filters shall be used to achieve ‘phase to phase’/
‘inter-circuit coupling’. Connection between secondaries of the two phase to earth type
coupling device shall be through a balancing transformer/hybrid such that reliable
communication shall be ensured even when one of the coupled phase is earthed or open
circuited on the line side.
8.4 Coupling device shall conform to IEC-60481 and shall have the following carrier frequency
characteristics as applicable to a phase to earth type coupling device:
a) Nominal line side i) 240 ohms for 765kV and 400 kV Quad/triple
impedance bundle conductor line.
ii) 320 ohms for 400kV twin bundle conductor
line.
iii) 400 ohms for 220kV line
b) Nominal equipment 75 ohms (unbalanced)
side impedance
c) Composite loss Not more than 2 dB
d) Return Loss Not less than 12 dB
Volume-II (Section-K), SDH And PLCC 215
e) Bandwidth Shall suit the frequency plan between 36 and 500
kHz
f) Nominal peak Not less than 650 Watt.
envelope power
(for Inter-modulation product 80 dB down)
8.5 The coupling device shall be suitable for outdoor mounting. Temperature of metallic
equipment mounted outdoor is expected to rise upto 65 deg. C during the maximum ambient
temperature of 50 deg. C specified. The equipment offered by the Bidder shall operate
satisfactorily under these conditions.
8.6 The H.T. Terminal of coupling device shall be connected to H.F. Terminal of the CVT by
means of 6 mm sq. copper wire with suitable lugs & taped with 11 kV insulation by the
contractor.
8.7 Coupling device shall have at least two terminals for carrier equipment connection. Bidder
shall confirm that such a parallel connection to coupling device directly will not result in any
additional attenuation.
8.8 The coupling device including the drainage coil, surge arrester and earthing switch shall
conform to type tests and shall be subject to routine tests as per IEC- 60481/IS:8998.
Routine tests shall include but not be limited to the following :
i) Composite loss and return loss tests on coupling device.
ii) Turns ratio test and insulation tests on the balancing transformer.
iii) Milli volt drop test, power frequency voltage test and mechanical operation test on
earthing switch.
iv) Power frequency spark over test for lightning arrester as per relevant IS/IEC.
8.9 Reports for the following type tests on coupling device shall be submitted :
1) Return loss test.
2) Composite loss test.
3) Distortion and inter modulation test .
4) Impulse voltage test.
5) Tests on Arrestors
Bidder shall furnish, alongwith his bid copies of all type and routine test conducted earlier
on similar coupling device in accordance with relevant standards.
Volume-II (Section-K), SDH And PLCC 216
9.0 High Frequency Cable
9.1 High frequency cable shall connect the coupling device installed in the switchyard to the
PLC terminal installed indoor.
9.2 The cable shall be steel armoured and its outer covering shall be protected against attack by
termites. Bidder shall offer his comments on method employed by him for earthing of screen
and submit full justification for the same with due regard to safety requirements.
Bidder must enclose in his bid a detailed construction drawing of the cable being offered,
with mechanical and electrical parameters.
9.3 Impedance of the cable shall be such as to match the impedance of the PLC terminal on one
side and to that of the coupling device on the other side over the entire carrier frequency
range of 40-500 kHz.
9.4 Conductor resistance of cable shall not exceed 16 ohms per Km at 20°C.
9.5 The cable shall be designed to withstand test voltage of 4 kV between conductor and outer
sheath for one minute.
9.6 Bidder shall specify attenuation per Km of the cable at various carrier frequencies in the
range of 40 to 500 kHz. The typical attenuation figures for H.F. cable shall be in the range of
1 to 5 dB/km in the frequency range of 40-500 kHz.
9.7 The H.F. cable shall conform to type tests and be subjected to routine tests as per IS
11967(Part 2/Sec 1): 1989/IS 5026:1987.
9.8 All HF cables within the scope of this specification shall be laid and termination shall be
carried out by the Contractor.
9.9 The cables shall be supplied wound on drums containing nominal length of 500 meters each.
However, exact requirement of drum lengths shall be finalized during detailed engineering
to avoid joint in HF cable and its wastage.
10.0 Power Line Carrier Terminal
10.1 As already indicated the information link shall be provided for speech, protection, telex and
data services.
10.2 PLC terminal shall use Amplitude Modulation and shall have single side band transmission
mode. These shall be equipped for fixed frequency duplex working. Characteristic input and
output parameters of the SSB PLC terminals shall be as per IEC-60495, unless otherwise
specified.
10.3 The salient features are detailed out below:
Volume-II (Section-K), SDH And PLCC 217
a) Mode of transmission Amplitude Modulation single side band with suppressed
carrier or reduced carrier.
b) Carrier frequency 40 to 500 kHz range
c) Nominal carrier frequency 4.0 kHz band in either direction of transmission
d) Power output (PEP) 20/40/80 Watt
at HF terminal
e) Frequency difference Frequency difference between VF signal at the transmitting
and
between a pair of rece iving ends will not exceed 2 Hz with suppressed
carrier.
PLC terminals With reduced carrier frequency difference shall be zero.
This shall include permissible ambient temperature
variation and supply frequency and voltage variation of (+)
15% and (-) 10%.
f) Automatic gain For 40 dB change in carrier frequ ency signal level within
the
control regulation range, change in VF receive levels of both
speech and other signals shall be less than 1dB.
g) Supply voltage 48 V DC + 15%, - 10%. (Positive pole earthed)
10.4 All the PLC terminals shall be of multipurpose type. The Bidder shall confirm that the total
transmission time for teleprotection shall not exceed 20 ms for permissive and 30 ms for
direct tripping signals. Speech and teleprotection channels shall independently fulfill the
SNR requirements out of the power allocated to its channel from the total power of the PLC
terminals.
Detailed calculation for SNR requirement and power allocation over different channels
should be furnished alongwith the bid.
10.5 In the input circuit of the PLC terminal protective devices shall be provided in the form of
zener diodes or surge suppressers in order to eliminate any surge transfer through the
coupling device or the surge induced in the connecting path of H.F. cable.
10.6 To improve voice transmission characteristics for the system, compressors and expanders
shall be provided. The companders shall have at least 2:1 compression ratio with a
corresponding expansion ratio of 1:2. The operating range of compander shall be compatible
with the audio power levels specified for 4 wire operation. The improvement gained by
Volume-II (Section-K), SDH And PLCC 218
companders shall however not be taken into account for power allocation and shall be in-
hand reserve.
10.7 Sudden changes in input level to the receiver shall not cause false tripping. The Bidder shall
clearly indicate in his offer the methods adopted to ensure above phenomenon. The receiver
design shall also provide protection against false tripping from random noise.
10.8 Fail-safe devices shall be provided, so that a malfunction in one unit or subassembly cannot
cause damage elsewhere in the system. All plug-in equipment shall be fitted with features to
prevent improper insertion. The electrical cables shall not be routed across sharp edges or
near sources of high temperature. The adjustments, which are susceptible to misadjustment
from accidental contact/vibration, shall be equipped with suitable locking devices.
10.9 The PLC set shall be designed to give guaranteed performance from 0 deg. C to 50 deg. C
ambient temperature. The thermal capability of the equipment shall be so designed that the
equipment remains operational successfully upto 60 deg. C ambient temperature. Any
ventilation fans provided for circulation of air inside the cabinets shall conform to relevant
Indian Standards.
10.10 The terminals shall be provided with built-in indicating instrument to facilitate checking of
important voltages and current values and signal levels in different parts of the PLC
Terminals. Protection fuses shall be provided in all important circuits and fuses shall be so
mounted as allow their easy inspection and replacement. All test points shall be easily
accessible. The carrier set shall be provided with suitable supervision and alarm facilities.
Individual parts of the carrier set should be accessible from front, making it possible to place
the carrier cabinets side-by-side. All components and parts of the carrier set shall be suitably
tropicalised.
10.11 PLC terminals shall be housed in floor mounting sheet metal cabinets, suitable for mounting
on concrete plinth as well as channel frame by means of nuts and bolts or welding. All the
panels shall be properly earthed to the Owner’s earthing grid by the Contractor. Contractor
shall submit detailed drawings for earthing connections.
10.12 All the panels shall be protected against moisture ingress and corrosion during storage.
Panels shall be properly dried before they are installed and energized.
Bidder shall indicate measures adopted to prevent ingress of moisture during operation.
10.13 All cabinets having PLC terminals shall be provided with lamps of sufficient wattage for
interior illumination with switch. Each panel shall be provided with 240 V AC single phase
socket with switch to accept 5 & 15A standard Indian plugs.
Volume-II (Section-K), SDH And PLCC 219
10.14 A name plate shall be provided on the front door of each cabinet indicating channel
function, transmitter frequency and direction etc.
10.15 Reports for the following type tests for PLC Terminals shall be submitted:
Tests to determine various characteristics of PLC terminals as per IEC –60495.
a) Voltage variation
b) Carrier frequency range band.
c) Frequency accuracy
d) Transmit/Receive frequency difference.
e) Automatic gain control
f) Harmonic distortion
g) Selectivity
h) Output impedence, Return loss&Tapping loss
i) Return loss, Afinputs/Outputs
j) Balance to ground
k) Limiter action
l) Spurious emission
m) Carrier frequency levels and levels
n) Attenuation distortion
o) Noise generated within terminal
p) Near and far end cross talk
q) Group delay distortion
r) Conducted noise
s) Telephone signaling channel
t) Speech levels
u) Voltage withstand test
v) Insulation test
10.16 Heat Soaking of panels
All the solid state equipment/system panels shall be subjected to the Heat Soaking as per the
following procedure:
Volume-II (Section-K), SDH And PLCC 220
All solid state equipment shall be burn-in for minimum of 120 hours continuously under
operation condition. During the last 48 hours of testing, the ambient temperature of the test
chamber shall be 50°C. Each PLC panel shall be complete with all associated sub-systems
and the same shall be in operation during the above test. During the last 48 hours of the
above test, the temperature inside the panel shall be monitored with all the doors closed. The
temperature of the panel interior shall not exceed 65°C.
11.0 SPEECH COMMUNICATION
11.1 PLC equipment offered shall provide telephone communication between the stations where
the transmission lines are terminating. The equipment shall be suitable for providing the
following facilities :
a) It shall be possible for subscriber at any of the stations to contact the subscriber at all
other stations connected in the system as shown in the specification drawing by
dialing his call number. To achieve this 32 lines EPAX with 4 wire interface &
remote subscriber units shall be provided/available at different stations.
b) The equipment shall contain all normal facilities like ring back tone, dial tone,
engage tone & priority tone, and suitable pulses to establish and disconnect
communication between subscribers.
c) The equipment shall be provided with necessary alarm circuits and fuses etc.
d) The equipment shall be of 4 kHz bandwidth on either direction and be suitable for
providing superimposed data and teleprinter facilities at a later date without major
modifications and high cost. The Bidder shall clearly indicate in his bid the
provision made in his proposal for future development and the extent to which such
additional facilities can be added at a later date.
e) The system shall be completely automatic with definite number allocated for each
telephone. The numbering scheme for telephones, exchange and tie lines shall be
developed by the Bidder and indicated in the bid. Final numbering scheme shall be
fully coordinated with the existing/ proposed future systems by the Contractor.
f) Arrangement for over-riding facilities shall be provided by means of priority keys
wherever specified. The over-riding facility shall enable cutting-in ongoing calls
with the priority key and ask the concerned parties to finish their conversation. The
wanted number should then get automatically connected without having to redial the
number.
Volume-II (Section-K), SDH And PLCC 221
g) All the carrier telephone conversations shall be secret and it should not be possible
for anybody to over hear the conversation going on between any two parties
excepting those provided with over-riding facilities.
h) The necessary cables for connecting all the telephone instruments ordered for at
each sub-station (including wiring and termination) shall be provided by the
Contractor. These telephone instruments shall be located within control room
building at respective sub-station.
i) The cabinets housing the equipment for EPAX, four wire E/M interface & remote
subscriber units (four wire) shall have mounting arrangement similar to that for PLC
terminals.
j) All the terminals for speech shall be with Transit Band Pass Filter suitable for tuning
at site and shall be wired for addition of VFTs in future.
k) Equipment for speech communication must be fully compatible with Owner’s
existing equipment. Any interfaces required for proper matching and connection
with the Owner’s existing equipment shall be provided by the Contractor.
l) Terminals for protection shall be suitable for speech between two ends of each
transmission line or on tandem operation basis with back to back connection at the
intermediate stations.
n) Each PLC terminal for speech as well as protection purposes shall be provided with
a plug-in type service telephone and buzzer. Further, 4 wire remote telephone
instruments (parallel to service telephone) shall also be provided on one PLC
terminal for protection for each link. These instruments shall be located in respective
Switchyard control room to enable the operator to make emergency calls on point-
to-point basis. Each such instrument shall be equipped with a buzzer and ‘press-to-
call’ key and shall not require any additional power supply units.
11.2 Electronic Private Automatic Exchange (EPAX)
11.2.1 The 32 line Electronic Private Automatic Exchange (EPAX) wherever specified
shall be connected to minimum six trunk routes thorough PLCC channels (speech
panel) with Four-wire E/M’ interface unit. This 4-wire interface unit either shall
form an integral part of the ‘EPAX’ system or be suitable for mounting/housing in
the carrier panel. The exchange will have its own ringing current and tone generator
etc. The exchange shall be suitable for working on 48 V DC Power Supply (positive
pole earthed).
Volume-II (Section-K), SDH And PLCC 222
The exchange shall be fully automatic, solid state, and of modular construction and
shall have multiple switching routes (minimum 4-routes).
11.2.2 ‘EPAX’ shall also be provided with two (2) additional interface units and operate
exclusively with Owner’s leased subscriber lines, of Department of
Telecommunication (DOT) and compatible with 2 wire full duplex, voice grade
mode of operation.
The details of communication protocol, for interfacing of the ‘DOT’ leased lines,
shall be coordinated by the Contractor, with the licensing authority (DOT).
11.3 Remote End Four Wire ‘E/M’ Interface & Subscriber Unit or Equivalent EPAX (4x4)
11.3.1 The remote end four wire ‘E/M’ interface & subscriber units, wherever specified,
shall be of electronic type and be suitable for working on fixed frequency power line
carrier systems with E & M signaling. This shall be housed in the carrier set and be
fully wired to the power line carrier terminal equipment.
11.3.2 This unit shall receive and register various signals, on PLCC Channels, from remote
end exchanges or other remote end subscriber units and associated four wire
interface unit.
11.3.3 The four wire interface unit shall be equipped for routing transit calls and shall be
supplied pre-wired to handle calls for minimum eight directions, in a form suitable
for transmission over PLCC.
11.3.4 The bidder shall also indicate the total number of trunk-line capacity, available with
each four-wire interface unit.
The unit shall be suitable for connecting two-wire telephone sets. Further, the
associated telephone cables for locating two subscriber lines, within the control
room is in the scope of this specification.
11.4 Network Protection Equipment (Protection Coupler)
11.4.1 The Bidder shall offer voice frequency transmission equipment which shall work on
frequency shift or coded signal principle for transmission/reception of protection
signals as single purpose channel. The equipment shall be suitable for connection to
the power line carrier terminal.
11.4.2 The voice frequency transmission equipment shall not only be insensitive to corona
noise but shall also remain unaffected by impulse type noise which are generated by
electrical discharge and by the opening and closing of circuit breakers, isolators,
earthing switches etc. The equipment shall also be made immune to a field strength
Volume-II (Section-K), SDH And PLCC 223
of 10V/m expected to be caused by portable radio transmitters in the range of 20-
1000 MHz. In his offer, bidder shall clearly explain as to what measures have been
taken to make the equipment insensitive to corona noise, white noise and to impulse
noise of an amplitude larger than the wanted signal and submit full field test and
laboratory test reports. The guarantee on design data shall not be acceptable.
11.4.3 The equipment shall be unaffected by spurious tripping signals. The Bidder shall
submit proof as to how this is achieved satisfactorily.
11.4.4 The equipment shall be suitable for transmission of direct and permissive trip signal
as well as blocking signals for protective gear of power system. The equipment shall
be operated in the audio frequency range in speech band or above speech band as
superimposed channel in 4 kHz band of SSB carrier. The equipment shall operate
with full duplex frequency shift mode of operation or by switching between two
frequencies in case of coded signals . The protection signaling equipment shall be of
solid state design, modular in construction and have a proven operating record in
similar application over EHV systems. Details regarding application of the
equipment over 400kV/220kV systems shall be submitted along with the bid. Each
protection signaling equipment shall provide:
i) Transmission facilities for minimum three protection signals.
ii) Reception facilities for minimum three protection signals.
11.4.5 The equipment shall be designed for remote tripping/ blocking on permissive basis
and direct tripping for reactor fault and others. The overall time of PLC, VFT and
transmission path for permissive trip/blocking shall be 20 m. Sec. or less and for
direct tripping 30 m. Sec. or less even for the longest line section.
Operating time lower than specified above may be preferred provided they fulfill the
requirements of security and reliability as mentioned below :
False - trip probability 10-5
(Noise burst of any amplitude)
Fail to trip probability 10-2
for S/N 6 dB in 3.1 kHz Band
(white Noise Measurement)
11.4.6 It may be emphasized that specified time, as mentioned above is composed of the
following:
a) Back-to-back signal delay in frequency shift or coded signals protection
equipment.
Volume-II (Section-K), SDH And PLCC 224
b) Back-to-back delay in PLC terminal.
c) Delay in transmission line.
d) Operation time of interposing relay, if any, in frequency shift or coding
equipment.
Reference is invited in this regard to the guide lines expressed in CIGRE
Publication “Teleprotection” report by Committee 34 and 35.
11.4.7 The following transfer criteria shall be provided by the equipment:
a) Transmit side
One number potential free NO (normally open) contact of protective relays
(To be supplied by the Owner) of under noted rating for each of the
following functions:
i) Permissive trip command
ii) Direct trip command
Contact Rating:
Maximum voltage : 660 Volts
Maximum current rating : 5 amps
Maximum power rating : 1250 W/VA
b) Receive Side
Voice frequency transmission equipment for network protection shall be
provided with one potential free NO (normally open) contact of the under
noted rating for each of the following functions:
i) Permissive trip command
ii) Direct trip command
Contact Rating:
Rated voltage : 250 Volts DC
Rated current : 0.1 A DC
Other Parameters : As per IEC-60255-25
c) Alarm
Volume-II (Section-K), SDH And PLCC 225
In addition, the voice frequency protection terminal shall provide at least
one number potential free change over contact of the following rating for
alarm purposes.
Rated voltage : 250 volts DC
Rated current : 0.1 A DC
Other Parameters : As per IEC-60255-25
11.4.8 The Contractor shall submit drawings showing inter-connection between PLCC and
protection panels for approval by the Owner.
11.4.9 It has to be ensured that under no circumstances protection channel should share the
power. Each protection channel shall be able to transmit power for which system is
designed. For example, a 40 W PLC terminal shall transmit 40 Watt (max.) for
protection channel alone in the event of fault. Speech and superimposed data
channels, in the same protection terminal must get disconnected momentarily during
the operation of protection channels.
11.4.10 The equipment shall be constructed such that in permissive line protection system,
operational reliability of the protection channel may be checked over the carrier link
by means of a loop test. It shall be possible to carry out the above test from either
end of the carrier link. During healthy condition of the transmission line, the loop
test shall not initiate a tripping command. In the event of a system fault, while loop
test is in progress, protection signal shall over-ride the test signal.
11.4.11 The equipment shall be complete with built in counters for counting the number of
trip commands sent and number of trip commands received.
11.4.12 Reports for the following tests shall be submitted for approval for protection
coupler and the relays associated with PLCC equipment for network protection
signaling equipment and interface unit with protective relay units if any :
1) Protection coupler ( As per IEC 60834 -1)
a) Power supply variation
b) Power supply interruption
c) Reflected noise
d) Reverse polarity
e) Interference by discrete frequency
f) Transmission time
Volume-II (Section-K), SDH And PLCC 226
g) Interference by frequency deviation. ( Wherever applicable)
h) Alarm function
g) Security
h) Dependability
i) Voltage withstand test
j) Insulation test.
j) Electrical fast transient test (along with carrier terminal)
k) HF disturbance test (along with carrier terminal)
l ) Electro static discharge test (along with carrier terminal)
m) Radiated electromagnetic field susceptibility test (along with carrier
terminal)
n) Environment test (as per IS 9000 )
2. Relays.
a) Impulse voltage withstand test as per Clause 6.1 of IS:8686 (for a test
voltage appropriate to Class III as per Clause 3.2 of IS:8686).
b) High Frequency Disturbance test as per Clause 6.2 of IS:8686 (for a test
voltage appropriate to Class III as per Clause 3.2 of IS:8686).
12.0 Mandatory Testing & Maintenance Equipment
Print testing kit for PLCC terminal, E/M interface & subscriber unit, Protection coupler &
EPAX comprising of following items of reputed make in addition to any other special items
required for testing and maintenance of this equipment packed in a carrying brief case:
1. Screw driver set with multi up fixing feature
2. Nose pliers
3. Cutting pliers
4. Ordinary Pliers
5. Adjustable wrench
6. Soldering iron with tip earthed
a) 150 watts - 1 No.
b) 35 Watts - 1 No
Volume-II (Section-K), SDH And PLCC 227
c) 10 watts - 1 No.
operated with isolated (step down) transformer having provision for interchangeable
taps.
7. Desoldering pump
8. Print extender
9. Print puller
10. Large selection of test leads
11. Solder wire
12. Large selection of plugs, jacks & pistol probes compatible with equipment supplied
13. Dummy load
14. Interface card/print for Tx to Rx loop-back
15. Test oscillator/tone generator with indicating meters - either built in or separate
16. ESD wrist band
17. ESD conducting mat
11.0. LIST OF COMMISSIONING TESTS
The following tests shall be carried out on complete system/subsystem during
commissioning:
1. Composite loss and return loss on coupling device using dummy load.
2. Composite loss (Attenuation) for HF Cable coupling device.
3. End to end attenuation measurement for verification of optimum coupling mode. Test
shall be done for all combinations.
4. End to end return loss for optimum coupling mode.
a) open behind line trap.
b) grounded behind line trap.
5. If end to end return loss for optimum coupling mode is not satisfactory, same shall be
measured for other coupling modes also.
6. Adjustment of Tx/Rx levels on PLCC equipment as per test schedule.
7. AF frequency response (end to end) for the entire 4 kHz Bandwidth for speech and
teleoperation channels.
Volume-II (Section-K), SDH And PLCC 228
8. Measurement of noise in 2 kHZ bandwidth with and without line energised.
9. SNR (test-one) with line energised noting down weather conditions.
10. Transmission time for teleprotection and other data channels.
11. Observation of Tx/Rx levels (test-tone) for each channel at both ends by sequential
switching on/off parallel channels using dummy load and also with the transmission
line.
12. Observation of end to end and trunk dialing performance.
13. Observation of end-to-end protection signaling (command sent & received) in
conjunction with protective relays, noting down transmission/receipt of unwanted
commands under switching operations in the switchyard during protective relay
testing.
Notes:
1. All measurements for link attenuation, composite loss and return loss shall be carried out for
the entire range of carrier frequencies with specific attention to the frequencies.
i. within coupling device bandwidth.
ii. within line trap bandwidth, and
iii. operating frequencies.
2 Following tests shall be carried out independently at each and
i. Composite loss & return loss for coupling device.
ii. Attenuation test for HF cable + coupling device.
iii. Levels and other local adjustments (on dummy load).
Final adjustment shall be on end to end basis.
iv. Test for loading by parallel channels with dummy load.
This test can be done alongwith tests for coupling device.
v. Protection signaling under local loop test (dummy load).
3. Necessary test instruments required for all the above tests shall be brought by
commissioning engineers of the contractor.
12.0 Telecom NMS is to be provided at Indirapuram Substation for Central Network
Management. Following 7 substations will be monitored at Indirapuram:
a) 765/400/220kV AIS at Greater Noida
Volume-II (Section-K), SDH And PLCC 229
b) 765/400/220kV AIS at Hapur
c) 400/220kV AIS at Sikandarabad
d) 400/132kV AIS at Nehtaur
e) 400/220/33kV GIS at Ataur (Gaziabad)
f) 400/220/132kV GIS at Dasna
g) 400/ 220/33kV GIS at Indirapuram
13.0 Table-I:
Following is the line length
S.No.
Line Detail Length
1. 765kV S/C Mainpuri – Hapur line with Quad Bersimis conductor
219 Km
2. 765kV S/C Mainpuri - Greater Noida with Quad Bersimis conductor
202 Km
3. 765kV S/C Greater Noida - Hapur line with Quad Bersimis conductor
58 Km
4. LILO of (2xS/C) 765kV Meerut (PGCIL) - Agra (PGCIL) line at Greater Noida with Quad Bersimis conductor
24X2 Km
5. 400kV D/C Greater Noida – Sikandrabad line with Quad Moose conductor
24 Km
6. 400kV D/C (Quad) Hapur – Dasna line with Quad Moose conductor
22 Km
7. 400kV D/C (Quad) Greater Noida – Noida (Sector-148) line with Quad Moose conductor
16 Km
8. LILO of 400kV Moradabad - Muradnagar line at Hapur substation with Twin Moose conductor
2 Km
9. LILO of 400kV S/C Rishikesh – Kashipur line at Nehtaur Substation with Twin Moose conductor
16 Km
10. 400kV D/C Hapur - Ataur (Ghaziabad) line with Quad Moose conductor
55 Km
Volume-II (Section-L), Capacitor Bank 230
SECTION- (L)
TECHNICAL DETAILS OF CAPACITOR BANK
1.0 Technical particulars of capacitor bank is as follows:
Nominal Voltage 132kV
Highest System Voltage 145kV
Design Voltage 152kV
Bank Rating 100 MVAR
Bank Rating at design voltage 132.6 MVAR
Sub Bank rating 16.67MVAR
Capacitor bank should be provided with NCT protection and earthing blade for each
group. The complete bank shall be controlled by a suitable circuit breaker. The
capacitor bank switching control scheme shall be MANUAL.
The capacitor banks shall be of out-door type having internal fuse units, Suitable for
operation in the specified climatic conditions and also suitable for mounting on steel
racks. The mounting arrangement: could be either a Single /Two or Three tier
arrangement.
Each group of capacitor banks shall be connected in star formation, as per the
protection scheme offered, with their neutral points ungrounded.
The number of parallel units in each series group shall be such that failure of one unit
shall not preferably create more than 10% voltage rise on other units in the bank.
The details of over-voltage imposed on remaining unit with the blowing off of each
internal fuses should be clearly mentioned. It should be clearly mentioned as to how
many elements can go off without the need to trip the capacitor bank.
Individual capacitor units of banks shall be self contained, outdoor type, having
single to two bushing with a rating as per manufacturers practice to give the required
total bank capacity at 50Hz. The bushings should be of porcelain and shall be joined
to the case by solder-sealing method. The creepage distance of bushing shall not be
less than 31mm/kV of voltage stress appearing between the terminal & the case. The
Bushings shall be suitable for heavily polluted atmospheric conditions.
Volume-II (Section-L), Capacitor Bank 231
The impregnant shall be non-PCB & the impregnation shall be carried out under high
degree of vacuum and the units shall be of totally sealed type.
Each capacity unit shall be provided with an internal discharge resister designed to
drain out the residual charge upto 50 volts within 10 minutes after disconnection from
supply.
Each capacitor unit shall have internal fuses suitably rated for load current.
Each unit shall satisfactorily operate at 130% rated KVAR including the factor of
over voltage due to harmonic currents and manufacturing tolerances.
Terminal and mounting arrangement may be in accordance with Manufacturer’s
standard practice.
The containers of capacitor units shall all be of sufficiently thick sheet Steel, painted
with suitable anti-rust synthetic enamel primer paint and two finishing coats of paint
as per the manufacturer’s standard practices.
The capacitor banks shall conform to latest edition of IS:13925(Part –1), 1998/IEC-
70.
2.0 Mounting racks
The mounting racks shall be fabricated from suitable steel section duly hot dip
galvanised to impart durable weather resistance.
The racks shall be complete with rack insulators foundation bolts and other
hardwares etc., for assembly into complete banks. Suitable terminal connectors/
clamps for connection with other equipments shall also be provided. All various
parts including Bolts & Nuts shall be hot dip galvanised.
The height of the racks of capacitor banks shall be such that for making electrical
connections with other equipment, proper electrical clearance is maintained.
However, the capacitor banks shall be enclosed inside the pale fencing.
3.0 Tests: The equipment shall comply with the requirements of type test as per IS: 2834
and copies of these type test reports should be submitted along with offer. The
capacitor offered must have been also endurance tested as per IEC: 871-2/IS: 13925
and copies of reports submitted alongwith offer. The capacitors under the package
shall also be type tested as per relevant IS/IEC.
Acceptance & routine test: The equipment shall comply with all routine and
acceptance tests as per IS – 2834. Sampling to be done as per IS –2834.
Volume-II (Section-L), Capacitor Bank 232
4.0 132kV/ 33 kV Capacitor Bank Relay Panel
i) Capacitor bank unbalance relay
ii) A two pole IDMT over current relay & single pole IDMT earth fault relay shall be provided
iii) Over voltage relay
iv) High speed tripping relay.
v) 2-Trip circuit supervision relay for pre and post closing supervision of trip coil.
vi) Suitable size cable gland.
Volume-II (Section-M), Illumination System 233
SECTION-M
TECHNICAL DETAILS OF ILLUMINATION SYSTEM
1.0 LIGHTING SYSTEM
1.1 LIGHTING SYSTEM FOR SUBSTATION
The scope of work comprises of design, engineering, testing, supply, installation, testing and
commissioning of various lighting fixtures complete with lamps, supports and accessories,
ceiling fans complete with electronic regulators, exhaust fans for toilets and pantry &
accessories, lighting panels, lighting poles complete with distribution boxes, galvanized rigid
steel /rigid PVC conduits, lighting wires, G.I. Earthwire, receptacles, tag block & telephone
socket, switchboards, switches, junction boxes, pull out boxes complete with accessories,
Bidder shall quote unit rate against each item and payment shall be made as per final
executed quantity.
Street lighting of switchyard shall be done by “Solar based energy efficient pole mounted
lighting system” to achieve the desired lux level specified. Technical specifications of “Solar
based energy efficient pole mounted lighting system” are attached at Annexure-III. The
bidder shall quote unit rate for solar street lighting and the payment shall be made as per
final executed quantity. In addition to Solar lighting, all street lighting shall also be
connected with normal lighting system. A suitable changeover arrangement shall be
provided in each street pole to switchover to normal lighting in case of prolonged outage of
solar grid.
The entire control room building, fire fighting pump house lighting shall be done by LED
based low power consumption luminaries to achieve desired lux level specified. The bidder
shall quote on lumpsum basis on the basis of design criteria specified for each control room
building and Fire Fighting pump house.
The lighting of conference room and control room in the control room building shall be
powered by solar grid lighting arrangement. A changeover in the panel shall be provided to
switchover on normal lighting in case of requirement. The execution of entire arrangement
including design, solar grid interface with existing distribution, associated electrical panel,
VRLA battery set, cabling etc shall be in the scope of the bidder.
1.2 SYSTEM DESCRIPTION
i) AC Normal Lighting
Volume-II (Section-M), Illumination System 234
AC lights will be connected to AC lighting panels. All the lights connected to the AC
lighting system in different areas will be connected to the main lighting distribution boards.
ii) AC Emergency Lighting
This system will be available in control room building, Fire fighting pump house, &
switchyard. AC lighting load will be connected to this system which will be normally ‘ON’.
The lighting panels of this system will be connected to the Emergency lighting board which
is fed from diesel generator during the emergency. 25% of lighting fixtures shall be
connected on AC emergency lighting.
iii) D.C. Emergency lighting
A few DC emergency lighting fixtures operated on the DC system will be provided in the
strategic locations including staircase, corridors, electrical rooms, Battery charger room, LT
switchgear room in control room building, and Fire fighting pump house so that the
operating personnel can safely find their way even during emergency of a total AC failure.
These lights will be normally 'OFF' and will be switched 'ON' automatically when under
voltage occurs in the AC main lighting distribution board. GLS lamp down lighters in false
ceiling area and Bulkhead fixtures in non false ceiling area to be used.
iv) Exit Lightings
All Exit lightings in the buildings shall be fed by DC lighting panels. All necessary wiring
and its termination shall be in the contractor’s scope.
v) The lighting layout for and around Control Room Cum Administrative Office Building &
Fire fighting Pump House indicating the type & BOQ for items shall be prepared and
submitted by the contractor for owner’s approval during detailed engineering.
The lux levels to be maintained shall be as per following:
S.No. AREA AVERAGE LUX LEVEL
S.No. Area Average Lus Level At Floor Level
1. Control Room Building, Fire Fighting Pump house
i) Control Room & Conference room
350 Lux
ii) Battery room, Passage, Pantry, Toilets, Corridors etc
100 Lux
iii) All other rooms 200 Lux
Volume-II (Section-M), Illumination System 235
The minimum lux level to average lux level ratio should not be less than 0.6 (i.e Emin/Eav>
0.6). The maintenance factor for indoor illumination design shall be considered as 0.8. The
surface reflectance for ceiling/wall/floor shall be 50/30/10.
The contractor shall submit detailed calculation for reaching the above Lux level for
Employer’s approval during detailed engineering. Contractor shall conform the Lux levels at
different locations of the control room building and fire fighting pump house by
measurement.
vi) Ceiling fans (1400 mm sweep, AC 230 volts ) shall be provided in , fire fighting pump
house and non AC rooms in the control room building as per the requirements. Wall
mounted fans shall be provided in the conference room, control room, shift manager and
substation incharge rooms in control room building. Exhaust fans shall be provided in toilets
and pantry.
vii) One no. of aluminum ladder of each size shall be supplied by the contractor for maintenance
purpose.
viii) The following specific areas are included in the scope of lighting:
(a) Switchyard Area.
(b) Switchyard Control Room cum Administrative Office Building
(c) Fire fighting pump house
(d) Street lighting (Street lighting shall be done using “Solar based energy efficient pole
mounted lighting system”)
(e) DG area lighting
(f) LT Transformer area
ix) For Outdoor Illumination
The switchyard and street lighting, detailed drawings showing the lighting layout and
Electrical distribution diagram shall be prepared by the Contractor and submitted for
approval. The above layout drawings will include disposition and location of lighting
fixtures, receptacles, etc.
x) For Indoor Illumination
The conduit layout drawing for substation buildings based on the civil tender drawings,
Electrical distribution diagram for substation buildings, & for substation yard etc. shall be
prepared by the Contractor. All wiring including telephone wiring (tinned two pair copper)
shall be in concealed conduit.
Volume-II (Section-M), Illumination System 236
Concealed MS junction boxes for sockets and light points shall be provided in all the rooms
of Control Room cum Administrative Office Building and Fire Fighting pump house. In case
where false ceiling surface conducting is permissible, all down run conduits will be
concealed in wall below the false ceiling.
xi) Each cable run shall be tagged with number that appear in the cable schedules.
Cables shall be tagged at their entrance and/or exit from any piece of equipment, junction or
pull box, floor opening etc.
xii) The tag shall be made up of aluminum with the number punched on it and securely attached
to the cable by not less than two turns of G.I. wire. Cable tags shall be rectangular in shape
for power cables and circular shape for control cables.
xiii) Location of cables laid directly under ground shall be indicated clearly by cable marker
made of galvanised iron plate embedded in concrete block.
xiv) The location of underground cable joints if any, shall be clearly indicated with cable marker
with an additional inscription "cable joint".
xv) The marker, which is a concrete block, shall project 150 mm above ground and shall be
spaced at an interval of 30 meters and at every change of direction. It shall also be located on
both sides of the road or drain crossing.
2.0 LIGHTING SYSTEM FOR TOWNSHIP
2.1 The scope of work comprises of design, engineering, testing, supply, installation, testing and
commissioning of 415 V, 400Amp, Main Township Distribution board/Energy meter
Boards/Flat DBs etc Power and Control cables, various lighting fixtures complete with
lamps, supports and accessories, ceiling fans complete with electronic regulators, exhaust
fans for toilets and pantry & accessories, lighting panels, lighting poles complete with
distribution boxes, galvanized rigid steel/PVC conduits, lighting wires, G.I. Earthwire,
receptacles, tag block & telephone socket, bells, boxes for telephone/television & Air-
conditioners points, switchboards, switches, junction boxes, pull out boxes for various type
of quarters, parking, pump house, recreation centre and transit camp associated with
township.
2.2 SYSTEM DESCRIPTION
The township lighting system shall comprise of the following:
2.3 EXTERNAL ELECTRIFICATION WORKS
The entire External Electrification work including connection to various quarters, recreation
centres & transit camp associated with township including street lighting of township shall
Volume-II (Section-M), Illumination System 237
be in the scope of the contractor. 415V,400A, Main Township distribution board shall be fed
from 415V, 1000 A Main switchboard ( being supplied under LT switchgear package)
located in MCC room of main Switchyard through 2-3 ½ x300 sqmm XLPE insulated power
cable from each source. Supply of MainTownship DB & associated 3 ½ x300 sqmm XLPE
cable alongwith its interconnection, installation etc shall be in the scope of contractor.
The entire external electrification work comprising of feeder pillars, Cables and associated
glands and lugs, steel tubular poles, street lights, MS junction boxes, GI pipes for cable
protection, danger plates, Hume pipes, fire extinguishers, cable route markers etc as required
shall be in the scope of the contractor.. The exact location of quarters, recreation centre,
transit camp, streets etc shall be intimated to successful bidder during detailed engineering.
The bidder shall quote unit prices for items under external electrification work as per bill of
quantity for the estimated work.
2.4 INTERNAL ELECTRIFICATION WORKS
The entire work has to be performed in line with standard electrical layouts. The scope shall
broadly consist of entire concealed conduit work, wiring for
lights/power/fans/telephones/cables & air-conditioners, supply and fixing of metal boxes,
plates, switches, sockets, call bells, buzzers, exhaust fans, ceiling fans, MCBs, MCCBs, light
fittings, energy meters boards & flat DBs etc as per the requirements of various quarters,
recreation centres and transit camps. In addition to above complete earthing ( through
separate earth pit) and lightning protection for each type of quarters ,recreation centre and
transit camp shall be provided as per standard guidelines given in relevant Indian standards
and code of practices. The complete drawing for earthing and lightning protection shall be
submitted to owner for approval. The loop earthing inside the buildings shall be carried out
with minimum 1Cx1.5 sqmm PVC stranded Copper wire . All materials required or earthing
and lightning protection of township buildings shall be in the scope of contractor.
The bidder shall quote lumpsum prices for each type of quarters, recreation centre and transit
camp separately, including entire scope pertaining to lighting system, earthing and lightning
protection. Any item not specifically outlined in the layouts and specifications enclosed
herein shall necessarily be included by the contractor as per applicable buildings codes,
statutory electricity rules and code of practices for the completion of scope.
3.0 DESCRIPTION OF ITEMS
3.1 DESCRIPTION OF ITEMS FOR SUBSTATION LIGHTING
The Contractor shall supply and install the following equipment and accessories in
accordance with the specification.
Volume-II (Section-M), Illumination System 238
3.1.1 LIGHTING PANELS
i) OUTDOOR
415 AC lighting panel with 415V, 63A, 3 phase 4 wire bus and one no. 63A, TPN,
MCB with neutral unit as incomer and 20A, SP MCB as outgoing feeders, the
details are as follows.
Type Of Panel Description Detail Of Outgoing Feeders
ACP 2 Outdoor 6 nos- 20 A single pole MCB and 3 No. 32 A Triple pole MCB with Neutral and suitable timer and contactor for automatic switching.
ACP 3 Outdoor Street lighting Panel
3 nos.-32A Triple pole MCB with Neutral with suitable timer and contactor for automatic switching
Note: The number of outgoing feeders indicated above are the minimum.
ii) INDOOR
415 V indoor AC lighting panel ,63 A 3 phase 4 wire bus and one number 63 amp
FP MCB with 300ma 63 A FP RCCB. Flush mounted with per phase isolation and
LED indication lamps. The DB will be flush mounted and double door type.
Type Of Panel Description Detail Of Outgoing Feeders
ACP 1 Indoor 18 nos outgoing ,16 Amps SP MCB
220V DC indoor type change over board and 220V DC 32A two wire bus and one
32A contractor backed up by 32A double pole MCB as incomer. The panel shall
have local push button controls. Following are the various types of panels required
with control timer.
Type Of Panel Description Detail Of Outgoing Feeders
DCP Indoor 6 nos outgoing ,16 Amps DP MCB
iii) Sub-Lighting Panels
Type Of Panel Description Detail Of Outgoing Feeders
Volume-II (Section-M), Illumination System 239
SLP Outdoor 4 pole 32A Isolator suitable for 415V, 50 cycles AC supply, wlith LILO facility using 8 nos terminal blocks suitable for cable upto 16 mm sq cable Enclosure shall be suitable for outdoor use with IP-55 degree of protection as per IS:13947 (Part-1).
3.1.2 Lighting Fixtures
Please Refer Annexure-1
3.1.3 Receptacles
Type Of Receptacle
Description Detail Of Outgoing Feeders
RO Outdoor Outdoor 15A, 240V, Receptacle 2 pole, 3- pin type
RP Outdoor 63A, 415V, Interlocked switch socket, receptacle
RI Indoor 5/15A, 240V, Receptacle 3-pin type ( Modular)
3.1.4 Switch Boards
Modular type switches, 5/15 Amp. Receptacles.
3.1.5 Conduits And Accessories
Galvanised Rigid steel or Rigid PVC conduits of 20/25 /32 mm for Lighting and
Telephone wiring
3.1.6 Junction Boxes - with 5 Nos.of terminal blocks
3.1.7 Lighting Poles - (Type A1 poles & Type E1 poles)
3.1.8 FANS-1400 mm Sweep with Electronic regulator and 450 mm Wall Mounted fans
3.1.9 Maintenance Equipment
i) A type Aluminium ladder of 3 mtr vertical height.
ii) Cartwheel mounted aluminium ladder Vertical Extendable from 5.1m to 11m.
3.1.10 Receptacles
a) All receptacles shall be of cast steel/aluminium, heavy duty type, suitable for
fixing on wall/column and complete with individual switch.
Volume-II (Section-M), Illumination System 240
b) In general the receptacles to be installed are of the following types :
i) Type RO-15A, 240V, 2 pole, 3 pin type with third pin grounded, metal
clad with gasket having cable gland entry suitable for 2Cx6 sq.mm.
PVC/aluminium armoured cable and a metallic cover tied to it with a
metallic chain and suitable for installation in moist location and or
outdoor. The switch shall be of rotary type. Receptacles shall be housed in
an enclosure made out of 2 mm thick Gl sheet with hinged doors with
padlocking arrangements. Door shall be lined with good quality gasketing.
This shall conform to IP-55.
ii) Type RI The 5/15 amp 6 pin receptacles with switches will be of Modular
type with flush type switches and electroplated metal enclosures of
approved make
iii) Type RP - 63A, 415V, 3 phase, 4 pin interlocked plug and switch with
earthing contacts. Other requirements shall be same as type RO. The
receptacle shall be suitable for 3.5C x 35/3.5Cx70 sq.mm. aluminium
conductor cable entry and shall also be suitable for loop-in and loop out
connection of cables of identical size. Receptacle shall be suitable for
outdoor application. Receptacles shall be housed in a box made out of
2mm thick G.I. sheet, with hinged door with padlocking arrangement.
Door shall be lined with good quality gasketing. This shall conform to IP-
55
3.1.11 Lighting Panels (L.P.)
i) Each panel shall be provided with one incoming triple pole MCB with neutral link
and outgoing miniature circuit breakers as per clause 3.0. The panels shall conform
to IS-8623.
ii) Constructional Features
a) Panels shall be sheet steel enclosed and shall be dust, weather and vermin proof.
Sheet steel used shall be of thickness not less than 2.00 mm (cold rolled)
smoothly finished, levelled and free from flaws. Stiffners shall be provided
wherever necessary. The indoor lighting panels will be ready made DB of
minimum 1.6 mm sheet thickness .
b) The panels shall be of single front construction, front hinged and front
connected, suitable for either floor mounting on channels, sills or on
Volume-II (Section-M), Illumination System 241
walls/columns by suitable M.S. brackets. Indoor panels in control room shall be
flush mounted.
c) Panels shall have a dead front assembly provided with hinged door(s) and out
door panels will be with padlocking arrangement with single key supplied in
duplicate.
d) All out door panels, removable covers, doors and plates shall be gasket all
around with neoprene gaskets.
e) The outdoor panels shall be suitable for cable/conduit entry from the top and
bottom. Suitable removable cable gland-plate shall be provided on the top and
bottom of panels. Necessary number of double compression cable gland shall be
supplied, fitted on to this gland plate. The glands shall be screwed on top and
made of tinned brass.
f) The panels shall be so constructed as to permit free access to connection of
terminals and easy replacement of parts.
g) Each panel shall have a caution notice fixed on it.
h) Each panel will be provided with directory holder in which printed and
laminated as built circuit directory would be kept inside a document
holder/pasted at site.
i) Each Outdoor lighting panel shall be provided with one no. ‘ON’ indicating
lamp for each phase alongwith fuses.For indoor lighting panels din mounted
phase indication lamps will be provided , mounted along side of the MCB
j) Main Bus Bars
Bus bars shall be of aluminium alloy conforming to IS:5082 and shall have
adequate cross-section to carry the rated continuous and withstand short circuit
currents. Maximum operating temperature of the bus bars shall not exceed 85
deg. C. The bus bars shall be able to withstand a fault level of 9 kA for 1 sec. for
AC panels and 4 KA for 1 sec. for DC panels.The Indoor lighting panels shall
have copper bus bar
iii) Junction Boxes
a) The junction boxes shall be concealed type for indoor lighting and suitable for
mounting on columns, lighting poles, structures etc., for outdoor lighting.
Volume-II (Section-M), Illumination System 242
b) Junction boxes shall be of square/rectangular type of 1.6 mm sheet steel with
minimum 6 mm thick pressure die cast aluminium material LM-6 and shall have
bolted cover with good quality gasket lining.
c) The junction box and cover of sheet steel construction shall be hot dip
galvanised.
d) The junction boxes shall be complete with conduit knockouts/threaded nuts and
provided with terminal strips .The junction boxes shall be suitable for
termination of Cable glands of dia 20 mm, 25 mm, 32 mm, 40 mm on all sides.
The junction boxes shall be provided with 4 way terminals suitable for two
numbers 10 sq. mm. wire & for street lighting/switchyard lighting suitable for 2
numbers 4C x 16 Sq.mm Al. cable.
e) The junction boxes shall have the following indelible markings
(i) Circuit Nos. on the top.
(ii) Circuit Nos. with ferrules (inside)
(iii) DANGER sign in case of 415 volt junction box.
f) The junction boxes shall be weather proof type with gaskets conforming to IP 55
as per IS:13947 (Part I) .
iv) Occupancy Sensors:
Sufficient number of occupancy sensors shall be provided in the stairs area and
corridors of control room cum administrative building. Each occupancy sensor shall
be used for indoor use with time delay programmable in the minimum range of 1
sec. to 10 minutes to control the illumination in the area.
v) Led Luminaires
Indicative models of LED luminaries are indicated in Annexure-I. The offered
luminaries shall have minimum 50 lumens/watt capacity( ie ratio of total output
lumens & input power) including driver. The quantity of these luminaries shall be
decided on the basis of design criteria specified and lux level required at various
rooms/locations. The bidder shall submit complete type test certificates &
photometry reports of offered luminaries duly certified/conducted at accredited
laboratory for owner’s acceptance. The luminaries / drivers should generally comply
with following relevant standards.
1) CISPR – 15/ EN 55015 (for RFI / EMI)
2) IEC 61347 – 2 – 13 (for safety)
Volume-II (Section-M), Illumination System 243
3) IEC 62384 (for performance of controlgear)
4) IEC 61547 (for EMC immunity requirements)
5) IEC 61000- 3 -2 (for harmonics)
4.0 DESCRIPTION OF ITEMS FOR TOWNSHIP LIGHTING
415V, 400 Amp Main Township Distribution Board:-
400 Amp Main Township Distribution Board required for township lighting system shall
conform to standard technical specification for LT switchgear.
4.1 Power and Control Cables:-
Power and Control cables required under township lighting shall conform to standard
technical specification, Section-Power and Control cables annexed with bidding documents.
Power and Control cables shall be sourced from approved makes of Power Grid for
substation packages.
4.2 Earthing & Lightning Protection:-
Earthing and lightning protection system installation shall be in strict accordance with the
latest editions of Indian Electricity Rules, relevant Indian Standards and Codes of practice
and Regulations existing in the locality where the system is installed.
a) Code of practice for Earthing IS: 3043
b) Code of practice for the protection of Building and allied structures against lightning
IS: 2309.
c) Indian Electricity Rules 1956 with latest amendments.
5.0 DESCRIPTION OF COMMON ITEMS FOR LIGHTING
5.1 LIGHTING FIXTURES AND ACCESSORIES
5.1.1 General
All lighting fixtures and accessories shall be designed for continuous operation
under atmospheric conditions existing at site, without reduction in the life or without
any deterioration of materials, internal wiring.
5.1.2 Temperature Rise
All lighting fixtures and accessories shall be designed to have a low temperature rise
to the relevant Indian Standards. The design ambient temperature shall be taken as
50 deg.C.
5.1.3 Supply Voltage
Volume-II (Section-M), Illumination System 244
Lighting fixtures and accessories meant for 240V A.C. operation shall be suitable
for operation on 240V A.C. 50Hz, supply voltage variation of ± 10%, frequency
variation of ± 5% and combined voltage and frequency variation of ± 10%. Lighting
fixture and accessories meant for 220V DC operation shall be suitable for operation
on 220V DC with variation between 190 to 240 Volts.
5.1.4 Lighting Fixtures
a) The lighting fixtures shall be Philips or Bajaj or Crompton Greaves make only
except for LED luminaries for which make has been specified elsewhere in this
section. The different types of lighting fixtures are also indicated elsewhere in this
Section.
b) All fixtures shall be designed for minimum glare. The finish of the fixtures shall be
such that no bright spots are produced either by direct light source or by reflection.
c) All lighting fixtures shall be complete with fluorescent tubes / incandescent
lamps/mercury vapour/sodium vapour lamps as specified and shall be suitably wired
up.
d) All flourescent lamp fixture shall be complete with all accessories like ballasts,
power factor improvement capacitors, lamps, starters, holders etc.
e) High beam fixtures shall be suitable for pendant mounting and flood lights shall
have suitable base plate / frame for mounting on steel structural member. Hook
mounted high beam fixtures are not acceptable.
f) Each lighting fixture shall be provided with an earthing terminal suitable for
connection to 16 SWG GI earthing conductors.
g) All light reflecting surfaces shall have optimum light reflecting co-efficient such as
to ensure the overall light output as specified by the manufacturer.
h) Height of fixtures should be such that it is easy to replace the lamps with normal
ladder/stool. In case the ceiling height is very high, the fixtures may be placed on the
walls for ground lighting.
5.2 ACCESSORIES
5.2.1 Lamp holders and Starter Holders
(a) Lamp holders/starter holders for fluorescent tubes shall be of the spring loaded,
low contact resistance, bi-pin rotor type, resistant to wear and suitable for
operation at the specified temperature, without deterioration in insulation value,
Volume-II (Section-M), Illumination System 245
contact resistance or retention of the lamp/starter. They shall hold the
lamp/starter in position under normal condition of shock and vibration.
(b) Lamp holders/starter for incandescent lamps and HPMV/HPSV lamps shall be
of screwed type, manufactured in accordance with relevant standard and
designed to give long and satisfactory service.
5.2.2 Ballasts
a) All HPSV/HPMV/Metal halide lamp fixtures shall be provided with wire wound
ballasts. All fluorescent fixtures shall be provided with high frequency
electronic ballasts.The Ballasts shall be designed, manufactured and supplied in
accordance with relevant standard and function satisfactorily under site
condition specified. The ballasts shall be designed to have a long service life and
low power loss.
b) Ballasts shall be mounted using self locking anti-vibration fixing and shall be
easy to remove without dismantling the fixtures. They shall be totally enclosed
units.
c) The wire-wound ballasts shall be of the inductive, heavy duty type, filled with
thermosetting insulating moisture repellent polyester compound filled under
pressure or vacuum. The ballast wiring shall be of copper wire. They shall be
free from hum. Ballasts which produce humming sound shall be replaced free of
cost by the Contractor. Ballasts for high pressure mercury vapour/ HPSV lamps
shall be provided with suitable tappings to set the voltage within the range
specified. End connections and taps shall be brought out in a suitable terminal
block, rigidly fixed to the ballast enclosure.
d) Separate ballast for each lamp shall be provided in case of multi-lamp fixtures.
e) High frequency electronic ballasts shall be capable of satisfactory performance
in adverse environment like that of EHV substation. Ballasts shall consist of
AC/DC converter, high frequency power oscillator and low pass filter. The
ballasts shall be suitable for use of nominal voltage of 240V +/- 10%, 50 Hz
supply. The filter circuit shall suppress the feedback of high frequency signals to
the mains. The ballast shall be rated for 36/40W fluorescent fixtures. The
ballasts shall confirm to IEC 68-2-6FC, IEC 929 for performance, IEC 928 for
safety and EN 55015, EN 55022A for RFI and EN 61003.
5.2.3 Capacitors
Volume-II (Section-M), Illumination System 246
a) The capacitors shall have a constant value of capacitance and shall be connected
across the supply of individual lamp circuits.
b) Power factor of fluorescent lamp fixtures with HF electronic ballast shall not be
less than 0.90 and that of High pressure Sodium Vapour, Mercury Vapour and
Metal Halide lamp fixtures shall not be less than 0.85. The capacitors shall be
suitable for operation at supply voltage as specified and shall have a value of
capacitance so as to correct the power factors of its corresponding lamp circuit
to the extent of 0.98 lag.
c) The capacitors shall be hermetically sealed in a metal enclosure.
5.2.4 Lamps
a) General Lighting Services (GLS) lamps shall be provided with screwed caps and
shall be of 'clear' type unless otherwise specified.
b) The Bidder shall furnish typical wiring diagram for Fluorescent, HPMV &
HPSV fitting including all accessories. The diagram shall include technical
details of accessories i.e. starters, chokes, capacitors etc.
c) Flexible conduits if required, for any fixture shall be deemed to be included in
Contractor’s scope.
5.2.5 SWITCH AND SWITCHBOARD
(a) All Switch board/boxes, 5/15 Amp Receptacles and electronic fan regulators
located in office/building areas shall be modular flush mounted type or brick
wall with only the switch knob projecting outside.
(b) Switch boards/boxes shall have conduit knock outs on all the sides.
(c) The exact number of switches including regulator for fans and layout of the
same in the switchboard shall be to suit the requirement during installation.
(d) The maximum number of luminaires, controlled by one no 6 amp switch would
4 nos. For DC fixtures there will be no switch and the same shall be directly
controlled from DC LP
(e) The luminaires shall be wired in such a fashion that luminaires on each phase
are evenly distributed all over the room.
5.2.6 CONDUITS & CONDUIT ACCESSORIES
Volume-II (Section-M), Illumination System 247
a) The conduits shall conform to IS:9537 or IS 3419 as applicable. All steel
conduits shall be seemed by welding, shall be of heavy gauge and shall be hot
dip galvanised.
b) Flexible conduits wherever required shall be made with bright, cold rolled
annealed and electro-galvanised mild steel strips or PVC/Plastic.
c) All conduits accessories shall conform to relevant IS and shall be hot dip
galvanized or High quality virgin PVC and shall be ISI marked.
5.2.7 TERMINAL BLOCKS
Each terminal shall be suitable for terminating upto 2 Nos. 10 sq.mm. stranded
Aluminium Conductors without any damage to the conductors or any looseness of
connections. Terminal strips provided in street - lighting poles shall be suitable for
terminating upto 2 nos. 4C x 16 sq. mm aluminium cables.
5.2.8 PULL OUT BOXES
a) The pull out boxes shall be concealed type for indoor lighting and suitable for
mounting on column, structures etc., for outdoor lighting. The supply of bolts,
nuts and screws required for the erection shall be included in the installation
rates.
b) The pull out boxes shall be circular of cast iron or 16 SWG sheet steel and shall
have cover with good quality gasket lining.
c) The pull out boxes and cover shall be hot dip galvanised.
d) The pull out boxes shall be completed with conduit knock outs/threaded hubs
and provided at approximately 3 meters intervals in a conduit run.
5.2.9 Residual Current Circuit Breakerss (RCCB) For indoor panels 63A 4pole 300 ma
RCCB conforming IS 12640 will be provided along with incomer
5.2.10 Miniature Circuit Breaker (MCB)
a) The miniature circuit breakers shall be suitable for manual closing, opening,
automatic tripping under overload and short circuit. The MCBs shall also be trip
free. MCB of Type C tripping characterstics as per IS 8828 will be used for
Switchyard lighting.
b) Single pole as well as three pole versions shall be furnished as required in the
Schedule of Lighting Panels.
Volume-II (Section-M), Illumination System 248
c) The MCBs and panel MCCB together shall be rated for full fault level. In case
the MCB rating is less than the specified fault level the bidder shall co-ordinate
these breaker characteristics with the back up MCCB in such a way that if fault
current is higher than breaker rating, the MCCB should blow earlier than the
breaker. If the fault current is less than MCB breaking capacity, MCB shall
operate first and not the incomer MCCB.
d) The MCBs shall be suitable for housing in the lighting panels and shall be
suitable for connection with stranded copper wire connection at both the
incoming and outgoing side by copper lugs or for bus bar connection on the
incoming side.
e) The terminals of the MCBs and the ‘open’ ‘close’ and ‘trip’ conditions shall be
clearly and indelibly marked.
f) The tenderer shall check and co-ordinate the ratings of MCBs with respect to
starting characteristics of discharge lamps. The vendor has to furnish overload
and short circuit curve of MCB as well as starting characteristics curves of
lamps for Employer’s approval.
g) The MCB shall generally conform to IS:8828.
5.2.11 CONTACTORS
Contactors shall be of the full voltage, direct-on line air break, single throw, electro-
magnetic type. They shall be provided with atleast 2-’NC’ and 2’NO’ auxiliary
contacts. Contactor shall be provided with the three element, positive acting,
ambient temperature compensated time lagged, hand reset type thermal overload
relay with adjustable settings to suit the rated current. Hand reset button shall be
flush with the front of the cabinet and suitable for resetting with starter compartment
door closed. The Contactor shall be suitable for switching on Tungsten filament
lamp also. The bidder shall check the adequacy of the Contactors rating wire with
respect to lighting load.
5.2.12 PUSH BUTTONS
All push buttons shall be of push to actuate type having 2 ‘NO’ and 2 ‘NC’ self
Technical Specification, reset contacts. They shall be provided with integral
escutcheon plates engraved with their functions. Push buttons shall be of reputed
make.
Volume-II (Section-M), Illumination System 249
5.2.13 LABELS
a) The lighting panels shall be provided on the front with panel designation labels
on a 3 mm thick plastic plate of approved type. The letter shall be black
engraved on white back ground.
b) All incoming and outgoing circuits shall be provided with labels. Labels shall be
made of non-rusting metal or 3 ply lamicold. Labels shall have white letters on
black or dark blue background.
5.2.14 EARTHING TERMINALS
Panels shall be provided with two separate and distinct earthing terminals suitable to
receive the earthing conductors of size 50x6 G.S. Flat.
5.2.15 Type test reports for following tests on all lighting panels shall be submitted for
approval as per clause 9.0 of SEC-B OF VOL-1
(i) Wiring continuity test
(ii) High voltage (2.5 KV for 1 minute) and insulation test
(iii) Operational test
(iv) Degree of protection (not less than IP-55 test on outdoor Lighting Panels and
IP-52 test on indoor Lighting Panels as per IS 13947 (part I))
(v) Heat run test
5.2.16. LIGHTING POLES
a) The Contractor shall supply, store and install the following types of steel tubular
lighting poles required for street lighting.
i) Type A1 Street Lighting Pole - for one fixture
ii) Type E1 Post top lantern pole - for one fixture
b) In front of control room building , and Fire Fighting Buildings, decorative post top
lantern (Type E1) poles and Bollards shall be installed.
c) Lighting poles shall be complete with fixing brackets and junction boxes. Junction
boxes should be mounted one meter above ground level.
d) The lighting poles shall be coated with bituminous preservating paint on the inside
as well as on the embedded outside surface. Exposed outside surface shall be coated
with two coats of metal primer (comprising of red oxide and zinc chromate in a
synthetic medium).
Volume-II (Section-M), Illumination System 250
e) The galvanised sheet steel junction box for the street lighting poles shall be
completely weather proof conforming to IP-55 and provided with a lockable door
and HRC fuse mounted on a fuse carrier and fuse base assembly. The fuses &
junction box shall be as specified in the specification. However, terminals shall be
stud type and suitable for 2 nos. 16 sq.mm. cable.
f) Wiring from junction box at the bottom of the pole to the fixture at the top of the
pole shall be done through 2.5 sq. mm wire.
g) Distance of centre of pole from street edge should be approximately 1000 to 1200
mm.
h) Earthing of the poles should be connected to the switchyard main earth mat
wherever it is available and the same should be earthed through 3M long, 20 mm
dia, earth electrode.
5.2.17 CEILING & WALL MOUNTED FANS AND REGULATORS
a) The contractor shall supply and install 1400 mm sweep ceiling fans complete with
electronic regulator and switch, suspension rod, canopy and accessories.The wall
mounted fans shall be of 400 mm sweep
b) The contractor shall supply and install the switch, electronic regulator and board for
mounting switch and electronic regulator for celling fans. The regulator will be
housed in common switchboard for lighting and shall be of similar make and model
as that of modular switches.
c) Winding of the fans and regulators shall be insulated with Class-E insulating
material. Winding shall be of copper wire.
d) Electronic regulator with stepped control shall be provided.
e) Ceiling Fans and Wall mounted Fans shall be of Alstom / Crompton Greaves / Bajaj
Electricals / Usha Electricals make.
5.2.18 LIGHTING WIRES
a) The wiring used for lighting shall be standard products of reputed manufacturers.
b) The wires shall be of 1100 V grade, PVC insulated product of reputed
manufacturers.
c) The conductor sizes for wires used for point wiring beyond lighting panels shall be
2.5 sq.mm, 4 sq.mm, 6 sq.mm and 1.5 sq.mm stranded copper wire.
Volume-II (Section-M), Illumination System 251
d) The wires used for connection of a lighting fixture from a nearest junction box or for
loop-in loop-out connection between two fluorescent fixtures shall be single core
copper stranded conductor, 1100V grade flexible PVC insulated cords, unsheathed,
conforming to IS:694 with nominal conductor cross sectional areas of 2.5 sq. mm.
e) The wires shall be colour coded as follows:
Red for R - Phase
Yellow for Y - Phase
Blue for B - Phase
Black for Neutral
White for DC (Positive)
Grey for DC (Negative)
5.2.19 LIGHTING SYSTEM INSTALLATION WORKS
i) General
In accordance with the specified installation instructions,Contractor shall unload,
erect, install, test and put into commercial use all the electrical equipment included
in the contract. Equipment shall be installed in a neat, workmanship manner so that
it is level, plumb square and properly aligned and oriented.
All apparatus, connections and cabling shall be designed so as to minimise risk of
fire or any damage which will be caused in the event of fire.
ii) Conduit System
a) Contractor shall supply, store and install conduits required for the lighting
installation as specified. All accessories/fittings required for making the
installation complete, including but not limited to pull out boxes (as specified
in specification ordinary and inspection tees and elbow, checknuts, male and
female bushings (brass or galvanised steel), caps, square headed make plugs,
nipples, gland sealing fittings, pull boxes, conduits terminal boxes, glands,
gaskets and box covers, saddle terminal boxes, and all steel supporting work
shall be supplied by the Contractor. The conduit fittings shall be of the same
material as conduits.
The contractor shall also supply 20 mm mm PVC conduit and accessories for
telephone wiring.
Volume-II (Section-M), Illumination System 252
b) All unarmoured cables/wires shall run within the conduits from lighting
panels to lighting fixtures, receptacles. etc.
c) Size of conduit shall be suitably selected by the Contractor.
d) Conduit support shall be provided at an interval of 750 mm for horizontal runs
and 1000 mm for vertical runs.
e) Conduit supports shall be clamped on the approved type spacer plates or
brackets by saddles or U-bolts. The spacer plates or brackets in turn, shall be
securely fixed to the building steel by welding and to concrete or brick work
by grouting or by nylon rawl plugs. Wooden plug inserted in the masonary or
concrete for conduit support is not acceptable.
f) Where conduits are along with cable trays they shall be clamped to supporting
steel at an interval of 600 mm.
g) For directly embedding in soil, the conduits shall be coated with an asphalt-
base compound. Concrete pier or anchor shall be provided wherever necessary
to support the conduit rigidly and to hold it in place.
h) For long conduit run, pull boxes shall be provided at suitable intervals to
facilitate wiring.
i) Conduit shall be securely fastened to junction boxes or cabinets, each with a
lock nut inside and outside the box.
j) Conduits joints and connections shall be made through water-tight and rust
proof by application of a thread compound which insulates the joints. White
lead is suitable for application on embedded conduit and red lead for exposed
conduit.
k) The entire metallic/PVC conduit system, shall be embedded, electrically
continuous and thoroughly grounded. Where slip joints are used, suitable
bounding shall be provided around the joint to ensure a continuous ground
circuit.
l) Conduits and fittings shall be properly protected during construction period
against mechanical injury. Conduit ends shall be plugged or capped to prevent
entry of foreign material.
iii) Wiring
Volume-II (Section-M), Illumination System 253
a) Wiring shall be generally carried out by PVC insulated wires in conduits. All
wires in a conduit shall be drawn simultaneously. No subsequent drawings of
wires is permissible.
b) Wires shall not be pulled through more than two equivalent 90 deg. bends in a
single conduit run. Where required, suitable junction boxes shall be used.
c) Wiring shall be spliced only at junction boxes with approved type terminal
strip.
d) For lighting fixtures, connection shall be teed off through suitable round
conduit or junction box, so that the connection can be attended without taking
down the fixture.
e) For vertical run of wires in conduit, wires shall be suitably supported by
means of wooden/hard rubber plugs at each pull/junction box.
f) Maximum two wires can be terminated to each way of terminal connections.
g) Separate neutral wires are to be provided for each circuit.
iv) Lighting Panels
a) The lighting panels shall be erected at the locations to be finalised during
detailed engineering.
b) Suitable foundations/supporting structures for all outdoor type lighting panels
shall be provided by the Contractor.
v) Foundation & civil works
a) Foundation for street lighting poles, panel foundation and transformer
foundation shall be done by the Contractor..
b) All final adjustment of foundation levels, chipping and dressing of foundation
surfaces, setting and grouting of anchor bolts, sills, inserts and flastening
devices shall be carried out by the Contractor including minor modification of
civil works as may be required for erection.
c) Any cutting of masonary / concrete work, which is necessary shall be done by
the Contractor at his own cost and shall be made good to match the original
work.
Volume-II (Section-M), Illumination System 254
ANNEXURE-1
S.No. Type of Lighting Fixture
Description Philips Catalogue No
CGL Catalogue No
Bajaj Catalogue No
1. F1 2x28W T5 type fluorescent lamps in industrial reflector type fixture, complete with accessories and suitable for pendent /surface mounting.
TMS 122/228 HF
T5GP228EB BTIR 228
2. FF 2x28 T5 energy efficient fluorescent lamps with low glare, mirror optics suitable for recess mounting type lighting fixture.
TBS 088/228 C5 HF
TSCQ12228EB
BTMRA 228 MATT
3. FL
2x28W T5 energy efficient fluorescent lamps with low glare mirror optics suitable for pendent/surface mounting with all accessories
TCS 398/228 D6 HF
--------------- BTSMU 228 MSS
4. TL Sleek and Functional electronic decobatten suitable for use with 1x'TLD'36W fluorescent lamp with dual tone end caps. Pre-phosphated & powder coated CRCA steel channel complete with all electrical accessories like electronic ballast, lamp holders all prewired up to a terminal block
TMS500/136 HF
DMLU14EB BC1R136WEB
5. IB 60/100w GLS lamp in Bulkhead fixtures with Cast Aluminium alloy body, suitable for column, wall,and ceiling mounting finished stove enameled silver grey outside
NXC101 IBH1110/BC BJDB100BC
6. BL Aesthetic wall/ceiling mounted luminaire suitable for 1x PL-C 13W OR 11W CFL. Low loss O.C. Copper ballast.Built in high gloss anodized reflector. Twin finish UV stabilised SAN diffuser for protection & elimination of lamp glare.
FMC21/113 TLN11 BJC111
7. SL Aesthetic ceiling mounted luminaire for Ecotone crystal/ Décor CFL of 2x9W or 1x18W. ABS housing pre-wired with porcelain lampholder. Prephospated plated CRCA gear tray.
FL343/118 CBHE29 -------------
Volume-II (Section-M), Illumination System 255
8. BH Bulkhead luminaire suitable for use with PL-S 9W CFL. Single piece pressure diecast aluminium & cover retaining Frame. Opal acrylic cover along with a gasket made of E.P.R.
FXC 101/109 ICBH10 BJBE19
9. BLD 2X9 Or 1x18 watt CFL bollard light for landscape lighting having FRP/LLDPE housing
FGC202 /118 CFBL1229 BJBOL 03 29 CFL
10. DLR 2x18 watt CFL Downlighter with HF ballast suitable for recess mounting
FBH145/218L HF
DDLH218TG BJDR 65C 218 DL
11. DSM 1X13 WATT surface mounted CFL
FCS100/113 ----------------- BJDS110/113C WEB
12. IF Incandescent GLS lamp down light
DN622 DDLV10BC BJDR 100W
13. SF1 1 X 400W HPSV lamps in high flood lighting fixture with integral control gear
SWF 330/1X400
FAI40IH BJFL
400SV TS
14. SF2 2 X 400W HP sodium Vapour lamps in high flood lighting, non-integral control gear:
RVP302/2x400W
FHD1424 BJENF 22
15. SF3 1 X 250W HPSV lamps in high flood lighting fixture with integral control gear:
SWF 330/1X250
FAI1125IH 250 SV TS
16. SF4 150W HP Metal halide MHNTD lamp in flood lighting fixture with integral control gear.
SWF230/150 MHN-TD
FAD1215IH/MH
BGEMF150MH DE
17. SF5 125 HP MV Lamp in weather proof post top lantern for mounting on pole top
HPC-101/125 HPF
MPT1112IL/BM/ES
BJDPTI 125 MV
18. SC 150W SON-T Tubular Sodium Vapour lamp in street lighting luminaire with toughned glass cover.
SRX-51/150 SSG2315IH. BGEST 150 SV
19* LED LUMINIARIES Type Description Phillips Insta Power
a)* I-LED1 2x2, luminaries with high efficacy
and low power consumption suitable for general office lighting, conference room and cabins applications.
QUADRA LED BCS705 20xLXML/NW PSU-E-220- 240V BBS705 20xLXML/NW PSU-E-220- 240V BBS 805 2xLLM1800/ 840 PSU-E 220-240V
INSTA PRISMA 45W/OMEGA 45W
Volume-II (Section-M), Illumination System 256
b)* I-LED2 19W, Recessed type LED luminaries with high efficacy and low power consumption for passages, corridor and toilet areas.
LUX SPACE BBS480 1XDLED-4000 PSU-E 220-240V WH
INSTA DL12W-6SH
c)* S-LED Street lighting luminaries BETA Power BRP320 1x24LEDHP/ CW PSU GR
VERSAT-2-48
*The conventional luminaries shall also be offered as an alternative.
Volume-II (Section-M), Illumination System 257
ANNEXURE-2 S.NO. ITEM ABBREVIA
TION ITEM DESCRIPTION MAKE(S)
1. TELEPHONE BOX/TELEVISION BOX
TB Termination box for Television and Telephone
Approved makeS
2. FLAT DB TYPE A DB 240V Indoor AC Distribution board, 63A or 32A, DP RCCB as Incomer with 12 Nos. 16A SP MCBs as outgoing. DB shall be flush mounted type.
Legrand/Hagger
3. METER DB TYPE-A & TYPE-B
MB According to feeder details
Approved makes
4. SWITCHBOARD WITHOUT 6A SOCKET
SBA Modular switchboard with 5a switches as required
Anchor/Crabtree
5. TWO WAY SWITCHBOARD FOR STAIRS
SBB MODULAR SWITCHBOARD WITH 5A TWO WAY SWITCH
Anchor/Crabtree
6. SWITCHBOARD WITH 6A SOCKET
SBC MODULAR SWITCHBOARD WITH 1 No. Socket and 5A SWITCHES AS REQUIRED
Anchor/Crabtree
7. TELEPHONE POINT TP TP Modular Socket Anchor/Crabtree
8. TELEVISION POINT TV TV Modular Socket Anchor/Crabtree
9. AIRCONDITIONER POINT WITH 15A SWITCH
RAC RAC Socket with Switch Metal clad Type
Anchor/Crabtree
10. 15A POWER POINT WITH 15A SWITCH
RB Modular Socket with Switch
Anchor/Crabtree
11. 5A POWER POINT WITH 5A SWITCH
RA Modular Socket with Switch
Anchor/Crabtree
12. CHANDELIER CH Decorative fixture with 1 X 60 W GLS Lamp
Any Reputed Make
13. BELL PUSH BP Modular Type Anchor/Crabtree
14. BELL BELL Call Bell Anchor/Crabtree
15. EXHAUST FAN EFC 300 mm sweep Trans'Air CGL/Bajaj/Usha
16. CEILING FAN CFC 1200 mm sweep with electronic regulator
CGL/Bajaj/Usha
Volume-II (Section-M), Illumination System 258
ANNEXURE-3
SOLAR BASED ENERGY EFFICIENT POLE MOUTED STREET LIGHTING SYSTEM I. SCOPE
A stand alone solar based energy efficient pole mounted street lighting system comprising of
galvanized steel tubular pole, LED type light source, lead acid tubular type maintenance free
battery, photovoltaic (PV) module (s), control electronics, inter-connecting wires / cables,
Module mounting hardware, Battery box, any other item for safe and trouble free operation
etc shall be provided with each unit.
II. DUTY CYCLE
The system should be designed to automatically switch ON at dusk. operate through out the
night and automatically switch OFF at the dawn under average daily insolation of 5.5 kWh
/sq.m. on a horizontal surface.
III. LIGHT SOURCE
i. The light source shall be of white LED type, single lamp or multiple lamps can be
used. View angles shall be of wider range with a minimum of 120 degre and above
above. The luminous performance of LEDs used should not be less than 50
lumen/watt including driver. LEDs which emit ultraviolet light is not acceptable.
ii. The light output from the white LED light source should be constant throughout the
duty cycle.
iii. The lamps should be housed in an assembly suitable for outdoor use. The make, model
number, country of origin and technical characteristics of white LEDs used in the
lighting system must be furnished.
IV. BATTERY
i. The battery shall be of maintenance free lead acid tubular type.
ii. The battery will have a minimum rating of 12V, 75 Ah (at C/10) discharge rate.
iii. 75 % of the rated capacity of the battery should be between fully charged & load cut
off conditions.
V. ELECTRONICS
i. The inverter should be of quasi sine wave/sine wave type. with frequency in the range
of 20 - 35 KHz. Half-wave operation is not acceptable.
Volume-II (Section-M), Illumination System 259
ii. The total electronic efficiency should be at least 80 %.
iii. No blackening or reduction in the lumen output by more than 10% should be observed
after 1000 ON/OFF cycles (two minutes ON followed by four minutes OFF is one
cycle)
iv. The idle current consumption should not be more than 10 mA
v. Electronics should operate at 12 V and should have temperature compensation for
proper charging of the battery throughout the year.
vi. Necessary lengths of wires/cables and fuses should be provided. Wires and cables
shall be of approved make and shall be BIS marked.
vii. The PV module will be used to sense the ambient light level for switching ON and
OFF the lamp.
VI. PV MODULE (S)
i. The PV module(s) shall contain single or multi crystalline silicon solar cells. Test
reports for solar cells being offered shall be duly conducted at accredited laboratory.
The module must be manufactured by a company, which has obtained a valid test
certificate for module qualification as per prevailing IEC or BIS standards for any of
the modules manufactured by that company. A copy of the test certificate must be
submitted for owner’s acceptance. The power output of the module(s) under STC
should be a minimum of 74 W Either two module; of minimum 37 W output each or
one module of 74 W output should be used.
ii. The operating voltage corresponding to the power output mentioned above should be
16.4 V.
iii. The open circuit voltage of the PV modules under STC should be at least 21.0 Volts.
iv. The terminal box on the module should have a provision for opening for replacing the
cable if required
v. A strip containing the following details should be laminated inside the module so as to
be clearly visible from the front side.
a) Name of the Manufacturer or distinctive Logo
b) Model or type No
c) Serial No & year of manufacturing.
VII. ELECTRONIC PROTECTIONS
Volume-II (Section-M), Illumination System 260
i. Adequate protection is to be incorporated under no -load conditions e.g when the lamp
is removed and the system is switched ON.
ii. The system should have protection against battery overcharge and deep discharge
conditions.
iii. Fuses should be provided to protect against short circuit conditions.
iv. A blocking diode should be provided as part of the electronics, to prevent reverse flow
of current through the PV module(s), in case such a diode is not provided with the
solar module (s)
v. Full protection against open circuit accidental short circuit and reverse polarity should
e provided.
vi. The light output should remain constant with variations in the battery voltages.
VIII. MECHANICAL HARDWARE
i. A metallic frame structure (with corrosion resistance paint) to be fixed on the pole to
hold the SPV module(s) The frame structure should have provision to adjust its angle
of inclination to the horizontal between 0 and 45, so that the module(s) can be oriented
at the specified tilt angle
ii. The pole should be made of mild steel pipe with a height of 4 metres above the ground
level, after grouting and final installation. The pole should have the provision to hold
the we proof lamp housing It should be painted with a corrosion resistant paint.
iii. A vented, acid proof and corrosion resistant painted metallic box for outdoor use
should be provided for housing the battery.
IX. OTHER FEATURES
1. The system should be provided with 2 LED indicators a green light to indicate
charging in progress and a red LED to indicate deep discharge condition of the battery.
The green LED should glow only when the battery is actually being charged
2. There will be a Name Plate on the system which will give
a) Name of the Manufacturer or Distinctive Logo
b) Serial Number & year of manufacture
3. Components and parts used in the solar street lighting systems should conform to the
latest BIS specifications, wherever such specifications are available and applicable.
4. The PV module(s) will be warranted for a minimum period of 10 years from the date
of supply and the street lighting system (including the battery) will be warranted for a
Volume-II (Section-M), Illumination System 261
period of two years from the date of supply. The Warranty Card to be supplied with
the system must contain the details of the system supplied. The manufacturers can also
provide additional information about the system and conditions of warranty as
necessary.
5. An Operation Instruction and Maintenance Manual , in English and the local language
should be provided with the solar street lighting system.
The following minimum details must be provided in the Manual
a. About Photovoltaics
b. About solar street lighting system - its components and expected performance
c. About PV module
d. About CFL
e. About battery.
f. Clear instructions about erection of pole and mounting of PV module and lamp
housing assembly on the pole.
g. About electronics.
h. About charging and significance of indicators
i. DO’s and DON’T’s,
j. Clear instructions on regular maintenance and trouble shooting of the solar street
lighting system.
k. Name and address of the contact person in case of non-functionality of the solar
street lighting system.
Note: The conventional luminaries shall also be offered as an alternative.
Volume-II (Section-N), Switchyard Erection 262
SECTION- (N)
TECHNICAL DETAILS OF SWITCHYARD ERECTION
1.0 GENERAL
The detailed scope of work includes design, engineering, manufacture, testing at works,
supply on for destination site basis, insurance, handling, storage, erection testing and
commissioning of various items and works as detailed herein.
This section covers the description of the following items.
A. Supply of
- String insulators and hardware
- AAC / ACSR conductor
- Galvanised Steel Earthwire
- Aluminium Tubular Bus Bars
- Spacers, Clamps & Connectors
- Bus post insulators
- Earthing & Earthing materials
- Lightning protection materials
- Cabling material
- Other items
B. Erection Of all items
1.1 String Insulators & Hardware
The insulators for suspension and tension strings shall conform to IEC-60383 and long rod
insulators shall conform to IEC-60433. Insulator hardware shall conform to IS:2486.
1.1.1 Construction Features
i) For porcelain insulators
a) Suspension and tension insulators shall be wet process porcelain with ball and
socket connection. Insulators shall be interchangeable and shall be suitable for
forming either suspension or tension strings. Each insulator shall have rated
strength markings on porcelain printed and applied before firing.
b) Porcelain used in insulator manufacture shall be homogeneous, free from
laminations, cavities and other flaws or imperfections that might affect the
Volume-II (Section-N), Switchyard Erection 263
mechanical or dielectric quality and shall be thoroughly vitrified, tough and
impervious to moisture.
c) Glazing of the porcelain shall be uniform brown colour, free from blisters, burrs
and other similar defects.
1.2 Long Rod Insulators
i) As an alternative to disc insulator, Bidder can offer long rod porcelain/composite insulators
strings, with suitable hardware. The combination should be suitable for application specified
and should offer the identical/equivalent parameters as would be available from insulator
string comprising disc insulators and hardware combination.
ii) All constructional features specified at Clause 1.1.1 of this Section shall also apply to the
long rod insulator string.
1.3 Tests
In accordance with the stipulations of the specification, the suspension and tension strings,
insulator and hardware shall be subjected to the following type tests, acceptance tests and
routine tests:
1.3.1 Type Tests on Insulator Strings: The test reports for following type tests shall be
submitted for approval as per clause 9.0 of Section – VOLUME-I, TR.
a) Power frequency voltage withstand test with corona control rings under wet
condition as per IEC- 60383.
b) Switching surge voltage withstand test [400 kV and above class only] under wet
condition as per IEC-60383.
c) Lightning Impulse voltage withstand test with corona control rings under dry
condition as per IEC-60383
d) Voltage distribution test (Dry)
The voltage across each insulator unit shall be measured by sphere gap method. The
result obtained shall be converted into percentage. The voltage across any disc shall
not exceed 6.5% for 765 kV suspension and tension insulator strings, 9% and 10%
for 400KV suspension string and tension insulator string respectively, 13% for
220KV suspension and tension insulator strings, 20% and 22% for 132KV
suspension and tension insulator strings respectively.
e) Corona Extinction Voltage test (Dry)
Volume-II (Section-N), Switchyard Erection 264
The sample assembly when subjected to power frequency voltage shall have a
corona extinction voltage of not less than 508 kV (rms) for 765 kV, 320kV (rms) for
400kV and 156kV (rms) for 220kV line to ground under dry condition. There shall
be no evidence of Corona on any part of the sample. The atmospheric condition
during testing shall be recorded and the test results shall be accordingly corrected
with suitable correction factor as stipulated in IEC 60383.
f) RIV Test (Dry)
Under the conditions as specified under (e) above the insulator string alongwith
complete hardware fittings shall have a radio interference voltage level below 2500
microvolts at 1 MHz when subjected to 50 Hz AC line to ground voltage of 508 kV
for 765 kV and 1000 microvolts at 1 MHz when subjected to 50 Hz AC line to
ground voltage of 320kV for 400kV and 156kV for 220kV string under dry
conditions. The test procedure shall be in accordance with IS 8263/IEC 60437.
g) Mechanical strength test
The complete insulator string alongwith its hardware fitting excluding arcing horn,
corona control ring, grading ring, tension/suspension clamps shall be subjected to a
load equal to 50% of the specified minimum ultimate tensile strength (UTS) which
shall be increased at a steady rate to 67% of the minimum UTS specified. The load
shall be held for five minutes and then removed. After removal of the load, the
string components shall not show any visual deformation and it shall be possible to
dismantle them by hand. Hand tools may be used to remove cotter pins and loosen
the nuts initially. The string shall then be reassembled and loaded to 50% of UTS
and the load shall be further increased at a steady rate till the specified minimum
UTS and held for one minute. No fracture should occur during this period. The
applied load shall then be increased until the failing load is reached and the value
recorded.
1.3.2 Type Tests on Insulators
Type test report for Thermal Mechanical Performance tests as per IEC - 60575,
Clause 3 / IEC: 61109, clause 5.1 (for composite long rod insulators) shall be
submitted for approval as per clause 9.0 of Section - VOLUME-I, TR.
1.3.3 Acceptance Tests for Insulators:
a) Visual examination as per IEC-60383/ IEC-61109 clause no. 7.2 (for composite long
rod insulators).
b) Verification of Dimensions as per IEC- 60383.
Volume-II (Section-N), Switchyard Erection 265
c) Temperature cycle test as per IEC- 60383.
d) Puncture Test as per IEC-60383 (Applicable only for porcelain insulators).
e) Galvanizing Test as per IEC- 60383.
f) Mechanical performance test as per IEC-60575 Cl. 4 / IEC-61109 clause no. 7.2 (for
composite long rod insulators).
g) Test on locking device for ball and socket coupling as per IEC-60372(2).
h) Porosity test as per IEC- 60383 (Applicable only for porcelain insulators).
i) Thermal shock test as per IEC-60383 (Applicable only for glass insulators)
1.3.4 Acceptance Test on Hardware Fitting
a) Visual Examination as per Cl. 5.10 of IS:2486 (Part-I).
b) Verification of Dimensions as per Cl. 5.8 of IS : 2486 (Part-I)
c) Galvanising/Electroplating tests as per Cl. 5.9 of IS : 2486 (Part-I).
d) Slip strength test as per Cl 5.4 of IS-2486 (part-I)
e) Shore hardness test for the Elastometer (if applicable as per the value guaranteed by
the Bidder).
f) Mechanical strength test for each component (including corona control rings and
arcing horns).
The load shall be so applied that the component is stressed in the same way as it
would be in actual service.
g) Test on locking devices for ball and socket coupling as per IEC -60372(2).
1.3.5 Routine Test on Insulator
a) Visual Inspection as per IEC-60383
b) Mechanical Routine Test as per IEC-60383
c) Electrical Routine Test as per IEC-60383
1.3.6 Routine Test on hardware Fittings
a) Visual examination as per Cl 5.10 of IS : 2486 (Part-I) / IEC-61109 (for composite
long rod insulators).
b) Mechanical strength Test as per Cl. 5.11 of IS : 2486 (Part-I)/ IEC-61109 (for
composite long rod insulators).
1.3.7 Test during manufacture on all Components as applicable on insulator
Volume-II (Section-N), Switchyard Erection 266
a) Chemical analysis of zinc used for galvanising:
Samples taken from the zinc ingot shall be chemically analyzed as per IS : 209. The
purity of zinc shall not be less than 99.95%.
b) Chemical Analysis, mechanical hardness tests and magnetic particle inspection for
malleable casting:
The chemical analysis, hardness tests and magnetic particle inspection for malleable
casting will be as per the internationally recognized procedures for these tests. The
sampling will be based on heat number and heat treatment batch. The details
regarding tests will be as discussed and mutually agreed to by the Contractor and
Owner in Quality Assurance Program.
1.3.8 Test during manufacture on all components as applicable on hardware fittings:
a) Chemical analysis of zinc used for galvanising: Samples taken from the zinc ingot
shall be chemically analyzed as per IS : 209. The purity of zinc shall not be less than
99.95%
b) Chemical analysis, hardness tests and magnetic particle for forgings:
The chemical analysis, hardness tests and magnetic particle inspection for forgings
will be as per the internationally recognized procedures for these tests. The sampling
will be based on heat number and heat treatment batch. The details regarding tests
will be as discussed and mutually agreed to by the Contractor and Owner in Quality
Assurance Programme.
c) Chemical analysis and mechanical hardness tests and magnetic particle inspection
for fabricated hardware: The chemical analysis, hardness tests and magnetic particle
inspection for fabricated hardware will be as per the internationally recognized
procedures for these tests. The sampling will be based on heat number and heat
treatment batch. The details regarding tests will be as discussed and mutually agreed
to by the Contractor and Owner in Quality Assurance programme.
1.4 Parameters
1.4.1 Disc Insulators
765/400/220/132 kV
a) Type of insulators : Anti Fog type
b) Size of insulator units (mm) : 255x145 or 280x145
Volume-II (Section-N), Switchyard Erection 267
c) Electro mechanical strength : 120 kN/ 160kN(As per technical
requirements)
d) Creepage distance of individual : 430 mm insulator units (minimum
and as required to meet total
creepage distance)
e) Markings :
i) For Porcelain insulators : Markings on porcelain shall be
printed and applied before firing
ii) For toughened glass : Markings shall be done insulators
on initial parts
f) Power frequency puncture : 1.3 times the actual wet withstand
voltage flashover voltage.
*Long rod porcelain/composite insulators should conform to equivalent
electrical and mechanical parameters.
1.4.2 INSULATOR STRING
S.NO. DESCRIPTION 765kV 400kV 220kV 132kV
1. Power frequency withstand voltage of the complete string with corona control ring (wet) – KV rms
870 680 460 275
2. Lightning impulse withstand Voltage of string with corona control rings (dry) - kVp
± 2100
± 1550 ±1050 ±650
3. Switching surge withstand voltage of string with corona control rings (wet) - kVp
±1550 ±1050 NA NA
4. Minimum corona extinction voltage level of string with Corona Control rings (dry) – kV
508 320 156 NA
5. Maximum RIV level in micro volts of string with Corona Control rings at 508 kV (rms) for 765 kV, 320 kV (rms) for 400 kV string and 156 kV for 220 kV string across300 Ohms resistor at 1 MHz
2500 10000 1000 NA
Volume-II (Section-N), Switchyard Erection 268
6. Minimum total creepage distance of the insulator string (mm)
20000 10500 6125 3625
7. Total no. of discs per strings 42 25 15 16
For tension application, double insulator strings for 765 kV, 400 KV, 220 KV and single
insulator strings for 132 kV system shall be used. For suspension purpose single suspension
insulator string shall be used for 765 kV, 400 KV, 220 KV & 132 kV system.
2.0 AAC / ACSR CONDUCTOR
2.1 Details of AAC Conductor
2.1.1 The Conductor shall conform to IS: 398 (Part V) - 1992 except where otherwise
specified herein.
Owner has also standardised the guaranteed technical particulars for the conductors
which are enclosed in Annexure-E of this Section. The contractor shall supply the
conductor as per the standard guaranteed technical particulars.
2.1.2 The details of the AAC Bull and AAC Tarantula conductor are tabulated below:
S.No Description Unit AAC BULL
AAC TARANTULA
1. Stranding and wire diameter mm 61/4.25 37/5.23
2. Number of Strands
1st Aluminium Layer Nos. 1 1
2nd Aluminium Layer Nos. 6 6
3rd Aluminium Layer Nos. 12 12
4th Aluminium Layer Nos. 18 18
5th Aluminium Layer Nos. 24 --
3. Total sectional area Sq.mm 865.36 794.8
4. Overall diameter mm 38.25 36.60
5. Approximate weight kg/ km 2400 2191
6. Calculated d.c. resistance at 20°C ohm/km 0.0334
0.03628
7. Minimum UTS kN 139 120
2.1.3 The details of Aluminium strand are as follows:
Volume-II (Section-N), Switchyard Erection 269
S.No Description Unit AAC BULL
AAC TARANTULA
1. Minimum breaking load of strand before stranding
KN 2.23 1.29
2. Minimum breaking load of strand after stranding
KN 2.12 1.23
3. Maximum D.C. resistance of strand at 20 deg. Centigrade
Ohm/KM 3.651 3.627
2.2 Details of ACSR Conductor
2.2.1 The Conductor shall conform to IS: 398 (Part V) - 1992 except where otherwise
specified herein.
2.2.2 The details of the ACSR Bersimis, ACSR Moose, ACSR Zebra and ACSR
Panther conductors are tabulated below:
ACSR BERSIMIS & ACSR MOOSE CONDUCTOR:
S.No Description Unit ACSR BERSIMIS
ACSR MOOSE
1. Stranding and wire diameter mm 42/4.57 (Al)+ 7/2.54 (Steel)
54/3.53 (Al)+ 7/3.53 (Steel)
2. Number of Strands
Steel centre Nos. 1 1
1st Steel Layer Nos. 6 6
1st Aluminium Layer Nos. 8 12
2nd Aluminium Layer Nos. 14 18
3rd Aluminium Layer Nos. 20 24
3. Sectional area of Aluminium Sq. mm
689.5 528.5
4. Total sectional area Sq. mm
725.00 597.00
5. Overall diameter mm 35.05 31.77
6. Approximate weight kg/km 2181 2004
7. Calculated d.c. resistance at 20°C Ohm/ km 0.04189 0.05552
8. Minimum UTS kN 154 161.2
ACSR ZEBRA & ACSR PANTHER CONDUCTOR:
S.No Description Unit ACSR ZEBRA
ACSR PANTHER
Volume-II (Section-N), Switchyard Erection 270
1. Stranding and wire diameter mm 54/3.18(Al)+ 7/3.18(Steel)
30/3.0 (Al)+ 7/3.0 (Steel)
2. Number of Strands
Steel centre Nos. 1 1
1st Steel Layer Nos. 6 6
1st Aluminium Layer Nos. 12 12
2nd Aluminium Layer Nos. 18 18
3rd Aluminium Layer Nos. 24 -
3. Sectional area of Aluminium Sq. mm
428.90 212.10
4. Total sectional area Sq. mm
484.50 261.50
5. Overall diameter mm 35.05 31.77
6. Approximate weight kg/km 1621 974
7. Calculated d.c. resistance at 20°C Ohm/ km 0.06869 0.140
8. Minimum UTS kN 130.32 89.67
2.2.3 The details of Aluminium strand are as follows: ACSR BERSIMIS & ACSR MOOSE CONDUCTOR:
S.No Description Unit ACSR BERSIMIS
ACSR MOOSE
1. Minimum breaking load of strand before stranding
KN 2.64 1.57
2. Minimum breaking load of strand after stranding
KN 2.51 1.49
3. Maximum D.C. resistance of strand at 20 deg. Centigrade
Ohm/KM 1.738 2.921
ACSR BERSIMIS & ACSR MOOSE CONDUCTOR:
S.No Description Unit ACSR ZEBRA
ACSR ZEBRA
1. Minimum breaking load of strand before stranding
KN 1.29 1.17
2. Minimum breaking load of strand after stranding
KN 1.23 1.11
3. Maximum D.C. resistance of strand at 20 deg. Centigrade
Ohm/KM 3.651 4.107
2.2.4 The details of steel strand are as follows:
ACSR BERSIMIS & ACSR MOOSE CONDUCTOR:
Volume-II (Section-N), Switchyard Erection 271
S.No Description Unit ACSR BERSIMIS
ACSR MOOSE
1. Minimum breaking load of strand before stranding
KN 6.87 12.86
2. Minimum breaking load of strand after stranding
KN 6.53 12.22
3. Minimum number of twists to be withstood in torsion test when tested on a gauge length of 100 times diameter of wire
Nos. 18 (Before stranding) 16 (Before stranding
18 (Before stranding) 16 (Before stranding
ACSR ZEBRA & ACSR PANTER CONDUCTOR:
S.No Description Unit ACSR ZEBRA
ACSR ZEBRA
1. Minimum breaking load of strand before stranding
KN 10.43 9.29
2. Minimum breaking load of strand after stranding
KN 9.91 8.83
3. Minimum number of twists to be withstood in torsion test when tested on a gauge length of 100 times diameter of wire
Nos. 18 (Before stranding) 16 (Before stranding
18 (Before stranding) 16 (Before stranding
2.3 Workmanship
2.3.1 The finished conductor shall be smooth, compact, uniform and free from all
imperfections including kinks (protusion of wires), wire cross over, over riding,
looseness (wire being dislocated by finger/hand pressure and/or unusual bangle
noise on tapping), material inclusions, white rust, powder formation or black spot
(on account of reaction with trapped rain water etc.), dirt, grit etc.
2.3.2 All the Aluminium and steel strands shall be smooth, uniform and free from all
imperfections, such as spills and splits, diemarks, scratches, abrasions, etc., after
drawing.
2.3.3 The steel strands shall be hot dip galvanised and shall have a minimum zinc coating
of 260 gms/sq.m. after stranding of the uncoated wire surface. The zinc coating shall
be smooth, continuous and of uniform thickness, free from imperfections and shall
withstand minimum three dips in standard Preece test. The finished strands and the
individual wires shall be of uniform quality and have the same properties and
characteristics as prescribed in ASTM designation : B 498-74.
Volume-II (Section-N), Switchyard Erection 272
2.3.4 The steel strands shall be preformed and post formed in order to prevent spreading
of strands in the event of cutting of composite core wire. Care shall be taken to
avoid, damages to galvanisation during pre-forming and post-forming operation.
2.4 Joints in Wires
2.4.1 Aluminium Wires
Joints in aluminium wires shall be as per IS:398.
2.4.2 Steel Wires
There shall be no joint of any kind in the finished wire entering into the manufacture
of the strand. There shall also be no strand joints or strand splices in any length of
the completed stranded steel core of the conductor.
2.5 Tolerances
The manufacturing tolerances shall be as per IS:398.
A. AAC Bull and AAC Tarantala conductor:
a) Diameter of Aluminium and Steel Strands
AAC BULL AAC TARANTALA Standard Maximu
m Minimum Standard Maximu
m Minimum
Aluminium 4.25 mm 4.29 mm 4.21 mm 5.23 mm 5.28 mm 5.18 mm
b) Lay ratio of Conductor
AAC BULL AAC TARANTALA Maximum Minimum Maximum Minimum Aluminium 6 wire layer 16 10 16 10 12 wire layer 16 10 16 10 18 wire layer 16 10 16 10 24 wire layer 14 10 - -
B. ACSR Bersimis and ACSR Moose conductor:
a) Diameter of Aluminium and Steel Strands
ACSR BERSIMIS ACSR MOOSE Standard Maximum Minimum Standard Maximum Minimum
Aluminium 4.57 mm 4.61 mm 4.53 mm 3.53 mm 3.55 mm 3.51 mm
Steel 2.54 mm 2.57 mm 2.51 mm 3.53 mm 3.60 mm 3.46 mm
b) Lay ratio of Conductor
ACSR BERSIMIS ACSR MOOSE
Maximum Minimum Maximum Minimum Steel Steel 6 wire
layer 18 13 18 16
Aluminium 8/12 wire 17 10 14 12
Volume-II (Section-N), Switchyard Erection 273
layer 14/18 wire
layer 16 10 13 11
20/24 wire layer
14 10 12 10
C. ACSR ZEBRA and ACSR PANTHER conductor: a) Diameter of Aluminium and Steel Strands
ACSR ZEBRA ACSR PANTHER Standard Maximum Minimum Standard Maximum Minimum
Aluminium 3.18 mm 3.21 mm 3.15 mm 3.00 mm 3.03 mm 2.97 mm
Steel 3.18 mm 3.24 mm 3.12 mm 3.00 mm 3.3.06 mm 2.94 mm
b) Lay ratio of Conductor
ACSR ZEBRA ACSR PANTHER
Maximum Minimum Maximum Minimum Steel Steel 6 wire
layer 18 13 28 16
Aluminium 12 wire layer 17 10 16 10 18 wire layer 16 10 14 10 24 wire layer 14 10 - -
2.6 Materials
2.6.1 Aluminium
The aluminium strands shall be hard drawn from electrolytic aluminium rods having
purity not less than 99.5% and a copper content not exceeding 0.04%.
2.6.2 Steel
The steel wire strands shall be drawn from high carbon steel wire rods and shall
conform to the following chemical composition:
Element % Composition Carbon 0.50 to 0.85
Manganese 0.50 to 1.10 Phosphorous Not more than 0.035
Sulphur Not more than 0.045 Silicon 0.10 to 0.35
2.6.3 Zinc
The zinc used for galvanising shall be electrolytic High Grade Zinc of 99.95%
purity. It shall conform to and satisfy all the requirements of IS:209 -1979.
2.7 Standard Length
Volume-II (Section-N), Switchyard Erection 274
2.7.1 The conductor shall be supplied as required. No joint shall be allowed within a
single span of stringing, jumpers and equipment interconnection.
2.8 Tests:
2.8.1 The following type, acceptance & routine tests and tests during manufacturing shall
be carried out on the conductor.
2.8.2 Type Tests
In accordance with the stipulation of specification, the following type tests reports of
the conductor shall be submitted for approval as per clause 9.0 of Section -
VOLUME-I, TR.
a) UTS test on stranded conductor.
b) Corona extinction voltage test (dry) ) As per Annexure-A
c) Radio Interference voltage test (dry) )
d) DC resistance test on stranded conductor )
2.8.3 Acceptance Tests
a) Visual check for joints, scratches etc. and ) As per Annexure - A
lengths of conductor )
b) Dimensional check on steel and aluminium )
strands )
c) Check for lay ratios of various layers ) -do-
d) Galvanising test on steel strands )
e) Torsion and Elongation test on steel strands )
f) Breaking load test on steel and aluminium )
strands )
g) Wrap test on steel and aluminium strands ) IS:398 (Part V) 1982
) Clauses 12.5.2, 12.7&
12.8
h) DC resistance test on aluminium strands )
i) UTS test on welded joint of aluminium ) As per Annexure - A
strands )
NOTE:
Volume-II (Section-N), Switchyard Erection 275
All the above tests except test mentioned at (a) shall be carried out on aluminium and steel
strands after stranding only.
2.8.4 Routine Tests
a) Check to ensure that the joints are as per specification.
b) Check that there are no cuts, fins etc. on the strands.
c) All acceptance test as mentioned in Clause 2.7.3 above to be carried out on each
coil.
2.8.5 Tests During Manufacture
a) Chemical analysis of zinc used for galvanising )
b) Chemical analysis of aluminium used for ) As per Annexure
- A
making aluminium strands )
c) Chemical analysis of steel used for making )
steel strands )
2.8.6 Sample Batch for Type Testing
The Contractor shall offer material for selection of samples for type testing, only
after getting quality assurance plans approved from Owner’s Quality Assurance
Department. The sample shall be manufactured strictly in accordance with the
Quality Assurance Plan approved by Owner.
3.0 Galvanised Steel Earth wire
3.1 Details of Earth wire
3.1.1 The galvanised steel earth wire shall generally conform to the specification of ACSR
core wire as mentioned in IS: 398 (Part-II)-1976 except where otherwise specified
herein.
Owner has also standardised the guaranteed technical particulars for the earthwire
which are enclosed in Annexure-E of the technical details, Section – Switchyard
Erection. The contractor shall supply the earthwire as per the standard guaranteed
technical particulars.
3.1.2 The basic details of the earth wire are tabulated below:
S.NO. DESCRIPTION UNIT VALUE
1. Stranding & Wire diameter mm 7/3.66 (steel)
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2. Strands a) Steel Core
b) Outer layer
No. No.
1 (one) 6 (six)
3. Total sectional area Sq. mm. 73.65
Other technical details are furnished in of Annexure -E of this Specification.
3.2 Workmanship
3.2.1 All steel strands shall be smooth, uniform and free from all imperfections, such as
spills and splits, die marks, scratches, abrasions and kinks after drawing and also
after stranding.
3.2.2 The finished material shall have minimum brittleness as it will be subjected to
appreciable vibration while in use.
3.2.3 The steel strands shall be hot dip qalvanised (and shall have minimum Zinc coating
of 275 gms/sq.m) after stranding of the uncoated wire surface. The zinc coating shall
be smooth, continuous, of uniform thickness, free from imperfections and shall
withstand three and a half dips after stranding in standard Preece test. The steel wire
rod shall be of such quality and purity that, when drawn to the size of the
strandsspecified and coated with zinc, the finished strands shall be of uniform
quality and have the same properties and characteristics as prescribed in ASTM
designation B498-74.
3.2.4 The steel strands shall be preformed and post formed in order to prevent spreading
of strands while cutting of composite earth wire. Care shall be taken to avoid
damage to galvanisation during preforming and postforming operation.
3.2.5 To avoid susceptibility towards wet storage stains (white rust), the finished material
shall be provided with a protective coating of boiled linseed oil.
3.3 Joints in Wires
There shall be no joint of any kind in the finished steel wire strand entering into the
manufacture of the earth wire. There shall be no strand joints or strand splices in any length
of the completed stranded earth wire.
3.4 Tolerances
The manufacturing tolerance to the extent of the following limits only shall be permitted in
the diameter of the individual steel strands and lay length of the earth wire:
Standard Maximum Minimum
Diameter 3.66 mm 3.75 mm 3.57 mm
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Lay length 181 mm 198 mm 165 mm
3.5 Materials
3.5.1 Steel
The steel wire strands shall be drawn from high carbon steel rods and shall conform
to the following requirements as to the chemical composition.
Element % Composition Carbon Not more than 0.55
Manganese 0.4 to 0.9 Phosphorous Not more than 0.04
Sulphur Not more than 0.04 Silicon 0.15 to 0.35
3.5.2 Zinc
The zinc used for galvanising shall be electrolytic High Grade Zinc of 99.95%
purity. It shall conform to and satisfy all the requirements of IS: 209 -1979.
3.6 Standard Length
3.6.1 The earth wire shall be supplied in standard drum length of manufacturer.
3.7 TESTS
3.7.1 The following type, routine & acceptance tests and tests during manufacturing shall
be carried out on the earthwire.
3.7.2 TYPE TESTS
In accordance with the stipulation of specification, the following type tests reports of
the earthwire shall be submitted for approval as per clause 9.0 of Section –
VOLUME-I, TR.
a) UTS test As per Annexure - B
b) DC resistance test
3.7.3 ACCEPTANCE TESTS
a) Visual check for joints, scratches etc. and )
length of Earthwire )
b) Dimensional check ) As per Annexure - B
c) Galvanising test )
d) Lay length check )
e) Torsion test )
Volume-II (Section-N), Switchyard Erection 278
f) Elongation test )
g) Wrap test )
h) DC resistance test ) IS:398 (Part-III) - 1976
i) Breaking load test )
j) Chemical Analysis of steel )
3.7.4 ROUTINE TESTS
a) Check that there are no cuts, fins etc. on the strands.
b) Check for correctness of stranding.
3.7.5 TESTS DURING MANUFACTURE
a) Chemical analysis of ) As per Annexure - B
zinc used for galvanising )
b) Chemical analysis of steel )
3.7.6 SAMPLE BATCH FOR TYPE TESTING
The Contractor shall offer material for sample selection for type testing, only after
getting quality assurance programme approved by the Owner. The samples for type
testing shall be manufactured strictly in accordance with the Quality Assurance
Programme approved by the Owner.
4.0 TUBULAR BUS CONDUCTORS
4.1 General
Aluminium used shall be grade 63401 WP (range 2) conforming to IS:5082.
Owner has also stardardised the guaranteed technical particulars for the aluminium tube
which are enclosed in Annexure- E of these technical details. The contractor shall supply the
aluminium tube as per the standard guaranteed technical particulars.
4.2 Constructional Features
4.2.1 For outside diameter (OD) & thickness of the tube there shall be no minus tolerance,
other requirements being as per IS : 2678 and IS: 2673.
4.2.2 The aluminium tube shall be supplied in suitable cut length to minimize wastage.
4.2.3 The welding of aluminium tube shall be done by the qualified welders duly
approved by the owner.
4.3 Tests
Volume-II (Section-N), Switchyard Erection 279
In accordance with stipulations of the specification, Routine tests shall be conducted on
tubular bus conductors as per IS:5082. Also the wall thickness and ovality of the tube shall
be measured by the ultrasonic method. In addition to the above tests, 0.2% proof tests on
both parent metal and Aluminium tube after welding shall be conducted.
4.4 Technical Parameters
S.NO. DESCRIPTION 3” AL. TUBE
4” AL. TUBE
4.5” AL. TUBE
5” AL. TUBE
1. Size 3" IPS (EH Type)
4" IPS (EH Type)
4.5" IPS (EH Type)
5" IPS (H Type)
2. Outer diameter 88.9 mm 114.2 mm 120.00 mm 141.30 mm
3. Thickness 7.62 mm 8.51 mm 12.00 mm 9.53 mm 4. Cross-sectional area 1945.76
sq.mm 2825.61 sq.mm
4071.50 sq.mm
3945.11 sq.mm
5. Weight 5.25 kg/m 7.7 kg/m 11.034 kg/m 10.652 kg/m
5.0 EARTHING CONDUCTORS
5.1 General
All conductors buried in earth and concrete shall be of mild steel. All conductors above
ground level and earthing leads shall be of galvanised steel, except for cable trench earthing.
5.2 Constructional Features
5.2.1 Galvanised Steel
a) Steel conductors above ground level shall be galvanised according to IS:2629.
b) The minimum weight of the zinc coating shall be 618 gm/sq. m. and minimum
thickness shall be 85 microns.
c) The galvanised surfaces shall consist of a continuous and uniformly thick coating of
zinc, firmly adhering to the surfaces of steel. The finished surface shall be clean and
smooth and shall be free from defects like discoloured patches, bare spots,
unevenness of coating, spelter which is loosely attached to the steel globules, spiky
deposits, blistered surfaces, flaking or peeling off etc. The presence of any of these
defects noticed on visual or microscopic inspection shall render the material liable to
rejection.
5.3 Tests
In accordance with stipulations of the specifications galvanised steel shall be subjected to
four one minute dips in copper sulphate solution as per IS : 2633.
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6.0 SPACERS
6.1 General
Spacers shall conform to IS : 10162. The spacers are to be located at a suitable spacing to
limit the short circuit forces as per IEC -60865. Wherever Owner’s 400 kV & 220 kV
standard gantry structures are being used, the spacer span(s) for different conductor / span
configurations and corresponding short circuit forces shall be as per Annexure-D. For strung
buses, flexible type spacers shall be used whereas for jumpers and other connections rigid
type spacers shall be used.
Wherever Owner’s 400 kV & 220 kV standard gantry structures are not being used,
necessary spacer span calculation shall be provided by the contractor during detailed
engineering for the approval of Owner.
6.2 Constructional Features
6.2.1 No magnetic material shall be used in the fabrication of spacers except for GI bolts
and nuts.
6.2.2 Spacer design shall be made to take care of fixing and removing during installation
and maintenance.
6.2.3 The design of the spacers shall be such that the conductor does not come in contact
with any sharp edge.
6.3 Tests
Each type of spacers shall be subjected to the following type tests, acceptance tests and
routine tests:
6.3.1 Type Tests: Following type test reports shall be submitted for approval as per clause
9.0 of Section - VOLUME-I, TR.
a) Clamp slip tests
The sample shall be installed on test span of twin conductor bundle string or
quadruple conductor bundle string (as applicable) at a tension of 44.2 kN. One of the
clamps of the sample when subjected to a longitudinal pull of 2.5 kN parallel to the
axis of the conductor shall not slip on the conductor. The permanent displacement
between the conductor and the clamp of sample measured after removal of the load
shall not exceed 1.0 mm. Similar tests shall be performed on the other clamps of the
same sample.
b) Fault current test as per Cl 5.14.2 of IS : 10162
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c) Corona Extinction Voltage Test (Dry).
This test shall be performed on 765 kV, 400 kV and 220 kV equipment as per
procedure mentioned at Annexure - C, Minimum Corona Extinction voltage shall be
508 kV (rms), 320 kV (rms) line to ground and 156 Kv (rms) line to ground for 765
kV, 400 kV and 220 kV spacers respectively.
d) RIV Test (Dry)
This test shall be performed as per procedure mentioned at Annexure - C, Maximum
RIV level at 508 kV (rms), 305 kV (rms) line to ground and 156 kV (rms) line to
ground for 765 kV, 400 kV and 220 kV spacers respectively shall be 1000 micro
volts, across 300 ohm resistor at 1 MHz
e) Resilience test (if applicable)
f) Tension Test
g) Log decremant test (if applicable)
h) Compression test
i) Galvanising test
6.3.2 Acceptance Test (As per IS: 10162 )
a) Visual examination
b) Dimensional verification
c) Movement test
d) Clamp slip test
e) Clamp bolt torque test (if applicable)
f) Assembly torque test
g) Compression test
h) Tension test
i) Galvanising test
j) Hardness test for neoprene (if applicable)
The shore hardness of different points on the elastometer surface of cushion grip
clamp shall be measured by shore hardness meter. It shall be between 65 to 80.
k) Ultimate Tensile Strength Test
Volume-II (Section-N), Switchyard Erection 282
The UTS of the retaining rods shall be measured. It shall not be less than 35 kg/Sq.
mm.
6.3.3 Routine test
a) Visual examination
b) Dimensional verification
7.0 BUS POST INSULATORS
The post insulators shall conform in general to latest IS : 2544, IEC-60168, IEC 60273 and
IEC-60815.
7.1 Constructional Features
7.1.1 Post type insulators shall consist of a porcelain part permanently secured in a metal
base to be mounted on the supporting structures. They shall be capable of being
mounted upright. They shall be designed to withstand any shocks to which they may
be subjected to by the operation of the associated equipment. Only solid core
insulators will be acceptable.
7.1.2 Porcelain used shall be homogeneous, free from lamination, cavities and other flaws
or imperfections that might affect the mechanical or dielectric quality and shall be
thoroughly vitrified, tough and impervious to moisture.
7.1.3 Glazing of the porcelain shall be of uniform brown in colour, free from blisters,
burrs and other similar defects.
7.1.4 The insulator shall have alternate long and short sheds with aerodynamic profile,
The shed profile shall also meet the requirements of IEC-60815 for the specified
pollution level.
7.1.5 When operating at normal rated voltage there shall be no electric discharge between
conductor and insulators which would cause corrosion or injury to conductors or
insulators by the formation of substance produced by chemical action.
7.1.6 The design of the insulators shall be such that stresses due to expansion and
contraction in any part of the insulator shall not lead to deterioration.
7.1.7 All ferrous parts shall be hot dip galvanised in accordance with the latest edition of
IS: 2633, & IS: 2629. The zinc used for galvanising shall be grade Zn 99.95 as per
IS : 209. The zinc coating shall be uniform, adherent, smooth, reasonably bright,
continuous and free from imperfections such as flux ash, rust stains, bulky white
Volume-II (Section-N), Switchyard Erection 283
deposits and blisters. The metal parts shall not produce any noise generating corona
under the operating conditions.
7.1.8 a) Every bolt shall be provided with a steel washer under the nut so that part of the
threaded portion of the bolts is within the thickness of the parts bolted together.
b) Flat washer shall be circular of a diameter 2.5 times that of bolt and of suitable
thickness. Where bolt heads/nuts bear upon the beveled surfaces they shall be
provided with square tapered washers of suitable thickness to afford a seating square
with the axis of the bolt.
c) All bolts and nuts shall be of steel with well formed hexagonal heads forged from
the solid and shall be hot dip galvanised. The nuts shall be good fit on the bolts and
two clear threads shall show through the nut when it has been finally tightened up.
7.1.9 Bidder shall make available data on all the essential features of design including the
method of assembly of shells and metals parts, number of shells per insulator, the
manner in which mechanical stresses are transmitted through shells to adjacent parts,
provision for meeting expansion stresses, results of corona and thermal shock tests,
recommended working strength and any special design or arrangement employed to
increase life under service conditions.
7.2 Tests
In accordance with the stipulations of the specification, the post insulators shall be subject to
type, acceptance, sample and routine tests as per IS : 2544 and IEC-60168.
7.2.1 In addition to acceptance/sample/routine tests as per IS: 2544 and IEC-60168, the
following tests shall also be carried out.
a) Ultrasonic test as an acceptance test
b) Soundness test, metallurgical tests and magnetic test on MCI caps and pedestal tests
as acceptance test.
c) All hot dip galvanised components shall be subject to check for uniformity of
thickness and weight of zinc coating on sample basis.
d) The bending test shall be carried out at 50% minimum failing load in four directions
as a routine test and at 100% minimum failing load in four directions as an
acceptance test.
e) Acceptance norms for visual defects allowed at site and also at works shall be
agreed in the Quality plan.
Volume-II (Section-N), Switchyard Erection 284
7.2.2 In accordance with the stipulation of specification, the following type tests reports of
the post insulators shall be submitted for approval as per clause 9.0 of Section –
VOLUME-I, TR.
a) Power frequency withstand test (dry & wet)
b) Lightning impulse test (dry)
c) Switching impulse test (wet) (For 420 kV and above class Insulator only)
d) Measurement of R.I.V (Dry) (As per Annexure – C)
e) Corona extinction voltage test (Dry) (As per Annexure – C)
f) Test for deflection under load
g) Test for mechanical strength.
7.3 Technical Parameters of Bus Post Insulators.
S.No. DESCRIPTION 800 kV 420 kV 245 kV 145 kV
1. Type Solid Core
Solid Core
Solid Core
Solid Core
2. Voltage Class (kV) 800 420 245 145 3. Dry and wet one minute
power frequency withstand voltage(Kv rms)
-- 680 460 275
4. Dry lightning impulse withstand Voltage (kVp)
± 2100 ±1425 ±1050 ±650
5. Wet switching surge withstand voltage (kVp)
± 1550 ± 1050 -- --
6. Max. radio interference voltage (in microvolts) at voltage of 508 kV (rms) , 305 kV (rms) and 156 (rms) for 765 kV, 400 kV &220 kV respectively between phase to ground.
2500 500 500 500
7. Corona extinction voltage (kV rms) (min.)
508 320 156 105
8. Total minimum cantilever strength (Kg)
800* 800 800 600
9. Minimum torsional moment As per IEC-273
As per IEC-273
As per IEC-273
As per IEC-273
10. Total height of insulator (mm)
3650 2300
11. P.C.D Top (mm) -- 127 127 -- Bottom (mm) -- 300 254 --
12. No. of bolts Top -- 4 4 -- Bottom -- 8 8 --
13. Diameter of bolt/holes (mm) Top -- M16 M16 --
Volume-II (Section-N), Switchyard Erection 285
Bottom -- 18 18 -- 14. Pollution level as per IEC-
815 Heavy(III) Heavy(III) Heavy(III) Heavy(III)
15. Minimum total creepage distance for Heavy Pollution (mm)
20000 10500 6125 3165
* value indicated for 765 kV is minimum, however same is to be increased as per layout
requirement , if required.
7.3.1 If corona extinction voltage is to be achieved with the help of corona ring or any
other similar device, the same shall be deemed to be included in the scope of the
Contractor.
8.0 EARTHING
The bidder shall assume/measure soil resistivity at site for quoting for the package. It may be
noted that no price adjustment would be entertained on account of variation of resistivity
value later.
8.1 The earthing shall be done in accordance with requirements given hereunder. Spacing for the
main earthmat shall be computed by the Contractor and the earthmat layout drawings shall
be prepared by the contractor based on the spacing approved bdesign. The resistivity of the
stone for spreading over the ground shall be considered as 3000 ohm-m. Contractor shall
ensure this value of resistivity of the gravel in a wet saturated stage.
The resistivity measurement of stone (to be used for stone spreading) shall also be done by
the Contractor to confirm the minimum resistivity value of stone considered in earth mat
design. For measurement purpose, one sample of stones from each source (in case stones are
supplied from more than one source) shall be used. The main earthmat shall be laid in the
switchyard area in accordance with the approved earthmat layout.
8.2 Neutral points of systems of different voltages, metallic enclosures and frame works
associated with all current carrying equipments and extraneous metal works associated with
electric system shall be connected to a single earthing system unless stipulated otherwise.
8.3 Earthing and lightning protection system installation shall be in strict accordance with the
latest editions of Indian Electricity Rules, relevant Indian Standards and
Codes of practice and Regulations existing in the locality where the system is installed.
a) Code of practice for Earthing IS: 3043
b) Code of practice for the protection of Building and allied structures against lightning
IS: 2309.
c) Indian Electricity Rules 1956 with latest amendments.
Volume-II (Section-N), Switchyard Erection 286
d) Guide for Safety in Substation Grounding.
8.4 Details of Earthing System
S.NO. ITEM SIZE MATERIAL 1. Main Earthing Conductor to be
buried in ground 40mm dia Mild Steel rod
2. Conductor above ground&
earthing leads (for equipment) 75x12mm G.S. flat Galvanised Steel
3. Conductor above ground&
earthing leads(for columns & aux. structures)
75x12mm G.S. flat Galvanised Steel
4. Earthing of indoor LT panels, Control panels and out door marshalling boxes, MOM boxes, Junction boxes& Lighting Panels etc.
50x6 mm G.S. flat Galvanised Steel
5. Rod Earth Electrode 40mm dia, 3000mm long
Mild Steel
6. Pipe Earth Electrode (in treated earth pit) as per IS.
40mm dia, 3000mm long
Galvanised steel
7. Earthing for motors 25x3mm GS flat Galvanised steel
8. Earthing conductor along outdoor cable trenches
50x6mm MS flat Mild steel
9. Earthing of Lighting Poles 20 mm dia 3000 mm long
Mild steel rod
The sizes of the earthing conductor indicated above are the minimum sizes.
8.5 Earthing Conductor Layout
8.5.1 Earthing conductors in outdoor areas shall be buried at least 600 mm below finished
ground level unless stated otherwise.
8.5.2 Wherever earthing conductor crosses cable trenches, underground service ducts,
pipes, tunnels, railway tracks etc., it shall be laid minimum 300 mm below them and
shall be circumvented in case it fouls with equipment/structure foundations.
8.5.3 Tap-connections from the earthing grid to the equipment/structure to be earthed
shall be terminated on the earthing terminals of the equipment/structure.
8.5.4 Earthing conductors or leads along their run on cable trench, ladder, walls etc. shall
be supported by suitable welding/cleating at intervals of 750 mm. Wherever it
passes through walls, floors etc., galvanised iron sleeves shall be provided for the
passage of the conductor and both ends of the sleeve shall be sealed to prevent the
passage of water through the sleeves.
8.5.5 Earthing conductor around the building shall be buried in earth at a minimum
distance of 1500 mm from the outer boundary of the building. In case high
Volume-II (Section-N), Switchyard Erection 287
temperature is encountered at some location, the earthing conductor shall be laid
minimum 1500 mm away from such location.
8.5.6 Earthing conductors crossing the road shall be laid 300 mm below road or at greater
depth to suit the site conditions.
8.5.7 Earthing conductors embeded in the concrete shall have approximately 50 mm
concrete cover.
8.6 Equipment and Structure Earthing
8.6.1 Earthing pads shall be provided for the apparatus/equipment at accessible position.
The connection between earthing pads and the earthing grid shall be made by two
short earthing leads (one direct and another through the support structure) free from
kinks and splices. In case earthing pads are not provided on the item to be earthed,
same shall be provided in consultation with Owner.
8.6.2 Steel/RCC columns, metallic stairs etc. shall be connected to the nearby earthing
grid conductor by two earthing leads. Electrical continuity shall be ensured by
bonding different sections of hand-rails and metallic stairs.
8.6.3 Metallic pipes, conduits and cable tray sections for cable installation shall be bonded
to ensure electrical continuity and connected to earthing conductors at regular
interval. Apart from intermediate connections, beginning points shall also be
connected to earthing system.
8.6.4 Metallic conduits shall not be used as earth continuity conductor.
8.6.5 Wherever earthing conductor crosses or runs along metallic structures such as gas,
water, steam conduits, etc. and steel reinforcement in concrete it shall be bonded to
the same.
8.6.6 Light poles, junction boxes on the poles, cable and cable boxes/glands, lockout
switches etc. shall be connected to the earthing conductor running alongwith the
supply cable which inturn shall be connected to earthing grid conductor at a
minimum two points whether specifically shown or not.
8.6.7 Railway tracks within switchyard area shall be earthed at a spacing of 30m and also
at both ends.
8.6.8 Earthing conductor shall be buried 2000 mm outside the switchyard fence. All the
gates and every alternate post of the fence shall be connected to earthing grid.
Volume-II (Section-N), Switchyard Erection 288
The stone spreading shall also be done 2000 mm outside switchyard fence. The
criterian for stone spreading shall be followed in line with requirement specified
elsewhere in the specification
8.6.9 Flexible earthing connectors shall be provided for the moving parts.
8.6.10 All lighting panels, junction boxes, receptacles fixtures, conduits etc. shall be
grounded in compliance with the provision of I.E. rules
8.6.11 A continuous ground conductor of 16 SWG GI wire shall be run all along each
conduit run. The conductor shall be connected to each panel ground bus. All
junction boxes, receptacles, switches, lighting fixtures etc. shall be connected to this
16 SWG ground conductor.
8.6.12 50mm x 6mm MS flat shall run on the top tier and all along the cable trenches and
the same shall be welded to each of the racks. Further this flat shall be earthed at
both ends and at an interval of 30 mtrs. The M.S. flat shall be finally painted with
two coats of Red oxide primer and two coats of Post Office red enamel paint.
8.6.13 One number 40 mm dia, 3000 mm long MS earth electrode with test link, CI frame
and cover shall be provided to connect each down conductor of surge arresters,
capacitive voltage transformers, lightning masts and towers with peak.
8.7 Jointing
8.7.1 Earthing connections with equipment earthing pads shall be bolted type. Contact
surfaces shall be free from scale, paint, enamel, grease, rust or dirt. Two bolts shall
be provided for making each connection. Equipment bolted connections, after being
checked and tested, shall be painted with anti corrosive paint/compound.
8.7.2 Connection between equipment earthing lead and main earthing conductors and
between main earthing conductors shall be welded type. For rust protections, the
welds should be treated with red lead and afterwards coated with two layers bitumen
compound to prevent corrosion.
8.7.3 Steel to copper connections shall be brazed type and shall be treated to prevent
moisture ingression.
8.7.4 Resistance of the joint shall not be more than the resistance of the equivalent length
of the conductor.
8.7.5 All ground connections shall be made by electric arc welding. All welded joints
shall be allowed to cool down gradually to atmospheric temperature before putting
any load on it. Artificial cooling shall not be allowed.
Volume-II (Section-N), Switchyard Erection 289
8.7.6 Bending of earthing rod shall be done preferably by gas heating.
8.7.7 All arc welding with large dia. conductors shall be done with low hydrogen content
electrodes.
8.7.8 The 75x12mm GS flat shall be clamped with the equipment support structures at
1000mm interval.
8.8 Power Cable Earthing
Metallic sheaths and armour of all multi core power cables shall be earthed at both
equipment and switchgear end. Sheath and armour of single core power cables shall be
earthed at switchgear end only.
8.9 Specific Requirement for Earthing Systems
8.9.1 Each earthing lead from the neutral of the power transformer/Reactor shall be
directly connected to two pipe electrodes in treated earth pit (as per IS) which in
turn, shall be buried in Cement Concrete pit with a cast iron cover hinged to a cast
iron frame to have an access to the joints. All accessories associated with
transformer/reactor like cooling banks, radiators etc. shall be connected to the
earthing grid at minimum two points.
8.9.2 Earthing terminal of each lightning arrester & capacitor voltage transformer shall be
directly connected to rod earth electrode which in turn, shall be connected to station
earthing grid.
8.9.3 Auxiliary earthing mat comprising of 40mm dia M.S. rods closely spaced (300 mm
x 300 mm) conductors shall be provided at depth of 300mm from ground level
below the operating handles of the M.O.M. Box of the isolators. M.O.M. boxes shall
be directly connected to the auxiliary earthing mat.
9.0 Main Bus Bars (Applicable for Aluminium tube)
The brief description of the bus switching scheme, bus bar layout and equipment connection
to be adopted are detailed our in the Volume-1 of the specification. The bus bar
arrangements are shown in respective Single Line Diagram’s.
9.1 The Contractor shall furnish supporting calculations for the bus bars/conductors to show
adequacy of design parameters for:
a) Fibre-stress
b) Cantilever strength of post insulators
c) Aeolain vibrations
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d) Vertical deflection of bus bars
e) Short circuit forces in bundle conductor and spacer location for each span of ACSR
conductor stringing .
9.1.1 The welds in the aluminium tubes shall be kept to the minimum and there shall not
be more than one weld per span. The procedure and details of welding shall be
subject to Owner’s approval. Material for welding sleeve shall be same as that of
Aluminium tube. Welding sleeve shall be of 600mm length
9.1.2 Corona bells shall be provided wherever the bus extends beyond the clamps and on
free ends, for sealing the ends of the tubular conductor against rain and moisture
and to reduce the electrostatic discharge loss at the end points. There shall be a small
drain hole in the corona bell. The material of Corona bell shall be Aluminium alloy
similar to that of clamps & connectors.
9.1.3 To minimise the vibrations in the aluminium tubes, damping conductor shall be
provided inside the aluminium tubes.
9.1.4 Details of past experience of the persons proposed to be employed for Aluminium
tube welding and the test reports of the welded pieces to prove the electrical and
mechanical characteristics shall also be furnished along with the bid. Welding at site
shall be done by adopting a qualified procedure and employing qualified welders as
per ASME-Section IX.
10.0 BAY EQUIPMENT
10.1 The disposition of various bay equipments shall be as per single line diagrams. The layout
drawings have to be developed by the Bidder/ Contractor.
10.2 Bay Marshalling Kiosk:-
One no. of bay marshalling kiosk shall be provided for each 765 kV, 400 kV, 220 kV and
132 kV bay under present scope. For one and half breaker scheme, one number bay
marshalling kiosk shall be provided for each controlling feeder (Line/ transformer/ bus
reactor etc) of the diameter and no bay marshalling kiosks are required to be provided for the
tie bays. In addition to the requirements specified elsewhere in the specification, the bay
marshalling kiosk shall have two distinct compartments for the following purpose:-
(i) To receive two incoming 415V, 3 phase, 63Amps, AC supply with auto changeover
and MCB unit and distribute minimum six (four in case of S/S having highest voltage
132kV) outgoing 415V, 3 phase, 16 Amps AC supplies controlled by MCB.
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(ii) To distribute minimum ten (six in case of S/S having highest voltage 132kV) outgoing
240V, 10 Amps single phase supplies to be controlled by MCB to be drawn from
above 3 phase incomers.
(iii) 200 (100 in case of s/s having highest voltage 132 kV) nos. terminal blocks in vertical
formation for interlocking facilities for substations without automation system.
10.3 BAY AND PHASE IDENTIFICATION
All the phases are to be identified by Red, Yellow and Blue colour as per asbuilt condition.
Phase identification colour is to be provided around the top of the structure with colour of
100 mm width at a height of approximately 2000mm from the finished ground level.
11.0 LIGHTNING PROTECTION
11.1 Direct stroke lightning protection (DSLP) shall be provided in the EHV switchyard by
lightning masts and shield wires.
11.2 The lightning protection system shall not be in direct contact with underground metallic
service ducts and cab.
11.3 Conductors of the lightning protection system shall not be connected with the conductors of
the safety earthing system above ground level.
11.4 Down conductors shall be cleated on the structures at 2000 mm interval.
11.5 Connection between each down conductor and rod electrodes shall be made via test joint
(pad type compression clamp) located approximately 1500 mm above ground level. The rod
electrode shall be further joined with the main earthmat.
11.6 Lightning conductors shall not pass through or run inside G.I. conduits.
12.0 EQUIPMENT ERECTION DETAILS
12.1 For equipment interconnection, the surfaces of equipment terminal pads, Aluminium tube,
conductor & terminal clamps and connectors shall be properly cleaned. After cleaning,
contact grease shall be applied on the contact surfaces of equipment terminal pad,
Aluminium tube/conductor and terminal clamps to avoid any air gap in between.
Subsequently bolts of the terminal pad/terminal connectors shall be tightened and the
surfaces shall be cleaned properly after equipment interconnection.
12.2 Muslin or leather cloth shall be used for cleaning the inside and outside of hollow insulators.
12.3 All support insulators, circuit breaker interrupters and other fragile equipment shall
preferably be handled with cranes having suitable booms and handling capacity.
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12.4 Bending of Aluminium tube and compressed air piping if any should be done by a bending
machine and through cold bending only. Bending shall be such that inner diameter of pipe is
not reduced.
12.5 Cutting of the pipes wherever required shall be such as to avoid flaring of the ends. Hence
only a proper pipe cutting tool shall be used. Hack saw shall not be used.
12.6 Handling of equipment shall be done strictly as per manufacturer’s/supplier’s
instructions/instruction manual.
12.7 Handling equipment, sling ropes etc. should be tested periodically before erection for
strength.
12.8 The slings shall be of sufficient length to avoid any damage to insulator due to excessive
swing, scratching by sling ropes etc.
13.0 STORAGE
13.1 The Contractor shall provide and construct adequate storage shed for proper storage of
equipments, where sensitive equipments shall be stored indoors. All equipments during
storage shall be protected against damage due to acts of nature or accidents. The storage
instructions of the equipment manufacturer/Owner shall be strictly adhered to.
14.0 CABLING MATERIAL
14.1 CABLE TAGS AND MARKERS
i) Each cable and conduit run shall be tagged with numbers that appear in the cable
and conduit schedule.
ii) The tag shall be of aluminium with the number punched on it and securely attached
to the cable conduit by not less than two turns of 20 SWG GI wire conforming to
IS:280. Cable tags shall be of rectangular shape for power cables and of circular
shape for control cables.
iii) Location of cables laid directly underground shall be clearly indicated with cable
marker made of galvanised iron plate.
iv) Location of underground cable joints shall be indicated with cable marker with an
additional inscription “Cable joints”.
v) The marker shall project 150 mm above ground and shall be spaced at an interval of
30 meters and at every change in direction. They shall be located on both sides of
road and drain crossings.
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vi) Cable tags shall be provided on all cables at each end (just before entering the
equipment enclosure), on both sides of a wall or floor crossing, on each duct/conduit
entry and at each end & turning point in cable tray/trench runs. Cable tags shall be
provided inside the switchgear, motor control centres, control and relay panels etc.,
wherever required for cable identification, where a number of cables enter together
through a gland plate.
14.2 Cable Supports and Cable Tray Mounting Arrangements
i) The Contractor shall provide embedded steel inserts on concrete floors/walls to
secure supports by welding to these inserts or available building steel structures.
ii) The supports shall be fabricated from standard structural steel members.
iii) Insert plates will be provided at an interval of 750 mm wherever cables are to be
supported without the use of cable trays, such as in trenches, while at all other places
these will be at an interval of 2000 mm.
14.3 Cable Termination and Connections
14.3.1 The termination and connection of cables shall be done strictly in accordance with
cable and termination kit manufacturer’s instructions, drawing and/or as directed by
the Owner.
14.3.2 The work shall include all clamping, fittings, fixing, plumbing, soldering, drilling,
cutting, taping, heat shrinking (where applicable), connecting to cable terminal,
shorting and grounding as required to complete the job.
14.3.3 Supply of all consumable material shall be in the scope of Contractor.
14.3.4 The equipment will be generally provided with undrilled gland plates for
cables/conduit entry. The Contractor shall be responsible for drilling of gland plates,
painting and touching up. Holes shall not be made by gas cutting.
14.3.5 Control cable cores entering control panel/switchgear/MCCB/MCC/ miscellaneous
panels shall be neatly bunched, clamped and tied with nylon strap or PVC perforated
strap to keep them in position.
14.3.6 The Contractor shall tag/ferrule control cable cores at all terminations, as instructed
by the Owner. In panels where a large number of cables are to be terminated and
cable identification may be difficult, each core ferrule may include the complete
cable number as well.
14.3.7 Spare cores shall be similarly tagged with cable numbers and coiled up.
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14.3.8 All cable entry points shall be sealed and made vermin and dust proof. Unused
openings shall be effectively closed.
14.3.9 Double compression type nickel plated (coating thickness not less than 10 microns)
brass cable glands shall be provided by the Contractor for all power and control
cables to provide dust and weather proof terminations.
14.3.10 The cable glands shall conform to BIS:6121. They shall comprise of heavy duty
brass casting, machine finished and nickel plated, to avoid corrosion and oxidation.
Rubber components used in cable glands shall be neoprene and of tested quality.
Cable glands shall be of approved make.
14.3.11 The cable glands shall also be suitable for dust proof and weather proof termination.
The test procedure, if required, has to be discussed and agreed to between Owner
and cable gland manufacturer.
14.3.12 If the cable-end box or terminal enclosure provided on the equipment is found
unsuitable and requires modification, the same shall be carried out by the
Contractor, as directed by the Owner.
14.3.13 Crimping tool used shall be of approved design and make.
14.3.14 Cable lugs shall be tinned copper solderless crimping type conforming to IS-8309
& 8394. Bimetallic lugs shall be used depending upon type of cables used.
14.3.15 Solderless crimping of terminals shall be done by using corrosion inhibitory
compound. The cable lugs shall suit the type of terminals provided.
14.4 Storage and handling of Cable Drums
i) Cable drums shall be unloaded, handled and stored in an approved manner and
rolling of drums shall be avoided as far as possible. For short distances, the drums
may be rolled provided they are rolled slowly and in proper direction as marked on
the drum.
15.0 DIRECTLY BURIED CABLES
i) The Contractor shall construct the cable trenches requried for directly buried cables. The
scope of work shall include excavation, preparation of sand bedding, soil cover, supply and
installation of brick or concrete protective covers, back filling and ramming, supply and
installation of route markers and joint markers.
The Bidder shall ascertain the soil conditions prevailing at site, before submitting the bid.
Volume-II (Section-N), Switchyard Erection 295
ii) The cable (power and control) between LT station, control room, DG set location and fire
lighting pump house shall be laid in the buried cable trenches. In addition to the above, for
lighting purpose also, buried cable trench can be used in outdoor area.
iii) Cable route and joint markers and RCC warning covers shall be provided wherever required.
The voltage grade of cables shall be engraved on the marker.
16.0 INSTALLATION OF CABLES
16.1 Cabling in the control room shall be done on ladder type cable trays while cabling in
switchyard area shall be done on angles in the trench.
16.2 All cables from bay cable trench to equipments including and all interpole cables (both
power and control) for all equipment, shall be laid in PVC pipes of minimum 50 mm
nominal outside diameter of class 4 as per IS 4985 which shall be buried in the ground at a
depth of 250mm below finish formation level. Separate PVC pipes shall be laid for control
and power cables. Cable pull boxes of adequate size shall be provided if required.
16.3 Cables shall be generally located adjoining the electrical equipment through the pipe insert
embedded in the floor. In the case of equipments located away from cable trench either pipe
inserts shall be embedded in the floor connecting the cable trench and the equipment or in
case the distance is small, notch/opening on the wall shall be provided. In all these cases
necessary bending radius as recommended by the cable manufacturer shall be maintained.
16.4 Cable racks and supports shall be painted after installation with two coats of metal primer
(comprising of red oxide and zinc chromate in a synthetic medium) followed by two
finishing coats of aluminium paint. The red oxide and zinc chromate shall conform to
IS:2074.
16.5 Suitable arrangement should be used between fixed pipe / cable trays and equipment
terminal boxes, where vibration is anticipated.
16.6 Power and control cables in the cable trench shall be laid in separate tiers. The order of
laying of various cables shall be as follows, for cables other than directly buried.
a) Power cables on top tiers.
b) Control instrumentation and other service cables in bottom tiers.
16.7 Single core cables in trefoil formation shall be laid with a distance of three times the
diameter of cable between trefoil centre lines. All power cables shall be laid with a minimum
centre to centre distance equal to twice the diameter of the cable of higher size of cables.
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16.8 Trefoil clamps for single core cables shall be of pressure die cast aluminium (LM- 6), Nylon
-6 or fibre glass and shall include necessary fixing GI nuts, bolts, washer etc. These are
required at every 2 metre of cable runs.
16.9 Power and control cables shall be securely fixed to the trays/supports with self locking type
nylon ties with deinterlocking facility at every 5 metre interval for horizontal run. Vertical
and inclined cable runs shall be secured with 25 mm wide and 2 mm thick aluminium strip
clamps at every 2m.
16.10 Cables shall not be bent below the minimum permissible limit. The permissible limits are as
follows:
Table of Cable and Minimum bending radius
Power cable 12D
Control cable 10 D
D is overall diameter of cable
16.11 Where cables cross roads, drains and rail tracks, these shall be laid in reinforced spun
concrete or steel pipes buried at not less than one metre depth.
16.12 In each cable run some extra length shall be kept at a suitable point to enable one (for LT
cables)/two (for H.T. cables) straight through joints to be made in case the cable develop
fault at a later date.
16.13 Selection of cable drums for each run shall be so planned as to avoid using straight through
joints. Cable splices will not be permitted except where called for by the drawings,
unavoidable or where permitted by the Owner. If straight through joints are unavoidable, the
Contractor shall use the straight through joints kit of reputed make.
16.14 Control cable terminations inside equipment enclosures shall have sufficient lengths so that
changing of termination in terminal blocks can be done without requiring any splicing.
16.15 Metal screen and armour of the cable shall be bonded to the earthing system of the station,
wherever required by the Owner.
16.16 Rollers shall be used at intervals of about two metres while pulling cables.
16.17 All due care shall be taken during unreeling, laying and termination of cable to avoid
damage due to twist, kinks, sharp bends, etc.
16.18 Cable ends shall be kept sealed to prevent damage. In cable vault, fire resistant seal shall be
provided underneath the panels.
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16.19 Inspection on receipt, unloading and handling of cables shall generally be in accordance with
IS:1255 and other Indian Standard Codes of practices.
16.20 Wherever cable pass through floor or through wall openings or other partitions, GI/PVC wall
sleeves with bushes having a smooth curved internal surface so as not to damage the cable,
shall be supplied, installed and properly sealed by the Contractor at no extra charges.
16.21 Contractor shall remove the RCC/Steel trench covers before taking up the work and shall
replace all the trench covers after the erection-work in that particular area is completed or
when further work is not likely to be taken up for some time.
16.22 Contractor shall furnish three copies of the report on work carried out in a particular week,
indicating cable numbers, date on which laid, actual length and route, testing carried out,
terminations carried out, along with the marked up copy of the cable schedule and
interconnection drawing wherever any modifications are made.
16.23 Contractor shall paint the tray identification number on each run of trays at an interval of 10
m.
16.24 In case the outer sheath of a cable is damaged during handling/installation, the Contractor
shall repair it at his own cost to the satisfaction of the Owner. In case any other part of a
cable is damaged, the same shall be replaced by a healthy cable at no extra cost to the
Owner, i.e. the Contractor shall not be paid for installation and removal of the damaged
cable.
16.25 All cable terminations shall be appropriately tightened to ensure secure and reliable
connections. The Contractor shall cover the exposed part of all cable lugs whether supplied
by him or not with insulating tape, sleeve or paint.
16.26 Cable trays ( shall be used for indoor installations)
i) The cable trays shall be of G.S.sheet and minimum thickness of sheet shall be 2mm.
ii) The Contractor shall perform all tests and inspection to ensure that material and
workmanship are according to the relevant standards.
Contractor shall have to demonstrate all tests as per specification and equipment shall
comply with all requirements of the specification.
a) Test for galvanising (Acceptance Test)
The test shall be done as per approved standards.
b) Deflection Test : (Type Test)
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A 2.5 metre straight section of 300mm, 600mm wide cable tray shall be simply supported at
two ends. A uniform distributed load of 76 kg/m shall be applied along the length of the tray.
The maximum deflection at the mid-span shall not exceed 7mm.
16.27 Conduits, Pipes and Duct Installation
a) Contractor shall supply and install all rigid conduits, mild steel pipes,flexible conduits, hume
pipes etc. including all necessary sundry materials such as tees, elbows, check nuts, bushing,
reducers, enlargers, coupling cap, nipples, gland sealing fittings, pull boxes etc as specified
and to be shown in detailed drawing.
The size of the conduit/pipe shall be selected on the basis of 40% fill criterion.
b) Contractor shall have his own facility for bending, cutting and threading the conduits at site.
Cold bending should be used. All cuts & threaded ends shall be made smooth without
leaving any sharp edges. Anticorrosive paint shall be applied at all field threaded portions.
c) All conduit/pipes shall be extended on both sides of wall/floor openings. The fabrication and
installation of supports and the clamping shall be included in the scope of work by
Contractor.
d) When two lengths of conduits are joined together through a coupling, running threads equal
to twice the length of coupling shall be provided on each conduit to facilitate easy
dismantling of two conduits.
e) Conduit installation shall be permanently connected to earth by means of special approved
type of earthing clamps. GI pull wire of adequate size shall be laid in all conduits before
installation. Each conduit run shall be painted with its designation as indicated on the
drawings such that it can be identified at each end.
f) Embedded conduits shall have a minimum concrete cover of 50 mm.
g) Conduit run sleeves shall be provided with the bushings at each end.
h) Metallic conduit runs at termination shall have two locknuts and a bushing for connection.
Flexible conduits shall also be suitably clamped at each end with the help of bushings.
Bushings shall have rounded edges so as not to damage the cables.
i) Where embedded conduits turn upwards from a slab or fill, the termination dimensions if
any, shall be taken to represent the position of the straight extension of the conduit external
to and immediately following the bend. At least one half of the arc length of the bend shall
be embedded.
j) All conduits/pipes shall have their ends closed by caps until cables are pulled.
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After cables are pulled, the ends of conduits/pipes shall be sealed in an approved manner to
prevent damage to threaded portions and entrance of moisture and foreign material.
k) For underground runs, Contractor shall excavate and back fill as necessary.
l) Contractor shall supply, unload, store and install conduits required for the lighting
installation as specified. All accessories/fittings required for making the installation
complete, including but not limited to pull out boxes, ordinary and inspection tees and
elbow, checknuts, male and female bushings (brass or galvanised steel), caps, square headed
male plugs, nipples, gland sealing fittings ,pull boxes, conduits terminal boxes, gaskets and
box covers, saddle terminal boxes, and all steel supporting work shall be supplied by the
Contractor. The conduit fittings shall be of the same material as conduits.
m) All unarmoured cables shall run within the conduits from lighting panels to lighting fixtures,
receptacles etc.
n) Size of conduit for lighting shall be selected by the Contractor during detailed engineering.
o) Exposed conduits shall be run in straight lines parallel to building columns, beams and walls.
Unnecessary bends and crossings shall be avoided to present a neat appearance. Conduit
supports shall be provided at an interval of 750mm for horizontal runs and 1000mm for
vertical runs. Conduit supports shall be clamped on the approved type spacer plates or
brackets by saddles or U- bolts. The spacer plates or brackets in turn, shall be securely fixed
to the building steel by welding and to concrete or brick work by grouting or by nylon rawl
plugs. Wooden plug inserted in the masonary or concrete for conduit support is not
acceptable.
q) Embedded conduits shall be securely fixed in position to preclude any movement. In fixing
embedded conduit, if welding or brazing is used, extreme care should be taken to avoid any
injury to the inner surface of the conduit. Spacing of embedded conduits shall be such as to
permit flow of concrete between them. Where conduits are placed alongwith cable trays,
they shall be clamped to supporting steel at an interval of 600mm.
r) For directly embedding in soil, the conduits shall be coated with an asphalt-base compound.
Concrete pier or anchor shall be provided wherever necessary to support the conduit rigidly
and to hold it in place.
s) Conduit shall be installed in such a way as to ensure against trouble from trapped
condensation. Conduits shall be kept, wherever possible, at least 300mm away from hot
pipes, heating devices etc. when it is evident that such proximity may reduce the service life
of cables.
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t) Slip joints shall be provided when conduits cross structural expansion joints or where long
run of exposed conduits are installed, so that temperature change will cause no distortion due
to expansion or contraction of conduit run.
u) For long conduit run, pull boxes shall be provided at suitable intervals to facilitate wiring.
Conduit shall be securely fastened to junction boxes or cabinets, each with a lock nut inside
and outside the box.
v) Conduits joints and connections shall be made thoroughly water-tight and rust proof by
application of a thread compound which insulates the joints. White lead is suitable for
application on embedded conduit and red lead for exposed conduit.
w) Field bends shall have a minimum radius of four (4) times the conduit diameter. All bends
shall be free of kinks, indentations of flattened surfaces. Heat shall not be applied in making
any conduit bend. Separate bends may be used for this purpose. The entire metallic conduit
system, whether embedded or exposed, shall be electrically continuous and thoroughly
grounded. Where slip joints are used, suitable bounding shall be provided around the joint to
ensure a continuous ground circuit.
x) After installation, the conduits shall be thoroughly cleaned by compressed air before pulling
in the wire.
y) Lighting fixtures shall not be suspended directly from the junction box in the main conduit
run.
17.0 JUNCTION BOX
a) The Contractor shall supply and install junction boxes complete with terminals as required.
The brackets, bolts, nuts, screws etc required for erection are also included in the scope of
the Contractor.
b) Junction boxes having volume less than 1600 cubic centimeters may be installed without any
support other than that resulting from connecting conduits where two or more rigid metallic
conduits enter and accurately position the box. Boxes shall be installed so that they are level,
plumb and properly aligned to present a pleasing appearance.
c) Boxes with volumes equal to or greater than 1600 cubic cm, and smaller boxes terminating
on less than two rigid metallic conduits or for other reasons not rigidly held, shall be
adequately supported by auxiliary steel of standard steel shapes or plates to be fabricated and
installed. The
Contractor shall perform all drilling, cutting, welding, shimming and bolting required for
attachment of supports.
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18.0 TESTING AND COMMISSIONING
18.1 An indicative list of tests for testing and commissioning is given below. Contractor shall
perform any additional test based on specialities of the items as per the field
Q.P./instructions of the equipment Contractor or Owner without any extra cost to the Owner.
The Contractor shall arrange all equipments instruments and auxiliaries required for testing
and commissioning of equipments alongwith calibration certificates and shall furnish the list
of instruments to the Owner for approval.
18.2 GENERAL CHECKS
(a) Check for physical damage.
(b) Visual examination of zinc coating/plating.
(c) Check from name plate that all items are as per order/specification.
(d) Check tightness of all bolts, clamps and connecting terminals using torque wrenches.
(e) For oil filled equipment, check for oil leakage, if any. Also check oil level and top up
wherever necessary.
(f) Check ground connections for quality of weld and application of zinc rich paint over weld
joint of galvanised surfaces.
(g) Check cleanliness of insulator and bushings.
(h) All checks and tests specified by the manufacturers in their drawings and manuals as well as
all tests specified in the relevant code of erection.
(i) Check for surface finish of grading rings (Corona control ring).
(j) Pressure test on all pneumatic lines at 18.5 times the rated pressure shall be conducted.
18.3 STATION EARTHING
a) Check soil resistivity
b) Check continuity of grid wires
c) Check earth resistance of the entire grid as well as various sections of the same.
d) Check for weld joint and application of zinc rich paint on galvanized surfaces.
e) Dip test on earth conductor prior to use.
18.4 AAC/ ACSR STRINGING WORK, TUBULAR BUS WORK AND POWER
CONNECTORS
a) Physical check for finish
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b) Electrical clearance check
c) Testing of torque by torque wrenches on all bus bar power connectors and other accessories.
d) Millivolt drop test on all power connectors.
e) Sag and tension check on conductors.
18.5 ALUMINIUM TUBE WELDING
a) Physical check
b) Millivolt drop test on all joints.
c) Dye penetration test & Radiography test on 10% sample basis on weld joints.
c) Test check on 5% sample joints after cutting the weld piece to observe any voids etc.
18.6 INSULATOR
Visual examination for finish, damage, creepage distance etc.
18.7 All pre/commissioning activities and works work for substation equipment shall be carried
out in accordance with owner approved ''Pre- Commissioning procedures and formats for
substation bay equipments". The detailed procedures shall be submitted by the Contractor.
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ANNEXURE “A”
(Testing Procedure for ACSR ‘MOOSE’ Conductor)
1.0 UTS Test on Stranded Conductor
Circles perpendicular to the axis of the conductor shall be marked at two places on a sample
of conductor of minimum 5 m length suitably compressed with dead end clamps at either
end. The load shall be increased at a steady rate upto 80 kN and held for one minute. The
circles drawn shall not be distorted due to Relative movement of strands. Thereafter the load
shall be increased at a steady rate to 161.2 kN and held for one minute. The applied load
shall then be increased until the failing load is reached and the value recorded.
2.0 Corona Extinction Voltage Test
Two samples of conductor of 5m length shall be strung with a spacing of 450 mm between
them at a height not exceeding 8.0 m above ground. This assembly shall be tested as per
Annexure-C, Corona extinction voltage shall not be less than 510 kV (rms) & 320 KV
(RMS) Line to ground for 765 kV & 400 kV respectively.
3.0 Radio Interference Voltage Test
The sample assembly similar to that specified under (2.0) above shall be tested as per
Annexure - C. Maximum RIV level (across 300 ohm resistor at 1 MHz) at 510 kV & 305
KV (RMS) line to ground voltage for 765 kV & 400 kV voltage respectively, shall be 1000
micro volts.
4.0 D.C Resistance Test on Stranded Conductor
On a conductor sample of minimum 5 m length two contact clamps shall be fixed with a pre-
determined bolt torque. The resistance shall be measured by a Kelvin double bridge by
placing the clamps initially zero metre and subsequently one metre apart. The test shall be
repeated at least five times and the average value recorded. The value obtained shall be
corrected to the value at 20°C as per clause no. 12.8 of IS:398 (Part V)-1982. The resistance
corrected at 20°C shall conform to the requirements of this specification.
5.0 Chemical Analysis of Zinc
Samples taken from the zinc ingots shall be chemically/spectrographically analysed. The
same shall be in conformity to the requirements stated in this specification.
6.0 Chemical Analysis of Aluminium and Steel
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Samples taken from the Aluminium ingots/coils/strands shall be
chemically/spectrographically analysed. The same shall be in conformity to the requirements
stated in this specification.
7.0 Visual Check for Joints, Scratches etc.
Conductor drums shall be rewound in the presence of the inspector. The inspector shall
visually check for scratches, joints, etc. and that the conductor generally conform to the
requirements of this specification. The length of conductor wound on the drum shall be
measured with the help of counter meter during rewinding.
8.0 Dimensional Check for Steel and Aluminium Strands.
The individual strands shall be dimensionally checked to ensure that they conform to the
requirements of this specification.
9.0 Check for Lay-ratios of various Layers.
The lay-ratios of various layers shall be checked to ensure that they conform to the
requirements of this specification and clause no. 9.4 and 9.5 of IS-398 (Part - V) 1982.
10.0 Galvanising Test
The test procedure shall be as specified in IS:4826-1968. The material shall conform to the
requirements of this specification.
11.0 Torsion and Elongation Tests on Steel Strands
The test procedures shall be as per relevant clause of IS:398 (Part V), 1982. In torsion test,
the number of complete twists before fracture shall not be less than 18 on a length equal to
100 times the standard diameter of the strand before stranding & 16 after stranding. In case
test sample length of less or more than 100 times the standard diameter of the strand, the
minimum number of twist will be proportionate to the length and if number comes in the
fraction then it will be rounded off to next higher whole number. In elongation test, the
elongation of the strand shall not be less than 4% for a gauge length of 200 mm.
12.0 Breaking load test on welded Aluminium strand:
Two Aluminium wires, shall be welded as per the approved quality plan and shall be
subjected to tensile load. The welded point of the wire shall be able to withstand the
minimum breaking load of the individual strand guaranteed by the bidder.
Volume-II (Section-N), Switchyard Erection 305
ANNEXURE “B”
(Testing procedure for Galvanised Steel Earthwire)
1. UTS TEST
Circles perpendicular to the axis of the earthwire shall be marked at two places on a sample
of earthwire of minimum 5m length suitably compressed with dead end clamps at either end.
The load shall be increased at steady rate upto 34 KN and held for one minute. The circles
drawn shall not be distorted due to relative movement of strands. Thereafter, the load shall
be increased at a steady rate of 68.4 KN and held for one minute. The earthwire sample shall
not fail during this period. The applied load shall then be increased until the failing load is
reached and value recorded.
2. D.C. RESISTANCE TEST
On an earthwire sample of minimum 5m length, two contact clamps shall be fixed with a
predetermined Bolt torque. The resistance shall be measured by a Kelvin double-bridge by
placing the clamps initially zero meter and subsequently one meter apart. The test shall be
repeated at least five times and the average value recorded. The value obtained shall be
corrected to the value at 20°C shall conform to the requirements of this specification.
3. Visual check for joints, scratches etc. and length of earthwire
Earthwire drums shall be rewound in the presence of the inspector. The inspector shall
visually check for joints, scratches etc. and see that the earthwire generally conforms to the
requirements of this specification. The length of earthwire wound on the drum shall be
measured with the help of counter meter during rewinding.
4. TORSION AND ELONGATION TESTS
The test procedure shall be as per relevant clause of IS:398 (Part-V). The minimum number
of twists which a single steel strand shall withstand during torsion test shall be eighteen for a
length equal to 100 times the standard diameter of the strand. In case the test sample length
is less or more than 100 times the standard diameter of the strand, the minimum number of
twists will be proportionate to the length and if number comes in the fraction then it will be
rounded off to next higher whole number. In elongation test, the elongation of the strand
shall not be less than 64% or a gauge length of 200 mm.
5. DIMENSIONAL CHECK
The individual strands shall be dimensionally checked to ensure that they conform to the
requirements of this specification.
Volume-II (Section-N), Switchyard Erection 306
6. LAY LENGTH CHECK
The lay length shall be checked to ensure that they conform to the requirements of this
specification.
7. GALVANISING TEST
The test procedure shall as specified in IS:4826-1968. The material shall conform to the
requirements of this specification.
8. CHEMICAL ANALYSIS OF ZINC USED FOR GALVANIZING
Samples taken from zinc ingots shall be chemically/spectrographically analysed. The same
shall be in conformity to the requirements stated in this specification.
9. CHEMICAL ANALYSIS OF STEEL
Samples taken from steel ingots/coils/strands shall be chemically/ spectrographically
analysed. The same shall be in conformity to the requirements stated in this specification.
Volume-II (Section-N), Switchyard Erection 307
ANNEXURE-C
CORONA AND RADIO INTERFERENCE VOLTAGE (RIV) TEST
1. General
Unless otherwise stipulated, all equipment together with its associated connectors, where
applicable, shall be tested for external corona both by observing the voltage level for the
extinction of visible corona under falling power frequency voltage and by measurement of
radio interference voltage (RIV).
2. Test Levels:
The test voltage levels for measurement of external RIV and for corona extinction voltage
are listed under the relevant clauses of the specification.
3. Test Methods for RIV:
3.1 RIV tests shall be made according to measuring circuit as per International Special-
Committee on Radio Interference (CISPR) Publication 16-1(1993) Part -1. The measuring
circuit shall preferably be tuned to frequency with 10% of 0.5 Mhz but other frequencies in
the range of 0.5 MHz to 2 MHz may be used, the measuring frequency being recorded. The
results shall be in microvolts.
3.2 Alternatively, RIV tests shall be in accordance with NEMA standard Publication No. 107-
1964, except otherwise noted herein.
3.3 In measurement of, RIV, temporary additional external corona shielding may be provided. In
measurements of RIV only standard fittings of identical type supplied with the equipment
and a simulation of the connections as used in the actual installation will be permitted in the
vicinity within 3.5 meters of terminals.
3.4 Ambient noise shall be measured before and after each series of tests to ensure that there is
no variation in ambient noise level. If variation is present, the lowest ambient noise level
will form basis for the measurements. RIV levels shall be measured at increasing and
decreasing voltages of 85%, 100% and 110% of the specified RIV test voltage for all
equipment unless otherwise specified. The specified RIV test voltage for 765 kV, 400 kV,
220 KV is listed in the detailed specification together with maximum permissible RIV level
in microvolts.
3.5 The metering instruments shall be as per CISPR recommendation or equivalent device so
long as it has been used by other testing authorities.
Volume-II (Section-N), Switchyard Erection 308
3.6 The RIV measurement may be made with a noise meter. A calibration procedure of the
frequency to which noise meter shall be tuned shall establish the ratio of voltage at the high
voltage terminal to voltage read by noisel meter.
4. Test Methods for Visible Corona
The purpose of this test is to determine the corona extinction voltage of apparatus,
connectors etc. The test shall be carried out in the same manner as RIV test described above
with the exception that RIV measurements are not required during test and a search
technique shall be used near the onset and extinction voltage, when the test voltage is raised
and lowered to determine their precise values. The test voltage shall be raised to 110% of
RIV test voltage and maintained there for five minutes. In case corona inception does not
take place at 110%, test shall be stopped, otherwise test shall be continued and the voltage
will then be decreased slowly until all visible corona disappears. The procedure shall be
repeated at least 4 times with corona inception and extinction voltage recorded each time.
The corona extinction voltage for purposes of determining compliance with the specification
shall be the lowest of the four values at which visible corona (negative or positive polarity)
disappears. Photographs with laboratory in complete darkeness shall be taken under test
conditions, at all voltage steps i.e. 85%, 100%, and 110%. Additional photographs shall be
taken at corona inception and extinction voltages. At least two views shall be photographed
in each case using Panchromatic film with an ASA daylight rating of 400 with an exposure
of two minutes at a lens aperture of f/5.6 or equivalent. The photographic process shall be
such that prints are available for inspection and comparison with conditions as determined
from direct observation. Photographs shall be taken from above and below the level of
connector so as to show corona on bushing, insulators and all parts of energised connectors.
The photographs shall be framed such that test object essentially, fills the frame with no cut-
off.
In case corona inception does not take place at 110%, voltage shall not be increased further
and corona extinction voltage shall be considered adequate.
4.1 The test shall be recorded on each photograph. Additional photograph shall be taken from
each camera position with lights on to show the relative position of test object to facilitate
precise corona location from the photographic evidence.
4.2 In addition to photographs of the test object preferably four photographs shall be taken of the
complete test assembly showing relative positions of all the test equipment and test objects.
These four photographs shall be taken from four points equally spaced around the test
arrangement to show its features from all sides.
Volume-II (Section-N), Switchyard Erection 309
Drawings of the laboratory and test set up locations shall be provided to indicate camera
positions and angles. The precise location of camera shall be approved by Purchaser’s
inspector, after determining the best camera locations by trial energisation of test object at a
voltage which results in corona.
4.3 The test to determine the visible corona extinction voltage need not be carried out
simultaneously with test to determine RIV levels.
4.4 However, both test shall be carried out with the same test set up and as little time duration
between tests as possible. No modification on treatment of the sample between tests will be
allowed. Simultaneous RIV and visible corona extinction voltage testing may be permitted at
the discretion of Purchaser’s inspector if, in his opinion, it will not prejudice other test.
5. Test Records:
In addition to the information previously mentioned and the requirements specified as per
CISPR or NEMA 107-1964 the following data shall be included in test report:
a) Background noise before and after test.
b) Detailed procedure of application of test voltage.
c) Measurements of RIV levels expressed in micro volts at each level.
d) Results and observations with regard to location and type of interference sources
detected at each step.
e) Test voltage shall be recorded when measured RIV passes through 100 microvolts in
each direction.
f) Onset and extinction of visual corona for each of the four tests required shall be
recorded.
Volume-II (Section-N), Switchyard Erection 310
ANNEXURE – D
A. SHORT CIRCUIT FORCES AND SPACER SPAN FOR 765kV GANTRY STRUCTURE Sl. Max. Span Conductor Ph-Ph Normal SCF per Spacer No. Configuration Spacing Tension Phase span
I. For Fault Level of 40 kA for 1 sec. 1. 54.0 mtr QUAD AAC BULL 15 mtr 3.96 T 5.98 T 3.5 mtr 2. 56.0 mtr QUAD AAC BULL 15 mtr 4.52 T 6.77 T 4.0 mtr 3. 87.9 mtr QUAD AAC BULL 15 mtr 8.35 T 11.22 T 6.5 mtr 4. 104.0 mtr QUAD AAC BULL 15 mtr 9.00 T 12.72 T 7.5 mtr
5. 108.61 mtr QUAD AAC BULL 15 mtr 9.00 T 12.72 T 8.0 mtr
B. SHORT CIRCUIT FORCES AND SPACER SPAN FOR 400kV GANTRY STRUCTURE Sl. Max. Span Conductor Ph-Ph Normal SCF per Spacer No. Configuration Spacing Tension Phase span
I. For Fault Level of 40 kA for 1 sec. 1. 54 mtr QUAD ACSR 7 mtr 4 T 5.64 T 6 mtr 2. 70 mtr TWIN ACSR 7 mtr 4 T 5.64 T 5 mtr 3. 54 mtr QUAD ACSR 6 mtr 4 T 5.10 T 5 mtr 4. 70 mtr TWIN ACSR 6 mtr 4 T 5.10 T 5 mtr 5. 48 mtr QUAD ACSR 6 mtr 4 T 4.82T 5 mtr 6. 52.5 mtr QUAD ACSR 6 mtr 4 T 4.85T 5 mtr 7. 56.5 mtr QUAD ACSR 6 mtr 4 T 4.88T 5 mtr 8. 52.5 mtr TWIN ACSR 6 mtr 4 T 4.97T 5 mtr 9. 56.5 mtr TWIN ACSR 6 mtr 4 T 5.00 T 5 mtr
II. For Fault Level of 50 kA for 1 sec. 1. 48 mtr QUAD AAC BULL 6 mtr 4 T 5.10 T 4 mtr 2. 52.5 mtr QUAD ACSR 6 mtr 4 T 5.18 T 4 mtr 3. 56.5 mtr QUAD ACSR 6 mtr 4 T 5.20 T 4 mtr
III. For Fault Level of 63 kA for 1 sec. 1. 48 mtr QUAD AAC BULL 6 mtr 4 T 6.00 T 4 mtr 2. 52.5 mtr QUAD ACSR 6 mtr 4 T 6.33 T 4 mtr
Volume-II (Section-N), Switchyard Erection 311
C. SHORT CIRCUIT FORCES AND SPACER SPAN FOR 220 kV GANTRY STRUCTURE
Sl. Max. Span Conductor Ph-Ph Normal SCF per SpacerNo. Configuration Spacing Tension Phase span
I. For Fault Level of 40 kA for 1 sec.
1. 54 mtr QUAD ACSR 4.5 mtr 4 T 5.00 T 2.5 mtr2. 54 mtr TWIN ACSR 4.5 mtr 2 T 3.50 T 2.5 mtr3. 74 mtr TWIN ACSR 4.5 mtr 4 T 5.00 T 2.5 mtr4. 54 mtr QUAD ACSR 4.0 mtr 4 T 5.70 T 2.5 mtr5. 54 mtr TWIN ACSR 4.0 mtr 2 T 3.50 T 2.5 mtr6. 74 mtr TWIN ACSR 4.0 mtr 4 T 5.70 T 2.5 mtr7. 48 mtr QUAD ACSR 4.0 mtr 4 T 5.30 T 2.5 mtr8. 52 mtr QUAD ACSR 4.0 mtr 4 T 5.35 T 2.5 mtr9. 68 mtr TWIN ACSR 4.0 mtr 4 T 5.20 T 2.5 mtr10. 56 mtr QUAD ACSR 4.0 mtr 4 T 5.50 T 2.5 mtr11. 72 mtr TWIN ACSR 4.0 mtr 4 T 5.27 T 2.5 mtr
II. For Fault Level of 50 kA for 1 sec.
1. 48 mtr QUAD ACSR 4.0 mtr 4 T 5.41 T 2.0 mtr2. 52 mtr QUAD ACSR 4.0 mtr 4 T 5.50 T 2.0 mtr3. 36 mtr TWIN ACSR 4.0 mtr 2 T 3.50 T 2.0 mtr
NOTE: ACSR conductor as mentioned above indicates that it is suitable for both
ACSR MOOSE as well as ACSR BERSIMIS conductor.
3. 56.5 mtr QUAD ACSR 6 mtr 4 T 6.37 T 4 mtr
Volume-II (Section-N), Switchyard Erection 312
ANNEXURE-E
STANDARD TECHNICAL DATA SHEETS FOR AAC/ACSR CONDUCTORS, GS EARTHWIRE AND ALUMINIUM TUBE
1.0 GENERAL Owner has stardardised the guaranteed technical particulars for the following
AAC/ACSR conductors, Galvanised steel earthwire and aluminum tube. The contractor shall supply the conductors as per the standard GTP mentioned below. Any deviation to the following GTP shall be clearly brought out by the bidder in their bid.
1.1 Guaranteed Technical Particulars (GTP) for conductors: A.
GTP of AAC BULL and AAC TARANTULA conductor:
S.No. Description Unit AAC BULL AAC TARANTULA
1.0 Applicable Standard IS:398
2.0 Raw Materials
2.1 Steel Wire / Rods
2.1.1 Aluminium
a) Minimum purity of % 99.50 99.50 Aluminium
b) Maximum copper % 0.04 0.04 content
3.0 Aluminum strands after stranding
3.1 Diameter
a) Nominal mm 4.25 5.23
b) Maximum mm 4.29 5.28
c) Minimum mm 4.21 5.18
3.2 Minimum breaking load of strand
a) Before stranding KN 2.23 3.44
b) After stranding KN 2.12 3.27
3.3 Maximum resistance of Ohm 0.00203 0.001341 1 m length of strand at
20 deg. C
4.0 AAC Conductor
4.1. a) Stranding Al – 61/4.25 mm Al – 37/ 5.23 mm
b) Number of Strands
i. 1st Aluminium Layer Nos. 1 1
ii. 2nd Aluminium Layer Nos. 6 6
iii. 3rd Aluminium Layer Nos. 12 12
iv. 4th Aluminium Layer Nos. 18 18
Volume-II (Section-N), Switchyard Erection 313
S.No. Description Unit AAC BULL AAC
TARANTULA
v. 5th Aluminium Layer Nos. 24 -
4.2 Sectional Area of Sq. 865.36 794.80
aluminium mm
4.3 Total sectional area Sq. 865.36 794.80
mm
4.4 Approximate Weight Kg/m 2.4 2.191
4.5 Diameter of the mm 38.25 36.60
conductor
4.6 UTS of the conductor kN 139 (Min.) 120 (Min.)
4.7 Lay ratio of the mm Max Max Min conductor Min
a) 6 wire Aluminium layer mm 16 16 10 10
b) 12 wire Aluminium mm 16 16 10 layer 10
c) 18 wire Aluminium mm 16 14 10 layer 10
d) 24 wire Aluminium mm 14 - - layer 10
4.8 DC resistance of the ohm/ 0.03340 0.03628
conductor at 20°C km
4.9 Standard length of the m 1000 1000
conductor
4.10 Tolerance on Standard % (+/-) 5 (+/-) 5
length
4.11 Direction of lay of Right Hand Right Hand
outer layer
4.12 Linear mass of the conductor
a) Standard kg/ 2400 2192
km
b) Minimum kg/ 2355 2150
km
c) Maximum kg/ 2445 2234
km
4.13 Modulus of Elasticity Kg/sq 4709 (Initial) 4709 (Initial)
.mm 5869 (Final) 5869 (Final)
4.14 Co-efficient of Linear Per 23.0x10-6
23.0x10-6
Expansion Deg.
C
4.15 Minimum Corona KV 508 320
Extinction Voltage (rms)
4.16 RIV at 1 Mhz Micro Less than 1000 Less than 1000 at
volts at 508 kV (rms) 320 kV (rms)
5.0 Drum Dimensions Generally conforms to IS:1778
a) Flange Diameter mm 1855 1855
b) Traverse width mm 925 925
c) Barrel Diameter mm 850 850
Volume-II (Section-N), Switchyard Erection 314
S.No. Description Unit AAC BULL AAC
TARANTULA
d) Flange thickness mm 50x50 50x50
B. GTP of ACSR BERSIMIS and ACSR MOOSE conductor:
S.No. Description Unit ACSR ACSR MOOSE
BERSIMIS
1.0 Applicable Standard IS:398 / IEC - 1089
2.0 Raw Materials
2.1 Aluminium
a) Minimum purity of % 99.50 99.50
Aluminium
b) Maximum copper % 0.04 0.04
content
2.2 Steel wires/ rods
a) Carbon % 0.50 to 0.85 0.50 to 0.85
b) Manganese % 0.50 to 1.10 0.50 to 1.10
c) Phosphorous % Not more than Not more than
0.035 0.035
d) Sulphur % Not more than Not more than
0.045 0.045
e) Silicon % 0.10 to 0.35 0.10 to 0.35
(Max.) (Max.)
2.3 Zinc
a) Minimum purity of Zinc % 99.95 99.95
3.0 Aluminum strands after stranding
3.1 Diameter
a) Nominal mm 4.57 3.53
b) Maximum mm 4.61 3.55
c) Minimum mm 4.53 3.51
3.2 Minimum breaking load of strand
a) Before stranding KN 2.64 1.57
b) After stranding KN 2.51 1.49
3.3 Maximum resistance of Ohm 0.001738 0.002921
1 m length of strand at
20 deg. C
4.0 Steel strand after stranding
4.1 Diameter
a) Nominal mm 2.54 3.53
b) Maximum mm 2.57 3.60
c) Minimum mm 2.51 3.46
Volume-II (Section-N), Switchyard Erection 315
S.No. Description Unit ACSR ACSR MOOSE
BERSIMIS
4.2 Minimum breaking load of strand
a) Before stranding KN 6.87 12.86
b) After stranding KN 6.53 12.22
4.3 Galvanising
a) Minimum weight of gm 260 260
zinc coating per sq.m.
b) Minimum number of Nos. 2 dips of one 2 dips of one
dips that the minute & 1 dip of minute & 1 dip of
galvanised strand can half minute half minute
withstand in the
standard preece test
c) Min. No. of twists in Nos 16 (After stranding) 16 (After stranding)
guage length equal 18 (Before 18 (Before
100 times the dia. of stranding) stranding)
wire which the strand
can withstand in the
torsion test (after
stranding)
5.0 ACSR Conductor
5.1.a) Stranding Al -42/4.57 mm+ Al -54/3.53 mm+ Steel-7/2.54 mm Steel-7/3.53 mm
b) Number of Strands
i. Steel centre Nos. 1 1
ii. 1st Steel Layer Nos. 6 6
iii. 1st Aluminium Layer Nos. 8 12
iv. 2nd Aluminium Layer Nos. 14 18
v. 3rd Aluminium Layer Nos. 20 24
5.2 Sectional Area of Sq. 689.50 528.50
aluminium mm
5.3 Total sectional area Sq. 725.00 597.00
mm
5.4 Approximate Weight Kg/m 2.181 2.004
5.5 Diameter of the mm 35.05 31.77
conductor
5.6 UTS of the conductor kN 154 (Min.) 161.20 (Min.)
5.7 Lay ratio of the mm Max Max Min conductor
a) Outer Steel layer mm 24 18 16 16
b) 8/12 wire Aluminium mm 17 14 12 layer 10
c) 14/ 18 wire Aluminium mm 16 13 11 layer 10
d) 20/24 wire Aluminium mm 13 12 10 layer 10
Volume-II (Section-N), Switchyard Erection 316
S.No. Description Unit ACSR ACSR MOOSE
BERSIMIS
5.8 DC resistance of the ohm/ 0.04242 0.05552
conductor at 20°C km
5.9 Standard length of the m 1800 1800
conductor
5.10 Tolerance on Standard % (+/-) 5 (+/-) 5
length
5.11 Direction of lay of - Right Hand Right Hand
outer layer
5.12 Linear mass of the conductor
a) Standard kg/ 2181 2004
km
b) Minimum kg/ 2142 1965
km
c) Maximum kg/ 2221 2045
km
5.13 Modulus of Elasticity Kg/sq 6860
(Final State) .mm
5.14 Co-efficient of Linear Per 21.5x10-6
19.3x10-6
Expansion Deg.
C
5.15 Minimum Corona KV 320 320
Extinction Voltage (rms)
5.16 RIV at 1 Mhz under Micro Max. 1000 at Max. 1000 at 320
dry condition volts 320 kV (rms) kV (rms)
6.0 Drum Dimensions Generally conforms to IS:1778
a) Flange Diameter mm 1800 1800
b) Traverse width mm 950 950
c) Barrel Diameter mm 650 650
d) Flange thickness mm 50x50 50x50
C. B. GTP of ACSR ZEBRA and ACSR PANTHER conductor:
S.No. Description Unit ACSR ZEBRA ACSR PANTHER
1.0 Applicable Standard IS:398 / IEC-1089
2.0 Raw Materials
2.1 Aluminium
a) Minimum purity of % 99.50 99.50
Aluminium
b) Maximum copper % 0.04 0.04
content
2.2 Steel wires/ rods
a) Carbon % 0.50 to 0.85 0.50 to 0.85
b) Manganese % 0.50 to 1.10 0.50 to 1.10
c) Phosphorous % Not more than Not more than
0.035 0.035
Volume-II (Section-N), Switchyard Erection 317
S.No. Description Unit ACSR ZEBRA ACSR PANTHER
d) Sulphur % Not more than Not more than
0.045 0.045
e) Silicon % 0.10 to 0.35 0.10 to 0.35
(Max.) (Max.)
2.3 Zinc
a) Minimum purity of Zinc % 99.95 99.95
3.0 Aluminum strands after stranding
3.1 Diameter
a) Nominal mm 3.18 3.00
b) Maximum mm 3.21 3.03
c) Minimum mm 3.15 2.97
3.2 Minimum breaking load of strand
a) Before stranding KN 1.29 1.17
b) After stranding KN 1.23 1.11
3.3 Maximum resistance of Ohm 0.003626 0.004107
1 m length of strand at
20 deg. C
4.0 Steel strand after stranding
4.1 Diameter
a) Nominal mm 3.18 3.00
b) Maximum mm 3.24 3.06
c) Minimum mm 3.12 2.94
4.2 Minimum breaking load of strand
a) Before stranding KN 10.43 9.29
b) After stranding KN 9.91 8.85
4.3 Galvanising
a) Minimum weight of gm 260 260
zinc coating per sq.m.
b) Minimum number of Nos. 2 dips of one 2 dips of one
dips that the galvanised minute & 1 dip of minute & 1 dip of
strand can withstand in half minute half minute
The standard preece
test
c) Min. No. of twists in Nos 16 (After 16 (After stranding)
guage length equal stranding) 18 (Before
18 (Before
100 times the dia. of stranding)
stranding)
wire which the strand
can withstand in the
torsion test (after
stranding)
5.0 ACSR Conductor
Volume-II (Section-N), Switchyard Erection 318
S.No. Description Unit ACSR ZEBRA ACSR PANTHER5.1.a) Stranding Al -54/3.18 mm+ Al -30/3.00 mm+
Steel-7/3.18 mm Steel-7/3.00 mm
b) Number of Strands
i. Steel centre Nos. 1 1
ii. 1st Steel Layer Nos. 6 6
iii. 1st Aluminium Layer Nos. 12 12
iv. 2nd Aluminium Layer Nos. 18 18
v. 3rd Aluminium Layer Nos. 24 NA
5.2 Sectional Area of Sq. 428.9 212.10
aluminium mm
5.3 Total sectional area Sq. 484.5 261.50
mm
5.4 Approximate Weight Kg/m 1.621 0.974
5.5 Diameter of the Mm 28.62 21.00
conductor
5.6 UTS of the conductor kN 130.32 (Min.) 89.67 (Min.)
5.7 Lay ratio of the mm Max Min Max Min conductor
a) Outer Steel layer mm 28 13 28 16
b) 12 wire Aluminium mm 17 10 16 10 layer
c) 18 wire Aluminium mm 16 10 14 10 layer
d) 24 wire Aluminium mm 14 10 NA
layer NA
5.8 DC resistance of the ohm/ 0.06868 0.140
conductor at 20°C km
5.9 Standard length of the m 1800 1800
conductor
5.10 Tolerance on Standard % (+/-) 5 (+/-) 5
length
5.11 Direction of lay of Right Hand Right Hand
outer layer
5.12 Linear mass of the conductor
a) Standard kg/ 1621 974
km
b) Minimum kg/ 1589 954
km
c) Maximum kg/ 1653 993
km
5.13 Modulus of Elasticity Kg/sq 8158
.mm
5.14 Co-efficient of Linear Per 19.3x10-6
17.8x10-6
Expansion Deg.
C
Volume-II (Section-N), Switchyard Erection 319
Sl. Description Unit ACSR ZEBRA ACSR PANTHER
5.15 Minimum Corona KV 154 92
Extinction Voltage (rms)
5.16 RIV at 1 Mhz Micro Less than 1000 Less than 500
volts at 154 kV (rms) at 92 kV (rms)
6.0 Drum Dimensions Generally conforms to IS:1778
a) Flange Diameter mm 1850 1850
b) Traverse width mm 925 925
c) Barrel Diameter mm 650 650
d) Flange thickness mm 50x50 50x50
1.2 Guaranteed technical particulars of Galvanised Steel Earthwire
Description Unit Standard Values
1.0 Raw Materials
1.1 Steel wires / rods
a) Carbon % Not more than 0.55
b) Manganese % 0.40 to 0.90
c) Phosphorous % Not more than 0.04
d) Sulphur % Not more than 0.04
e) Silicon % 0.15 to 0.35
1.2 Zinc
a) Minimum purity of Zinc % 99.95
2.0 Steel strands
2.1 Diameter
a) Nominal mm 3.66
b) Maximum mm 3.74
c) Minimum mm 3.58
2.2. Minimum breaking load of strand
a) After stranding KN 10.58
2.3 Galvanising
a) Minimum weight of zinc coating gms. 275
per sq.m. after stranding
b) Minimum number of dips that the Nos. 3 dips of 1 minute and
galvanized strand can withstand one dip of ½ minute
in the standard preece test
c) Minimum number of twists in a Nos. 18
gauge length equal to 100 times
diameter of wire which the
strand can withstand in the
torsion test, after stranding
3.0 Stranded Earth wire
Volume-II (Section-N), Switchyard Erection 320
3.1 UTS of Earth wire KN 68.4 (min.)
3.2 Lay length of outer steel layer
a) Standard mm 181
b) Maximum mm 198
c) Minimum mm 165
3.3 Maximum DC resistance of Ohm/km 3.375
earth wire at 200 C
3.4 Standard length of earth wire M 2000 or actual quantity
whichever is less.
3.5 Tolerance on standard length % ±5
3.6 Direction of lay for outside Right hand
layer
3.7 Linear mass
a) Standard Kg/km 583
b) Maximum Kg/km 552
c) Minimum Kg/km 600
3.8 Overall diameter mm 10.98
1.3 Guaranteed Technical Parameters of Aluminum Tube
A. GTP for 3” IPS & 4” IPS AL. TUBE
Sl. No. Description 3” AL. TUBE 4” AL. TUBE
1. Size 3" IPS (EH Type) 4" IPS (EH Type)
2. Material Aluminium Alloy 6101 T6 confirms to
63401 WP (range 2) of IS 5082 : 1998
3. Chemical Composition
i) Cu 0.05 Max
ii) Mg 0.4 to 0.9
iii) Si 0.3 to 0.7
iv) Fe 0.5 Max
v) Mn 0.03 Max
Vi) Al Remainder
4. Outer diameter 88.90 mm 114.2 mm
5. Tolerance on outer +2.2 m, - 0.0 m +2.2 m, - 0.0 m
diameter
6. Thickness 7.62 mm 8.51 mm
7. Tolerance on thickness +2.2 m, - 0.0 m +2.2 m, - 0.0 m
8. Cross-sectional area 1945.76 sq.mm 2825.61 sq.mm
9. Weight 5.25 kg/m 7.7 kg/m
10. Moment of Inertia 3999760.0 mm4
3970979.837 mm4
11. Section Modulus 69989.0 mm3
69544.3 mm3
12. Minimum Ultimate Tensile 20.5 Kg/sq.mm
Strength
13. Temperature co-efficient of 0.00364 per Deg.C
resistance
14. Minimum Electrical 55% of IACS
Conductivity at 20 deg.C
15. Linear Temperature Co- 0.000023
efficient of Expansion (20
Deg.C -200 Deg.C)
Volume-II (Section-N), Switchyard Erection 321
16. Modulus of Elasticity 6700 Kg/sq.mm
17. Minimum Elongation on 50 10%
mm
18. Thermal Conductivity at 100 0.43 Calories/sec/sq.mm/cm/deg.C Deg.C
19. Minimum 0.2% proof stress 17.34 Kg/sq.mm 20 Minimum Yield point 17.50 Kg/sq.mm 17.50 Kg/sq.mm21 Minimum Breaking Strength 20.42 Kg/sq.mm 20.42 Kg/sq.mm
B. GTP for 4.5” IPS & 5” IPS AL. TUBE
Sl. No. Description 4.5” AL. TUBE 5” AL. TUBE1. Size 4.5" IPS (EH Type) 5" IPS 2. Material Aluminium Alloy 6101 T6 confirms to
63401 WP (range 2) of IS 5082 : 19983. Chemical Composition
i) Cu 0.05 Max ii) Mg 0.4 to 0.9 iii) Si 0.3 to 0.7 iv) Fe 0.5 Max v) Mn 0.03 Max
Vi) Al Remainder 4. Outer diameter 120.0 mm 141.3 mm 5. Tolerance on outer +1.5 m, - 0.0 m +2.8 m, - 0.0 m
diameter
6. Thickness 12.0 mm 9.53 mm 7. Tolerance on thickness +1.0 m, - 0.0 m +0.8 m, - 0.0 m8. Cross-sectional area 4071.50 sq.mm 3945.11 sq.mm9. Weight 10.993 kg/m 10.652 kg/m
10. Moment of Inertia 59998841.86 mm4
3970979.837 mm
4 11. Section Modulus 99980.70 mm
3 69544.3 mm
3
12. Minimum Ultimate Tensile 20.5 Kg/sq.mm Strength
13. Temperature co-efficient of 0.00364 per Deg.C resistance
14. Minimum Electrical 55% of IACS Conductivity at 20 deg.C
15. Linear Temperature Co- 0.000023 efficient of Expansion (20
Deg.C -200 Deg.C)
16. Modulus of Elasticity 6700 Kg/sq.mm 17. Minimum Elongation on 50 10%
mm
18. Thermal Conductivity at 100 0.43 Calories/sec/sq.mm/cm/deg.C Deg.C
19. Minimum 0.2% proof stress 17.34 Kg/sq.mm 20 Minimum Yield point 14.50 Kg/sq.mm 17.50 Kg/sq.mm21 Minimum Breaking Strength 17.50 Kg/sq.mm 20.42 Kg/sq.mm
Volume-II (Section-O), Structures 322
SECTION- (O)
TECHNICAL DETAILS OF STRUCTURES
1.0 GENERAL
1.1 The scope of specification covers fabrication, proto-assembly, supply and erection of galvanized
steel structures for towers, girders, lightning masts and equipment support structures. Towers,
girders, lightning masts and equipment support structures. Towers, girders and lightning masts
shall be lattice type structure fabricated from structural steel conforming to IS 2062(latest).All
equipment support structures shall be fabricated from GI pipe conforming to YST 22 or of higher
grade as per IS 806 except for 132 kV and below for which the equipment structure shall be of
Lattice type.
The fabrication drawings along with BOM shall be provided to the successful bidder after the
award. Contractor shall only use these standard drawings for fabrication. Support structure for
circuit breaker is not standardized and shall be designed by the Contractor and approved by the
owner. Any other structures of 765/400kV/220/132kV class necessary to suit the layout for a
particular substation to complete the work in all its requirements shall be designed by the owner
at detailed Engineering stage. Design & drawing of structure other than 400kV/220kV class shall
also be prepared by the owner at detailed engineering stage.
It is the intent of the owner to provide structures which allow interchangeability of equipments at
a later stage. Accordingly equipment support structure standardization has been carried out with
the provision of stool. Stools shall be provided by the Contractor between the equipment and its
support structure to match the bus bar height. The top of stool shall be connected to the
equipment and the bottom of the stool shall be connected to the support structure. Details of the
stools shall be submitted to Owner for approval.
The scope shall include supply and erection of all types of structures including bolts, nuts,
washers, hangers, shackles, clamps ant climbing devices, bird guards, step bolts, inserts in
concrete, gusset plates, equipment mounting bolts, structure earthling bolts, foundation bolts,
spring washers, fixing plates, ground mounted marshalling boxes (AC/DC Marshalling box &
equipment control cabinets), structure mounted marshalling boxes and any other items as required
to complete the job.
The connection of all structures to their foundations shall be by base plates and embedded
anchor/foundation bolts. All steel structures and anchor/foundation bolts shall be fully
galvanized. The weight of the zinc coating shall be at least 0.610kg/m2 for anchor
Volume-II (Section-O), Structures 323
bolts/foundation bolts and for structural members. One additional nut shall be provided below the
base plate which may be used for the purpose of leveling.
Suitable modification shall be carried out in the drawings of equipment support structures by the
Contractor in order to suit fixation of accessories such as marshalling boxes, MOM boxes Control
Cabinets, Junction box, surge counter, etc. in the standard structure fabrication drawings.
Drawings of fixing of such accessories shall be submitted by the Contractor for approval.
2.0 DESIGN REQUIREMENTS FOR STRUCTURES NOT COVERED IN STANDARDISED
LIST
2.1 For design of steel structures loads such as dead loads, live loads, wind loads etc. shall be based
on IS:875, Part I to V
2.2 For materials and permissible stresses IS: 802, Part-I, Section-2 shall be followed in general.
However, additional requirements given in following paragraphs shall be also considered.
2.3 Minimum thickness of galvanized tower member shall be as follows:
Members’ Minimum thickness
(mm)
Leg members, Ground wire
Peak members/Main members 5
Other members 4
Redundant members 4
2.4 Maximum slenderness rations for leg members, other stressed members and redundant members
for compression force shall be as per IS-802.
2.5 Minimum distance from hole center to edge shall be 1.5 x bolt diameter.
Minimum distance between center to center of holes shall be 2.5 x bolt diameter.
2.6 All bolts shall be M16 of higher as per design requirement.
2.7 Step Bolts
Volume-II (Section-O), Structures 324
In order to facilitate inspection an maintenance, the structures shall be provide with climbing
devices. Each tower shall be provided with M16 step bolts 175mm long spaced not more than
450mm apart, staggered on faces one leg extending from about 0.5 meters above ground level to
the top of the tower. The step bolt shall conform to IS: 10238. Ladders along with safety guard
shall be provided for the Lightening Mast Tower.
2.8 Design criteria (To be referred only for structures for which design is included in the scope
of the Contractor)
A) All structures shall be designed for the worst combination of dead loads, live loads, wind loads as
per code IS:875, seismic forces as per code IS:1893 (latest), Importance factor of 1.5, loads due to
deviation of conductor, load due to unbalanced tension in conductor, torsional load due to
unbalanced vertical and horizontal forces, erection loads, short circuit forces including “snatch”
in the case of bundled conductors etc. Short circuit forces shall be calculated considering a fault
level of 40.0kA. IEC-865 may be followed for evaluation of short circuit forces.
B) Switchyard gantry structures shall be designed for the tow conditions i.e. normal condition and
short circuit condition. In both conditions the design of all structures shall be based on the
assumption that stringing is done only on one side i.e. all the three (phase) conductors broken on
the other side.
Factor of safety of 2.0 under normal conditions and 1.5 under short circuit condition shall be
considered on all external loads for the design of switchtyard structures.
C) Vertical load of half the span of conductors/string and the earth wires on either side of the beam
shall be taken into account for the purpose of design. Weight of man with tools shall be
considered as 150kgs. For the design of structures.
D) Terminal/line take off gantries shall be designed for a minimum conductor tension of 4 metric
tonnes per phase for 400 kv and 2 metric tonnes per phase for 220kv, 1 tonne per phase for
132kV or as per requirements whichever is higher. The distance between terminal gantry and
dead end tower shall be taken as 200 meters.
The design of these terminal gantries shall also be checked considering +/-30 deg deviation of
conductor in both vertical and horizontal planes. For other gantries the structural layout
requirements shall be adopted in design.
E) The girders shall be connected with lattice columns by bolted joints.
Volume-II (Section-O), Structures 325
F) All Pipe support used for supporting equipments shall be designed for the worst combination of
dead loads, erection load. Wind load/seismic forces, short circuit forces and operating forces
acting on the equipment and associated bus bars as per IS:806. The material specification shall be
as per IS: 1161 read in conjunction with IS: 806.
G) If luminaries are proposed to be fixed on gantries/towers, then the proper loading for the same
shall be considered while designing. Also holes for fixing the brackets for luminaries should be
provided wherever required.
H) Foundation bolts shall be designed for the loads for which the structures are designed.
I) Lightning Mast shall be 50m in height (47.5m lattice structure plus 2.5m pipe) and designed for
diagonal wind condition. Lightning masts shall be provided with a structural steel ladder within
its base up to a height of 25 meter. The ladder shall be provided with protection rings. Tow
platforms shall be provided one each at 12.5m and 25.0m height for mounting of lighting fixtures.
The platforms shall also have protection railing. The details of lighting fixtures would be as per
the approved drawings.
3.0 DESIGN DRAWINGS, BILL OF MATETRIALS AND DOCUMENTS
3.1 FOR STANDARD STRUCTURES
3.1.1 Towers, girders, lightning masts, equipment support structures etc of 400/220kV class have all
been standardized by the owner and fabrication drawings (structure assembly drawing) along with
Bill of Material shall be provided by the owner for all these standard structures to the successful
bidder after letter of award based on which structures shall be supplied.
3.1.2 Contractor shall however not be relieved of his responsibility for the safety of the structure and
good connections and any loss or damage occurring due to defective fabrication, erection or
workmanship shall be borne by the Contractor.
3.2 FOR STRUCTURES DESIGNED BY CONTRACTOR (To be referred only for structures for
which design is included in the scope of the Contractor)
3.2.1 The Contractor shall furnish design, drawing and BOMs and shop manufacturing drawings for
every member to the owner after award of the Contract. The design drawing should indicate not
only profile, but section, numbers and sizes of bolts and details of typical joints. In case owner
feels that any design drawing, BOM are to be modified even after its approval, Contractor shall
modify the designs & drawings and resubmit the design drawing, BOM as required in the
specification.
Volume-II (Section-O), Structures 326
3.2.2 The fabrication drawings to be prepared and furnished by the Contractor shall be based on the
design approved by the owner. These fabrication drawings shall indicate complete details of
fabrication and erection including all erection splicing details and typical fabrication splicing
details, lacing details, weld sizes and lengths. Bolt details and all customary details in accordance
with standard structural engineering practice whether or not given by the owner. The fabrication
drawings shall be submitted to the owner. Proto shall be made only after approval of fabrication
drawings.
3.2.3 Such approval shall, however, not relieve the Contractor of his responsibility for the safety of the
structure and good connections and any loss or damage occurring due to defective fabrication,
design or workmanship shall be borne by the Contractor.
3.3 The Mass fabrication work shall start only after the final approval to the proto corrected
Fabrication drawing is accorded y the owner. Proto- assembly shall be required to be carried out
only for those structures that have not been proto-assembled by the same fabricators for this
contract or for earlier contracts from OWNER. Wherever proto-assembly is not to be repeated,
proto-corrected drawings shall be submitted directly with a note on the drawing stating that proto-
assembly has been carried out under a particular previous contract.
4.0 FABRICATION OF STEEL MEMBERS
4.1 The fabrication and erection works shall be carried out generally in accordance with IS 802. A
reference however may be made to IS 800 in case of non-stipulation of some particular provision
in IS 802. All materials shall be completely shop fabricated and finished with proper connection
material and erection marks for ready assembly in the field.
5.0 PROTO- ASSEMBLY
i) The components parts shall be assembled in such manner that they are neither twisted nor
otherwise damaged and shall be so prepared that the specified camber, if any, is provided.
In order to minimize distortion in member the component parts shall be positioned by
using the clamps, clips,dogs,jigs and other suitable means and fasteners(bolts and welds)
shall be placed in a balanced pattern. If the individual components are to be bolted,
paralleled and tapered drifts shall be used to align the part so that the bolts can be
accurately positioned.
ii) Sample towers, beams and lightning masts and equipment support structures shall be trial
assembled in the fabrication shop and shall be inspected and cleared-by Contractor based
Volume-II (Section-O), Structures 327
on the approved fabrication drawing before mass fabrication. Owner may opt to witness
such trial assembly.
For all structures, B.O.Ms along with proto corrected fabrication drawings shall be
prepared and submitted to owner as document for information. Such BOM, which shall
be duly certified by the Contractor for its conformity to the drawings issued by Owner,
shall be the basis for owner to carry out inspection.
6.0 BOLTING
i) Every bolt shall be provided with a washer under the nut so that no part of the threaded
portion of the bolt is within the thickness of the parts bolted together.
ii) All steel items, bolts, nuts and washers shall be hot dip galvanized.
iii) 2.0% extra nuts and bolts shall be supplied for erection.
7.0 WELDING
The work shall be done as per approved fabrication drawings which shall clearly indicate various
details of joints to be welded, type of weld, length and size of weld, whether shop or site weld etc.
Symbols for welding on erection and shop drawings shall be according to IS: 813. Efforts shall be
made to reduce site welding so as to avoid improper joints due to constructional difficulties.
8.0 FOUNDATION BOLTS
8.1 Foundation bolts for the towers and equipment supporting structures and elsewhere shall be
embedded in first stage concrete while the foundation is cast. The Contractor shall ensure the
proper alignment of these bolts to match the holes in the base plate.
8.2 The Contractor shall be responsible for the correct alignment and leveling of all steel work on site
ensures that the towers/structures are plumb.
8.3 All foundation bolts for lattice structure, pipe structure are to be supplied by the Contractor.
8.4 All foundation bolts shall be fully galvanized so as to achieve 0.61kg. per Sq.m. of Zinc Coating
as per specifications.
8.5 All foundation bolts shall conform to IS 5624 but the material, however shall be MS conforming
to IS: 2062.
Volume-II (Section-O), Structures 328
9.0 STABILITY OF STRUCTURE
The supplier shall be responsible for the stability of the structure at all stages of its erection at site
and shall take all necessary measures by the additions of temporary bracings and guying to ensure
adequate resistance to wind and also to loads due to erection equipment and their operations.
10.0 GROUTING
The method of grouting the column bases shall be subject to approval of owner and shall be such
as to ensure a complete uniformity of contact over the whole area of the steel base. The
Contractor will be fully responsible for the grouting operations.
11.0 GALVANISING
11.1 All structural steel works and pipe supports shall be galvanized after fabrication.
11.2 Zinc required for galvanizing shall have to be arranged by the manufacturer. Purity of zinc to be
used shall be 99.95% as per IS: 209.
11.3 The contractor shall be required to make arrangement for frequesnt inspection by the owner as
well as continuous inspection by a resident representative of the owner, if so desired for
fabrication work.
12.0 TOUCH-UP PANTING
The touch up primers and paints shall consist of Red Oxide/Zinc chromate conforming to the
requirements of IS: 2074 with a pigment to be specified by the owner.
13.0 INSPENTION BEFORE DISPATCH
Each part of the fabricated steel work shall be inspected as per approved quality plans and
certified by the owner or his authorized representative as satisfactory before it is dispatched to the
erection site. Such certification shall not relieve the Contractor of his responsibility regarding
adequacy and completeness of fabrication.
14.0 TEST CERTIFICATE
Copies of all test certificates relating to material procured by the Contractor for the works shall be
forwarded to the owner.
15.0 ERECTION
Volume-II (Section-O), Structures 329
The Contractor should arrange on his own all plant and equipment, welding set, tools and tackles,
scaffolding, trestles equipments and all other accessories and ancillaries required for carrying out
erection without causing any stresses in the members which may cause deformation and
permanent damage.
16.0 MODE OF MEASURMENT
The measurement of the standard lattice and pipe structures for towers, beams, equipment support
structure etc. shall be made in numbers for each type of structures. This will include foundation
bolts and nuts and therefore no separate payment shall be made for the same. The unit rate quoted
for each type of structures shall be inclusive of supply, fabrication, galvanizing, erection, nuts,
bolts, wastages etc. complete. Nothing extra shall be payable for substitution necessitated due to
non- availability of section indicated in the standard drawing. Nothing extra shall be payable for
modifications or steel added to suit the contractors fixing arrangements for accessories etc.
The measurement of the non-standard lattice and pipe structure of tower structure, beam,
equipment structure etc. shall be measured in MT including the weight of foundation bolt. The
unit rate quoted shall be inclusive of supply, fabrication, galvanizing, erection, nuts, bolts,
(excluding foundation bolts), washers, wastages etc complete.
17.0 SAFETY PRECAUTIONS
The Contractor shall strictly follow at all stages of fabrication, transportation and erection of steel
structures, raw materials and other tools and tackles, the stipulations contained in Indian Standard
Code for Safety during erection of structural steel work-IS: 7205.
18.0 All tests mentioned in standard field quality plans have to be carried out and conformity of
materials and workmanship shall be ascertained.
Volume-II (Section-P), Fire Protection System 330
SECTION- (P)
TECHNICAL DETAILS OF FIRE PROTECTION SYSTEM
1.0 INTENT OF SPECIFICATION
This section covers the design and performance requirements of the following types of fire
protection systems;
a. Hydrant System
b. High Velocity Water (H.V.W) Spray System
c. Fire Detection and alarm System
d. Portable Fire Extinguishers
e. Wheel/ Trolley mounted Fire Extinguishers
1.1 It is not the intent to completely specify all details of design and construction. Nevertheless, the
system design and equipment shall conform in all respects to high standard of engineering, design
and workmanship and shall be capable of performing in continuous commercial operation in a
manner acceptable to the Owner. The system design shall also conform to TAC/ NFPA norms.
1.2 The scope of work include complete earthwork (i.e. excavation, backfilling etc.) for the entire
buried piping for the system, valve pits and pipe supports for buried, entrenched and over ground
piping.
1.3 The equipment offered shall comply with the relevant Indian Standards. The equipment
conforming to any other approved international standards shall meet the requirement called for in
the latest revision of relevant Indian Standard or shall be superior. The Deluge valves, HVW
spray nozzles & quartzoid bulb detectors shall have the approval of any of the following
agencies;
a. UL of USA.
b. F M of USA
c. LPCB of UK or
d. VDS of Germany,
1.4 Ambient temperature for design of all equipment shall be considered as 50°C.
1.5 The piping and instruments diagram for Hydrant and HVW spray system for
765kV/400kV/220kV/132kVsubstations shall be prepare by successful bidder. Detailed layout
Volume-II (Section-P), Fire Protection System 331
and piping drawing based on this drawing and other drawings such as road, drainage, cable
trench, switch yard layout, etc. as furnished by the Employer during detailed engineering.
1.6 Equipment under the fire protection system should be supplied from the suppliers approved by
Owner. All equipment shall conform to the data sheets attached in Appendix–1 and/or relevant
subsections/clauses of this specification. In case of contradiction between data specification
sheets and relevant subsections/clauses, then stipulations of the data sheets will prevail.
2.0 DESIGN AND CONSTRUCTION
2.1 Hydrant System
Hydrant system of fire protection essentially consists of a large network of pipe, both
underground and over ground which feeds pressurized water to a number of hydrant valves,
indoor (if applicable) as well as outdoor. These hydrant valves are located at strategic locations
near buildings, Transformers and Reactors. Hose pipes of suitable length and fitted with standard
accessories like branch pipes, nozzles etc. are kept in Hose boxes. In case of emergency, these
hoses are coupled to the respective hydrant valves through instantaneous couplings and jet of
water is directed on the equipment on fire. Hydrant protection shall be provided for the following
in substations of voltage levels 400kV and above. At least one hydrant post shall be provided for
every 60m of external wall measurement of buildings.
a) Control room building
b) L.T. Transformer area
c) Fire Fighting pump House.
d) Stores
e) Transformers
f) Shunt Reactors/ Bus Reactors.
2.1.1 *Each transformer and reactor is to be protected by H.V.W. spray type fire protection essentially
consisting of a network of projectors and an array of heat detectors around the system .The
system shall be designed in such a way that the same can be extended to protect additional
Transformer/ Reactor to be installed in future. However, for the purpose of design it shall be
assumed that only one Transformer/ Reactor will be on fire. The main header pipe size in the yard
shall be 250mmNB and the branch to the equipment (shall not be more than 20metres length)
shall be of the same size as of deluge valve.
Volume-II (Section-P), Fire Protection System 332
Note: * Nitrogen injection fire protection has also to be quoted as an alternative offer. However techno
commercial comparison of both should be given by the bidder.
2.1.2 A warning plate shall be placed near the hydrant points for the transformers and reactors and the
pump in 220kV substations to clearly indicate that water shall be sprayed only after ensuring that
the power to the transformer/ reactor which is on fire is switched off and there are no live parts
within 20metres of distance from the personnel using the hydrant.
2.2 HIGH VELOCITY WATER (H.V.W) SPRAY SYSTEM
H.V.W. spray type fire protection essentially consists of a network of projectors and an array of
heat detectors around the Transformer/Reactor to be protected. On operation of one or more of
heat detectors, Water under pressure is directed to the projector network through a Deluge valve
from the pipe network laid for this system. This shall be provided for transformers and reactors in
765kV and 400kV substations. Wet detection initiation system shall be employed for automatic
operation.
The system shall be designed in such a way that the same can be extended to protect additional
Transformer/ Reactor to be installed in future. However, for the purpose of design it shall be
assumed that only one Transformer/ Reactor will be on fire. The main header pipe size in the yard
shall be 250mmNB and the branch to the equipment (shall not be more than 20metres length)
shall be of the same size as of deluge valve.
2.2.1 The Electrical clearance between the Emulsifier system pipe work and live parts of the
protected equipment shall not be less than the values given below:
1. 765 kV bushing 4900 mm
2. 420 kV bushing 3500 mm
3. 245 kV bushing 2150 mm
4. 145 kV bushing 1300 mm
5. 36 kV bushing 320 mm
2.2.2 System shall be designed in such a way that the Water pressure available at any spray
nozzle shall be between 3.5bar and 5.0bar and shall be demonstrated through hydraulic
calculations. Water shall be applied at a minimum rate of 10.2 LPM/M2 of the surface
area of the transformer / Reactor including radiator, conservator, oil pipes, bushing
turrets, etc. (including bottom surface for transformer). The nozzle arrangement shall
ensure direct impingement of water on all exterior surfaces of transformer tank, bushing
Volume-II (Section-P), Fire Protection System 333
turrets, conservator and oil pipes, except underneath the transformer, where horizontal
spray may be provided.
2.2.3 Deluge Valve
Deluge Valve shall be water pressure operated manual reset type. The Deluge valve shall
be closed water tight when water pressure in the heat detector pipe work is healthy and
the entire pipe work shall be charged with water under pressure upto the inlet of the
Deluge valve. On fall of water pressure due to opening of one or more heat detectors, the
valve shall open and water shall rush to the spray water network through the open Deluge
valve. The valves shall be manually reset to initial position after completion of operation.
Each Deluge Valve shall be provided with a water motor gong which shall sound an
alarm when water after passing through the Deluge valve, is tapped through the water
motor. Each Deluge valve shall be provided with a local panel with provision of opening
of Deluge valve from local and remote from control room/ remote centre. In addition to
this, each valve shall be provided with local operation latch.
Deluge valves of 100mmNB size shall be used if the flow requirement is ≤ 200m3/hr and
150mmNB size shall be used for flow requirement >200m3/hr. Test valves shall simulate
the operation of Deluge valves and shall be of quick opening type. The general
construction shall conform to requirements under clause no.7.00.00 for piping, valves and
specialities.
2.2.4 High Velocity Spray Nozzles (Projectors)
High velocity spray system shall be designed and installed to discharge water in the form
of a conical spray consisting of droplets of water travelling at high velocity, which shall
strike the burning surface with sufficient impact to ensure the formation of an emulsion.
At the same time the spray shall efficiently cut off oxygen supply and provide sufficient
cooling.
2.2.5 Minimum set point of the heat detectors used in the HVW spray system shall be 79°C.
The optimum rating shall, however, be selected by the Bidder, keeping in mind the
maximum and minimum temperature attained at site.
2.3 Fire Detection and alarm System
This system shall be provided for control room building and Switchyard panel rooms of
substations.
Volume-II (Section-P), Fire Protection System 334
2.3.1 Suitable fire detection system using smoke detectors and/or heat detectors shall be
provided for the entire building, including corridor and toilets. Fire detectors shall be
located at strategic locations in various rooms of the building. Each Switchyard panel
room shall be considered a separate zone. Adequate number of extra zones shall be
provided for Switchyard panel rooms for future bays identified in Single line diagram of
the substation. The operation of any of the fire detectors/ manual call point should result
in the following;
1. A visual signal exhibited in the annunciation panels indicating the area where the fire
is detected.
2. An audible alarm sounded in the panel, and
3. An external audible alarm sounded in the building, location of which shall be decided
during detailed engineering.
4. If the zone comprises of more than one room, a visual signal shall be exhibited on the
outer wall of each room.
2.3.2 Each zone shall be provided with two zone cards in the panel so that system will remain
healthy even if one of the cards becomes defective.
2.3.3 Coverage area of each smoke detector shall not be more than 80 m2 and that of heat
detectors shall not be more than 40 m2. Ionisation type smoke detectors shall be provided
in all areas except pantry room where heat detectors shall be provided. If a detector is
concealed, a remote visual indication of its operation shall be provided. Manual call
points (Break glass Alarm Stations) shall be provided at strategic locations in the control
room building. All cabling shall be done through concealed conduits.
2.3.4 Cables used should be exclusively for fire detection and alarm system and shall be
2Cx1.5sq.mm Cu. cables. Un-armoured PVC insulated FR cables conforming to IS 1554
(Part 1) shall be used.
2.4 Portable and Wheel/ Trolley mounted Fire Extinguishers
2.4.1 Portable Fire Extinguishers
Adequate number of portable fire extinguishers of pressurised water, dry chemical
powder, and Carbon dioxide type shall be provided in suitable locations in control room
building and FFPH building. In addition to this one (1) CO2 type fire extinguisher of
Volume-II (Section-P), Fire Protection System 335
4.5kg capacity shall be provided for each Switchyard panel room. These extinguishers
will be used during the early phases of fire to prevent its spread and costly damage.
2.4.2 Wheel/ Trolley mounted Fire Extinguishers Wheel/Trolley mounted Mechanical foam
type fire extinguishers of 50litre capacity, conforming to IS: 13386, shall be provided for
the protection of the following:
1. Transformers and reactors in 220kV and 132 kV substations. Two (2) nos. for each
220kV or 132kV transformer and reactor.
2. LT transformers in all substations. One (1) no. for each transformer. The design,
construction & testing of Mechanical foam type 50 litre capacity shall meet the
requirements of relevant IS Codes.
2.5 Water Supply System (for substations of voltage levels 400kV and above) Water for hydrant &
HVW system shall be supplied by one electrical motor driven pump of rated capacity 410m3/hr.
at 70MWC head, with another pump of same capacity , driven by diesel engine, shall be used as
standby. Water storage tank with two compartments of adequate capacity shall be provided.
Pumps shall work under positive suction head. Annunciations of the hydrant & HVW spray
systems shall be provided in fire water pump house and repeated in 765kV/ 400 kV control room.
The outdoor piping for the system in general shall be laid above ground on concrete pedestals
with proper supporting arrangement. However, at road/rail crossings, in front/access of buildings,
places where movement of cranes/vehicles is expected and at any other place where above ground
piping is not advisable, the pipes shall be laid underground. Such locations shall be finalised
during detailed engineering. The whole system will be kept pressurised by providing combination
of air vessel and jockey pump of 10.8M3/hr. capacity at 80MWC. The capacity of air vessel shall
not be less than 3m3. Minor leakage will be met by Jockey pump. One additional jockey pump
shall be provided as standby. All pumps shall be of horizontal centrifugal type. Pumps and air
vessel with all auxiliary equipment will be located in firewater pump house. A pressure relief
valve of suitable rating shall be provided in water header to release excess pressure due to
atmospheric temperature variations.
Operation of all the pumps shall be automatic and pumps shall be brought into operation at preset
pressure. Fire pumps shall only be stopped manually. Manual start/stop provision shall be
provided in local control panel.
2.5.1 The general design of the fire fighting pump sets shall meet the requirements for
Horizontal centrifugal pumps, Diesel engines and Electrical motors.
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2.5.2 Each pump shall be provided with a nameplate indicating suction lift/delivery head,
capacity and number of revolutions per minute.
2.5.3 Design, construction, erection, testing and trial operation of piping, valves, strainers,
hydrant valves, hoses, nozzles, branch pipes, hose boxes, expansion joints etc. shall
conform to the requirements.
2.6 Instrumentation and Control System
2.6.1 All instruments like pressure indicators, differential pressure indicators, pressure
switches, level indicators, level switches, temperature indicators, alarms and all other
instruments and panels as indicated in the specification and those needed for safe and
efficient operation of the whole system shall be furnished according to the requirements
of clause 11.00.00. Pump running/ fails to start signal shall be taken from the pressure
switch immediately after the discharge of the pump.
2.6.2 Control Panel
Power feeder for motors will be from switchgear board located in control building but
control supply for all local control panels, annunciation panels, battery charger units,
space heaters etc. shall be fed from the AC and DC distribution boards located in pump
house. These AC & DC distribution boards will be fed from the switchgears and DCDBs
located in control building.
a) Panel for motor driven fire water pump
The panel shall be provided with the following:
1. TPN switch 1 No.
2. Auto/manual switch 1 No.
3. Start/Stop Push buttons with indication lamp 1 Set
4. DOL starter with thermal O/L relay 1 Set
5. Indicating lamp showing power ON 1 Set
6. ndication lamp with drive ON/OF 1 Set
7. Indication lamp showing Motor Trip 1 No.
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Main power cable from breaker feeder of main switchboard shall be terminated in
this panel and another cable shall emanate from this panel which shall be terminated
at motor terminals.
b) Panel for Two nos. Jockey Pump 1No.
The panel shall be provided with the following :
1. Fuse-switch unit for Jockey pumps 1 Set for each pump
2. Auto/manual switch for 1 No. for each pump
3. Selector switch for selecting either jockey pump 1 No.
4. D.O.L. starter with overload each relay self-resetting 1 No. each type, for all the drives.
5. Start/stop push button for 1 Set for each pump Jockey Pump with indication lamp with pad-locking arrangements in stop position
6. Indication lamp for trip 1 No. each for pump indication
c) Panel for 2 Nos. battery charger 1 No. & Diesel Engine driven fire water pump
The panel shall be provided with the following :
1. Auto/Manual switch for 1 No. Diesel Engine driven pump
2. Start/Stop push buttons 1 Set with indication lamp
3. Indicating lamp showing 1 Set drive ON/OFF
4. D.C. Voltmeter/Ammeter in 1 No. each the battery charger circuit
5. Battery charger will be as 1 Set per specification described
6. Selector switch for selecting either of 1 No. battery chargers for the battery sets.
7. Selector switch for selecting either 1No. set of batteries for Diesel engine starting.
8. Selector switch for boost 1 Set
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charging/Trickle charging of battery set.
d) Individual local control panel is to be considered for each transformer/ Reactor
deluge system wherever these equipment are envisaged. This panel shall contain push
buttons with indicating lamps for spray ON/OFF operation in the valve operation
circuit. Push buttons shall be concealed behind glass covers, which shall be broken to
operate the buttons. Provision shall be made in the panel for the field signal for the
annunciations such as spray ON and fire in the Transformer/Reactor. A signal for
spray ON shall also be provided in the control room fire alarm panel for employer’s
event logger. Remote operation facility to open the Deluge valve from control room/
remote centre shall also be provided.
2.6.3 Annunciation Panels
a) Location: Fire Water Pump House
i) Indicating lamps showing power supply "ON".
ii) Annunciation windows complete with buttons. Details are as follows:
S.No. Description Number
1. Electric motor driven fire water pump running 1
2. Electric motor driven fire water pump fails to start 1
3. Diesel engine driven fire water pump running 1
4. Diesel engine driven water pump fails 1
5. Jockey pump-1 running 1
6. Jockey pump-1 fails to start 1
7. Jockey pump-2 running 1
8. Jockey pump-2 fails to start 1
9. Fire in Transformer/ Reactor 1 for each equipment
10. Deluge system operating for Transformer/Reactor 1 for each equipment
11. Header pressure low 1
12. Fire in smoke detection system zone 1
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(Common Fire Signal)
13. Water storage tank water level low 2
14. High speed diesel tank level low 1
15. Spare 10
b) Location 400 kV Control Room
i) Indication lamp showing power supply 'ON'
ii) Provision shall be made in the panel for a signal for spray ON for each
Transformer/Reactor for owner's use for event logger.
iii) Each Switchyard panel room shall be considered as separate zone for fire detection
and alarm system.
iv) Following annunciations shall be provided:
S.No. Description Number
1. Fire in Transformer/ Reactor 1 for each equipment
2. Diesel engine driven fire water pump in operation 1
3. Motor driven fire water pump in operation 1
4. Jockey pump in operation 1
5. Fire fighting Water storage tank level Low 2
6. Fire/Fault (zone alarm module) 1+1(duplicate) For each zone
as applicable
7. Spare windows complete in all respect, with relays 10
8. Spare zone alarm modules Number of future A/c Kiosks
required for the bays
identified as per SLD
c) Each annunciation panel shall be provided with a hooter.
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d) Indication for fault in respective areas shall also be provided. Each zone alarm module
shall exhibit 'FIRE’ and 'FAULT' conditions separately.
2.6.4 The control and interlock system for the fire protection system shall meet the following
requirements:
1. Electric Motor Driven Fire water Pump
Pump should start automatically when the System header pressure is low.
Pump should be stopped manually only. Pump should also be started manually if
required from local control panel.
2. Diesel Engine Driven Standby Pump
The pump should automatically start under any of the following conditions:
a) System Header pressure low.
b) Electric motor operated fire water pump fails to start.
Pump should be stopped manually only. Pump should also be started manually if
required from the local control panel. The battery set which is connected for starting of
Diesel engine shall not be subjected to boost charge.
3. Jockey Pump
It shall be possible to select any one of the Jockey pumps as main and the other as
standby. Main Jockey pump shall start automatically when water pressure in header
falls below the set value. If the main jockey pump fails to start then the standby should
start. Jockey pump shall stop automatically when the pressure is restored to its normal
value. Manual starting/stopping shall be possible from the local control panel.
3.0 TESTS
3.1 Shop Tests
3.1.1 Shop tests of all major equipment centrifugal pumps, diesel engines, electrical drive
motors, piping, valves and specialties, pressure and storage vessels, MCC, electrical
panels, controls, instrumentation etc. shall be conducted as specified in various clauses
and as per applicable standards/codes.
3.1.2 Shop tests shall include all tests to be carried out at Contractor's works, works of his sub-
contractor and at works where raw materials supplied for manufacture of equipment are
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fabricated. The tests to be carried out shall include but not be limited to the tests
described as follows:
a) Materials analysis and testing.
b) Hydrostatic pressure test of all pressure parts, piping, etc.
c) Dimensional and visual check.
d) Balancing test of rotating components.
e) Response of heat/smoke detectors.
f) Performance characteristics of HVW spray nozzles (projectors).
g) Flow rate and operational test on Flow control valves.
h) Operational test of alarm valve (water-motor gang).
i) Calibration tests on instruments and tests on control panel.
j) Destruction/burst tests on 2% or minimum one (1) no. of hoses and portable type fire
extinguishers for each type as applicable. Any fraction number shall be counted as
next higher integer.
k) Performance test on fire extinguishers as required in the code.
3.1.3 In the absence of any Code/Standard, equipment shall be tested as per mutually agreed
procedure between the supplier and the Employer.
3.1.4 A comprehensive visual and functional check for panels would be conducted and will
include a thorough check up of panel dimensions, material of construction, panel finish,
compliance with tubing and wiring specifications, quality of workmanship, proper
tagging & locations of instruments/accessories. The wiring check shall be complete point
to point ring out and check for agreement with installation drawings and equipment
vendor prints of the complete system and an inspection of all field connection terminals
and levelling.
3.1.5 All test certificates and reports shall be submitted to the Employer for approval.
3.1.6 The Employer's representative shall be given full access to all tests.
The manufacturer shall inform the Employer allowing adequate time so that, if the
Employer so desires, his representatives can witness the test.
3.2 Pre-commissioning Tests
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3.2.1 General
a) All piping and valves, after installation will be tested hydraulically at a pressure of
16kg/cm2 for a period of 30 minutes to check against leak tightness.
b) All manually operated valves/gates shall be operated throughout 100% of the travel and
these should function without any trouble whatsoever, to the satisfaction of the Employer.
c) All pumps shall be run with the specified fluid from shut off condition to valve wide open
condition. Head developed will be checked from the discharge pressure gauge reading.
During the test, the pumps and drives shall run smoothly without any undue vibration,
leakage through gland, temperature rise in the bearing parts, noise, flow pulsation etc.
d) All pressure vessels should be tested hydraulically at the specified test pressure, singly or
in the system.
e) Painting shall be checked by dry type thickness gauges.
f) Visual check on all structural components, welding, painting etc. and if doubt arises,
these will be tested again.
g) All test instruments and equipment shall be furnished by the Contractor to the satisfaction
of the Employer.
h) Automatic starting of all the fire pumps by operating the test valves.
i) Automatic operation of the Jockey pump
j) Operation of the Deluge valve by breaking a detector as well as manual and remote
operation of the deluge valve.
k) Operation of entire annunciation system.
Replacement of fused/damaged quartzoid bulb detectors during the test shall be responsibility
of contractor.
3.2.2 After erection at site, the complete HVW spray protection and hydrant system shall be
subject to tests to show satisfactory performance for which detailed procedure shall be
submitted for Employer's approval. Full flow tests with water shall be done for the
system piping as a means of checking the nozzle layout, discharge pattern and coverage,
any obstructions and determination of relation between design criteria and actual
performance, also to ensure against clogging of the smaller piping and the discharge
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devices by foreign matter carried by the water. Rigidity of pipe supports shall also be
checked during the water flow.
3.2.3 All the detectors installed shall be tested for actuation by bringing a suitable source of
heat/smoke near the detector and creating a stream of hot air/ smoke over the detector.
The exact procedure of this test shall be detailed out by the Employer to the successful
Bidder.
4.0 SPARE PARTS
The Contractor shall indicate in his scope of supply all the mandatory spares in the relevant
schedules..
5.0 HORIZONTAL CENTRIFUGAL PUMPS
This clause covers the design, performance, manufacturing, construction features and testing of
horizontal centrifugal pumps used for the purpose of fire fighting.
5.1 The materials of the various components shall conform to the applicable IS/BS/ASTM/DIN
Standards.
5.1.1 In case of any contradiction with the aforesaid standards and the stipulations as per the
technical specification as specified hereinafter, the stipulations of the technical
specification shall prevail.
5.2 General Performance Requirements
5.2.1 The pump set shall be suitable for continuous operation at any point within the "Range of
operation".
5.2.2 Pumps shall have a continuously rising head capacity characteristics from the specified
duty point towards shut off point, the maximum being at shut off.
5.2.3 Pumps shall be capable of furnishing not less than 150% of rated capacity at a head of not
less than 65% of the rated head. The shut off head shall not exceed 120% of rated head.
Range of operation shall be 20% of rated flow to 150% of rated flow.
5.2.4 The pump-motor set shall be designed in such a way that there is no damage due to the
reverse flow through the pump which may occur due to any mal-operation of the system.
5.2.5 Drive Rating
The drive rating shall not be less than the maximum power requirement at any point
within the "Range of Operation" specified.
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During starting under reverse flow condition, the motor shall be capable of bringing the
pump to rated speed at normal direction with 90% rated voltage at motor terminals.
5.2.6 Pump set along with its drive shall run smooth without undue noise and vibration.
Acceptable peak to peak vibration limits shall generally be guided by Hydraulic Institute
Standards.
5.2.7 The Contractor under this specification shall assume full responsibility in the operation of
the pump and drive as one unit.
5.3 Design & Construction
5.3.1 Pump casing may be axially or radially split. The casing shall be designed to withstand
the maximum pressure developed by the pump at the pumping temperature.
5.3.2 Pump casing shall be provided with adequate number of vent and priming connections
with valves, unless the pump is made self-venting & priming. Casing drain, as required,
shall be provided complete with drain valves.
5.3.3 Under certain conditions, the pump casing nozzles will be subjected to reactions from
external piping. Pump design must ensure that the nozzles are capable of withstanding
external reactions not less than those specified in API-610.
5.3.4 Pump shall preferably be of such construction that it is possible to service the internals of
the pump without disturbing suction and discharge piping connections.
5.3.5 Impeller
The impeller shall be secured to the shaft and shall be retained against circumferential
movement by keying, pinning or lock rings. On pumps with overhung shaft impellers
shall be secured to the shaft by an additional locknut or cap screw. All screwed fasteners
shall tighten in the direction of normal rotation.
5.3.6 Wearing Rings
Replaceable type wearing rings shall be furnished to prevent damage to impeller and
casing. Suitable method of locking the wearing ring shall be used.
5.3.7 Shaft
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Shaft size selected shall take into consideration the critical speed, which shall be at least
20% away from the operating speed. The critical speed shall also be atleast 10% away
from runaway speed.
5.3.8 Shaft Sleeves
Renewable type fine finished shaft sleeves shall be provided at the stuffing
boxes/mechanical seals. Length of the shaft sleeves must extend beyond the outer faces
of gland packing or seal and plate so as to distinguish between the leakage between shaft
& shaft sleeve and that past the seals/gland.
5.3.9 Shaft sleeves shall be securely fastened to the shaft to prevent any leakage or loosening.
Shaft and shaft sleeve assembly should ensure concentric rotation.
5.3.10 Bearings
Bearings of adequate design shall be furnished for taking the entire pump load arising
from all probable conditions of continuous operation throughout its "Range of Operation"
and also at the shut-off condition.
The bearing shall be designed on the basis of 20,000 working hours minimum for the
load corresponding to the duty point. Bearings shall be easily accessible without
disturbing the pump assembly. A drain plug shall be provided at the bottom of each
bearing housing.
5.3.11 Stuffing Boxes
Stuffing box design shall permit replacement of packing without removing any part other
than the gland. Stuffing boxes shall be sealed/cooled by the fluid being pumped and
necessary piping, fittings, valves, instruments, etc. shall form an integral part of the pump
assembly.
5.3.12 Shaft Couplings
All shafts shall be connected with adequately sized flexible couplings of suitable design.
Necessary guards shall be provided for the couplings.
5.3.13 Base Plates & Sole Plate
A common base plate mounting both for the pump and drive shall be furnished. The base
plate shall be of rigid construction, suitably ribbed and reinforced. Base plate and pump
supports shall be so constructed and the pumping unit so mounted as to minimize
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misalignment caused by mechanical forces such as normal piping strain, hydraulic piping
thrust etc. Suitable drain taps and drip lip shall be provided.
5.3.14 Material of Construction
All materials used for pump construction shall be of tested quality. Material of
construction of the major parts of the pumps shall be as given below:
a) Casing Casting Grade FG: 260 of IS 210
b) Impeller Bronze Grade LTB 2 of IS: 318
c) Wearing ring Bronze Grade LTB 2 of IS: 318
d) Shaft Grade 40C8 of IS 1570 (Part 2, section 1.): 1979.
e) Shaft sleeve Bronze Grade LTB 2 of IS: 318 or Chrome steel
07Cr13 of IS 1570 (part 5) :1985.
f) Stuffing box 2.5% Nickel CI Grade FG 260 of IS:210
g) Gland --- do ---
5.3.15 Balancing
All rotating components shall be statically and dynamically balanced at shop.
5.3.16 All the components of pumps of identical parameters supplied under this specification
shall be interchangeable.
5.4 Tests and Inspection
5.4.1 The manufacturer shall conduct all routine tests required to ensure that the equipment
furnished conform to the requirements of this specification and are in compliance with
the requirements of applicable Codes and Standards. The particulars of the proposed tests
and the procedures for the tests shall be submitted to the Employer/Engineer for approval
before conducting the tests.
5.4.2 Where stage inspection is to be witnessed by Employer, in addition to above, the Bidder
shall submit to the Employer/Engineer at the beginning of the contract, the detailed
PERT-Chart showing the manufacturing programme and indicating the period where
Employer or his authorised inspecting agency are required at the shop.
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5.4.3 Material of Construction
All materials used for pump construction shall be of tested quality. Materials shall be
tested as per the relevant standards and test certificates shall be made available to the
Employer/Engineer.
5.4.4 Where stage inspection is to be witnessed by Employer, all material test certificates shall
be correlated and verified with the actual material used for construction before starting
fabrication, by Employer's Inspector who shall stamp the material. In case mill test
certificates for the material are not available, the Contractor shall carry out physical and
chemical tests at his own cost from a testing agency approved by the Employer, as per the
requirements of specified material standard. The samples for physical and chemical tests
shall be drawn up in presence of Employer's inspector who shall also witness the tests.
5.4.5 Shaft shall be subjected to 100% ultrasonic test and machined portion of the impeller
shall be subject to 100% DP test. On finished shaft DP test will also be carried out.
5.4.6 Hydraulic test at shop
All pressure parts shall be subjected to hydraulic testing at a pressure of 150% of
maximum pressure generated by the pump at rated speed or 200% of total dynamic head
whichever is higher, for a period not less than one (1) hour.
5.4.7 Performance test at shop
Pumps shall be subjected to routine tests to determine the performance of the pumps.
These tests shall be conducted in presence of Employer/Engineer's representative as per
the requirements of the Hydraulic Institute Standards/ASME Power Test Code PTC
8.2/BS- 599/I.S.S., latest edition. Routine tests shall be done on all the pumps.
5.4.8 Performance tests shall be conducted to cover the entire range of operation of the pumps.
These shall be carried out to span 150% of rated capacity upto pump shut-off condition.
A minimum of five combinations of head and capacity are to be achieved during testing
to establish the performance curves, including the design capacity point and the two
extremities of the Range of operation specified.
5.4.9 Tests shall preferably be conducted alongwith the actual drives being supplied.
5.4.10 The Bidders shall submit in his proposal the facilities available at his works to conduct
performance testing. If because of limitations of available facilities, a reduced speed test
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or model test has to be resorted to establish pump performance, the same has to be
highlighted in the offer.
5.4.11 In case of model testing, the stipulations of latest edition of Hydraulic Institute Standards
shall be binding. Prototype or model tests, however, shall be conducted with the suction
condition identical to the field conditions i.e. sigma values of prototype and model is to
be kept same.
5.4.12 Prior to conducting model testing, calculations establishing model parameters, sizes and
test procedure will be submitted to Employer/Engineer for approval.
5.4.13 All rotating components of the pumps shall be subjected to static and dynamic balancing
tests.
5.4.14 The Employer or his authorised representative shall have full access to all tests. Prior to
performance tests, the Contractor shall intimate the Employer allowing adequate time so
that if the Employer so desires, his representative can witness the test.
5.4.15 Report and test certificates of the above tests shall be submitted to the
Employer/Engineer for approval.
5.4.16 Pre commissioning tests.
After installation, pumps offered may be subjected to testing at field also by Employer. If
the performances at field are not found to meet the requirement, then the equipment shall
be rectified by the Contractor without any extra cost. Prior to performance testing, the
procedure for such tests will be mutually agreed between Employer and Contractor. The
Contractor shall furnish all necessary instruments, accessories and personnel for testing.
Prior to testing, the calibration curves of all instruments and permissible tolerance limit of
instruments shall be mutually agreed upon.
6.0 DIESEL ENGINES
This Clause covers the design, performance, manufacturing construction features and testing of
compression ignition diesel engines, used primarily for driving centrifugal pumps, used for the
purpose of fire fighting.
6.1 Design and Construction
General
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6.1.1 The diesel engine shall be of multicylinder type four-stroke cycle with mechanical
(airless) injection, cold starting type.
6.1.2 The continuous engine brake horse power rating (after accounting for all auxiliary power
consumption) at the site conditions shall be atleast 20% greater than the requirement at
the duty point of pump at rated RPM and in no case, less than the maximum power
requirement at any condition of operation of pump.
6.1.3 Reference conditions for rated output of engine shall be as per IS: 10000, part II or
ISO:3046, part I.
6.1.4 The engine shall be designed with regard to ease of maintenance, repair, cleaning and
inspection.
6.1.5 All parts subjected to substantial temperature changes shall be designed and supported to
permit free expansion and contraction without resulting in leakage, harmful distortion or
misalignment.
6.1.6 Starting
The engine shall be capable of both automatic and manual start. The normal mode of
starting is automatic but in the event of failure of automatic start or at the discretion of
the operator, the engine can be started manually from the LCP. Since the fire pumping
unit driven by the diesel engine is not required to run continuously for long periods and
the operation will not be frequent, special features shall be built into the engine to allow it
to start within a very short period against full load even if it has remained idle for a
considerable period.
6.1.7 If provision for manual start (cranking) is provided, all controls/ mechanisms, which
have to be operated during the starting process, shall be within easy reach of the operator.
6.1.8 Automatic cranking shall be effected by a D.C. motor having high starting torque to
overcome full engine compression. Starting power will be supplied from either of the two
(2) sets of storage batteries. The automatic starting arrangement shall include a 'Repeat
Start' feature for 3 attempts. The battery capacity shall be adequate for 3 (three)
consecutive starts without recharging with a cold engine under full compression.
6.1.9 The batteries shall be used exclusively for starting the diesel engine and be kept fully
charged all the time in position. Arrangement for both trickle and booster charge shall be
provided.
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Diesel engine shall be provided with two (2) battery charger units of aircooled design.
The charger unit shall be capable of charging one (1) set of battery at a time. Provision
shall, however, be made so that any one of the charger units can be utilised for charging
either of the two (2) batteries.
6.1.10 For detail design of battery and battery charger, sub- section Electrical may be referred
to.
6.1.11 Governing System:
The engine shall be fitted with a speed control device, which will control the speed under
all conditions of load.
6.1.12 The governor shall offer following features:
a) Engine should be provided with an adjustable governor capable of regulating engine
speed within 5% of its rated speed under any condition of load between shut-off and
maximum load conditions of the pumps. The governor shall be set to maintain rated
pump speed at maximum pump load.
b) Engine shall be provided with an over speed shut- down device. It shall be arranged
to shut-down the engine at a speed approximately 20% above rated engine speed and
for manual reset, such that the automatic engine controller will continue to show an
over speed signal until the device is manually reset to normal operating position
(Vol.II, NFPA, 1978).
6.1.13 The governor shall be suitable for operation without external power supply.
6.1.14 Fuel System
The diesel engine will run on High Speed Diesel.
6.1.15 The engine shall be provided with fuel oil tank of 250 litres capacity. The fuel oil tank
shall preferably be mounted near the engine. No fuel oil tank will be provided by the
Employer.
6.1.16 The fuel oil tank shall be of welded steel constructed to relevant standards for mild steel
drums. The outlet of the tank shall be above the inlet of fuel injection pump of the diesel
engine to ensure adequate pressure at suction of injection pump.
6.1.17 The fuel oil tank shall be designed in such a way that the sludge and sediment settles
down to the tank bottom and is not carried to the injection pump. A small sump shall be
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provided and fitted with drain plug to take out sludge/sediment and to drain oil. Adequate
hand holes (greater than 80 mm size) shall be provided to facilitate maintenance.
6.1.18 Pipeline carrying fuel oil shall be gradually sloped from the tank to the injection pump.
Any valve in the fuel feed pipe between the fuel tank and the engine shall be placed
adjacent to the tank and it shall be locked in the open position. A filter shall be
incorporated in this pipeline, in addition to other filters in the fuel oil system. Pipe joints
shall not be soldered and plastic tubing shall not be used. Reinforced flexible pipes may
also be used.
6.1.19 The complete fuel oil system shall be designed to avoid any air pocket in any part of the
pipe work, fuel pump, sprayers/injectors, filter system etc. No air relief cock is permitted.
However, where air relief is essential, plugs may be used.
6.1.20 A manual fuel pump shall be provided for priming and releasing of air from the fuel
pipelines.
6.1.21 Lubricating Oil System
Automatic pressure lubrication shall be provided by a pump driven by the crank shaft,
taking suction from a sump and delivering pressurized oil through cooler and fine mesh
filters to a main supply header fitted in the bed plate casing. High pressure oil shall be
supplied to the main and big end bearings, cam-shaft bearings, cam-shaft chain and gear
drives, governor, auxiliary drive gears etc. Valve gear shall be lubricated at reduced
pressure through a reducing valve and the cams by an oil bath.
6.1.22 Cooling Water System
Direct cooling or heat exchanger type cooling system shall be employed for the diesel
engine. Water shall be tapped from the fire pump discharge. This water shall be led
through duplex strainer, pressure breakdown orifice and then after passing through the
engine, the water at the outlet shall be taken directly to the sump through an elevated
funnel.
6.2 Testing & Inspection
6.2.1 The manufacturer shall conduct all tests required, to ensure that the equipment furnished
conforms to the requirement of this sub-sectionand in compliance with requirements of
applicable codes. The particulars of the proposed tests and the procedure for the tests
shall be submitted to the Employer for approval before conducting the tests.
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6.2.2 At manufacturer's works, tests shall be carried out during and after completion of
manufacture of different component/parts and the assembly as applicable. Following tests
shall be conducted.
6.2.3 Material analysis and testing.
6.2.4 Hydrostatic pressure testing of all pressure parts.
6.2.5 Static and dynamic balance tests of rotating parts at applicable overspeed and
determination of vibration level.
6.2.6 MPI/DPT on machined parts of piston and cylinder.
6.2.7 Ultrasonic testing of crankshaft and connecting rod after heat treatment.
6.2.8 Dimensional check of close tolerance components like piston, cylinder bore etc.
6.2.9 Calibration tests of all fuel pumps, injectors, standard orifices, nozzles, instruments etc.
6.2.10 Over speed test of the assembly at 120% of rated speed.
6.2.11 Power run test.
6.2.12 Performance test of the diesel engine to determine its torque, power and specific fuel
consumption as function of shaft speed. Performance test of the engine shall be carried
for 12 hours out of which 1 hour at full load and one hour at 110% overload.
6.2.13 Measurement of vibration & noise.
(i) Measurement of vibration
The vibration shall be measured during full load test as well as during the overload
test and limit shall be 100 microns.
(ii) Measurement of noise level
The equivalent 'A' weighted sound level measured at a distance of 1.5 M above floor
level in elevation and 1.0 M horizontally from the base of the equipment, expressed
in dB to a reference of 0.0002 microbar shall not exceed 93 dBA. Above tests for
vibration shall be repeated at site as pre-commissioning tests.
6.2.14 Adjustment of speed governor as per BS: 5514.
6.2.15 Diesel engine shall be subjected to routine tests as per IS: 10000/BS:5514.
7.0 PIPING, VALVES AND SPECIALITIES
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This clause covers the design, manufacture, shop testing, erection, testing and commissioning of
piping, valves and specialities.
7.2 Scope
The piping system which shall include but not be limited to the following:
i) Plain run of piping, bends, elbows, tees, branches, laterals, crosses, reducing unions,
couplings, caps, expansion joints, flanges, blank flanges, thrust blocks, anchors, hangers,
supports, saddles, shoes, vibration dampeners, sampling connections, hume pipes etc.
ii) Gaskets, ring joints, backing rings, jointing material etc. as required.Also all welding
electrodes and welding consumables including special ones, if any.
iii) Instrument tapping connections, stubs etc.
iv) Gate and globe valves to start/stop and regulate flow and swing check valves for one
directional flow.
v) Basket strainers and Y-type strainers
vi) Bolts, nuts, fasteners as required for interconnecting piping, valves and fittings as well as
for terminal points. For pipe connections into Owner's R.C.C. works, Bidder will furnish all
inserts.
vii) Painting, anti-corrosive coatings etc. of pipes and equipment. Adequate number of air
release valves shall be provided at the highest points in the piping system to vent any
trapped air in the system.
7.3 Design
7.3.1 Material of construction of various pipes shall be as follows :
(a) Buried Pipes
Mild steel black pipes as per IS:1239, Part-I medium grade (for pipes of sizes 200 NB
and above) suitably lagged on the outside to prevent soil corrosion, as specified
elsewhere.
(b) Overground Pipes normally full of water
Mild steel black pipes as per IS:1239, Part-I medium grade (for pipes for sizes 150 NB
and below) or IS:3589, Fe 410 grade (for pipes of sizes 200 NB and above).
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(c) Overground pipes normally empty, but periodic charge of water and for detector line for
HVW System.
Mild steel galvanised pipes as per IS:1239, Part-I medium grade (for pipes of sizes 150
NB and below) or IS:3589, Fe 410 grade (for pipes of sizes 200 NB and above).
7.3.2 All fittings to be used in connection with steel pipe lines upto a size of 80 mm shall be as
per IS:1239. Part-II Mild steel tubulars and other wrought steel pipe fittings, Heavy
grade. Fittings with sizes above 80 mm upto 150 mm shall be fabricated from IS:1239
Heavy grade pipes or steel plates having thickness not less than those of IS:1239 Part-I
Heavy grade pipes. Fittings with sizes above 150 mm shall be fabricated from IS:3589
Class-2 pipes. All fitting used in GI piping shall be threaded type. Welding shall not be
permitted on GI piping.
7.3.3 For steel pipeline, welded construction should be adopted unless specified otherwise.
7.3.4 All piping system shall be capable of withstanding the maximum pressure arising from
any condition of operation and testing including water hammer effects.
7.3.5 Gate/sluice valve shall be used for isolation of flow in pipe lines and shall be as per 778
(for size upto 40 mm) and IS:14846 (for sizes above 40 mm). Valves shall be of rising
spindle type and of PN 1.6 class
7.3.6 Gate Valves shall be provided with the following :
(a) Hand wheel.
(b) Position indicator.
(c) Locking facility (where necessary).
7.3.7 Gate valves shall be provided with back seating bush to facilitate gland removal during
full open condition.
7.3.8 Globe valves shall be provided with contoured plug to facilitate regulation and control of
flow. All other requirements should generally follow those of gate valve.
7.3.9 Non-return valves shall be swing check type. Valves will have a permanent "arrow"
inscription on its body to indicate direction of flow of the fluid. These valves shall
generally conform to IS: 5312.
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7.3.10 Whenever any valve is found to be so located that it cannot be approached manually from
the nearest floor/gallery/platform hand wheel with floor stand or chain operator shall be
provided for the same.
7.3.11 Valves below 50 mm size shall have screwed ends while those of 50 mm and higher
sizes shall have flanged connections.
7.3.12 Basket Strainer
a) Basket strainers shall be of 30mesh and have the following materials of
construction :
Body: Fabricated mild steel as per IS:2062 (Tested Quality).
Strainer Wires: stainless steel (AISI : 316), 30 SWG, suitably reinforced.
b) Inside of basket body shall be protected by two (2) coats of heavy duty bitumastic
paint.
c) Strainers shall be Simplex design. Suitable vent and drain connections with valves
shall be provided.
d) Screen open area shall be at least 4 times pipe cross sectional area at inlet.
e) Pressure drop across strainer in clean condition shall not exceed 1.5 MWC at 410
M3/hr flow. Pressure drop test report of strainer of same design shall be furnished.
7.3.13 Y-type On-line Strainer
Body shall be constructed of mild steel as per IS:2062 (tested quality). Strainer wires
shall be of stainless steel AISI:316, 30 SWG, 30 mesh. Blowing arrangement shall be
provided with removable plug at the outlet. Screen open area shall be atleast 4 times pipe
cross-sectional area at inlet.
Pressure drop test report of strainer of same design shall be furnished.
7.3.14 Hydrant Valve (Outdoor) and Indoor Hydrant Valves (Internal Landing Valves).
The general arrangement of outdoor stand post assembly, consisting of a column pipe and
a hydrant valve with a quick coupling end shall be as per TAC requirement.
Materials of construction shall be as follows :
a) Column pipe M.S. IS:1239 med. grade.
b) Hydrant Valve
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i) Body Gun metal.
ii) Trim Leaded tin bronze as per IS:318, Grade-LTB 2.
iii) Hand Wheel Cast Iron as per IS:210, Grade FG:200.
iv) Washer, gasket, etc. Rubber as per IS:638.
v) Quick coupling Leaded tin bronze as per connection IS: 318, Grade-LTB 2.
vi) Spring Phosphor Bronze as per IS: 7608.
vii) Cap and chain Leaded tin bronze as per IS:318, Grade-LTB etc.2.
The general design of hydrant valve shall conform to IS: 5290.
7.3.15 Hoses, Nozzles, Branch pipes and Hose boxes
(a) Hose pipes shall be of reinforced rubber-lined canvas construction as per type A of
IS:636 with nominal size of 63 MM (2 1/2") and lengths of 15 metre or 7.5 metre, as
indicated elsewhere. All hoses shall be ISI marked.
(b) Hosepipes shall be capable of withstanding an internal water pressure of not less than
35.7 kg/cm2 without bursting. It must also withstand a working pressure of 8.5 kg/cm2
without undue leakage or sweating.
(c) Each hose shall be fitted with instantaneous spring lock type couplings at both ends. Hose
shall be fixed to the coupling ends by copper rivets and the joint shall be reinforced by
1.5 mm galvanized mild steel wires and leather bands.
(d) Branch pipes shall be constructed of copper and have rings of leaded tin bronze (as per
IS:318 Grade-2) at both ends. One end of the branch pipe will receive the quick coupling
while the nozzles will be fixed to the other end.
(e) Nozzles shall be constructed of leaded tin bronze as per IS:318, Grade-2.
(f) Suitable spanners of approved design shall be provided in adequate numbers for easy
assembly and dismantling of various components like branch pipes, nozzles, quick
coupling ends etc.
(g) Hose pipes fitted with quick coupling ends, branch pipes, nozzles spanner etc. will be
kept in a hose box, which will be located near point of use. The furnished design must
meet the approval of Tariff Advisory Committee.
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(h) All instantaneous couplings, as mentioned under clause Nos.3.03.19, 3.03.20 and 3.03.21
above shall be of identical design (both male and female) so that any one can be
interchanged with another. One male, female combination shall get locked in by mere
pushing of the two halves together but will provide leak tightness at a pressure of 8
kg/cm2 of water. Designs employing screwing or turning to have engagement shall not be
accepted.
7.4 Fabrication & Erection
7.4.1 The contractor shall fabricate all the pipe work strictly in accordance with the related
approved drawings.
7.4.2 End Preparation
(a) For steel pipes, end preparation for butt welding shall be done by machining.
(b) Socket weld end preparation shall be sawing/machining.
(c) For tees, laterals, mitre bends, and other irregular details cutting templates shall be used
for accurate cut.
7.4.3 Pipe Joints
(a) In general, pipes having sizes over 25 mm shall be joined by butt welding. Pipes having
25 mm size or less shall be joined by socket welding/screwed connections. Galvanised
pipes of all sizes shall have screwed joints. No welding shall be permitted on GI pipes.
Screwed joints shall have tapered threads and shall be assured of leak tightness without
using any sealing compound.
(b) Flanged joints shall be used for connections to vessels, equipment, flanged valves and
also on suitable straight lengths of pipe line of strategic points to facilitate erection and
subsequent maintenance work.
7.4.4 Overground Piping
(a) Piping to be laid overground shall be supported on pipe rack/supports. Rack/supports
details shall have to be approved by Employer/Engineer.
(b) Surface of overground pipes shall be thoroughly cleaned of mill scale, rust etc. by wire
brushing. Thereafter one (1) coat of red lead primer shall be applied. Finally two (2) coats
of synthetic enamel paint of approved colour shall be applied.
7.4.5 Buried Pipe Lines
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(a) Pipes to be buried underground shall be provided with protection against soil corrosion
by coating and wrapping with two coats of coal tar hot enamel paint and two wraps of
reinforced fibre glass tissue. The total thickness of coating and wrapping shall not be less
than 3 mm. Alternatively corrosion resistant tapes can also be used for protection of pipes
against corrosion.
(b) Coating and wrapping and holiday testing shall be in line with IS:10221.
(c) Buried pipelines shall be laid with the top of pipe one meter below ground level.
(d) At site, during erection, all coated and wrapped pipes shall be tested with an approved
Holiday detector equipment with a positive signalling device to indicate any fault hole
breaks or conductive particle in the protective coating.
7.5 General Instruction for Piping Design and Construction
7.5.1 While erecting field run pipes, the contractor shall check, the accessibility of valves,
instrument tapping points, and maintain minimum headroom requirement and other
necessary clearance from the adjoining work areas.
7.5.2 Modification of prefabricated pipes, if any, shall have to be carried out by the contractor
at no extra charge to the Employer.
7.5.3 Welding
(i) Welding shall be done by qualified welders only.
(ii) Before welding, the ends shall be cleaned by wire brushing, filing or machine grinding.
Each weld-run shall be cleaned of slag before the next run is deposited.
(iii) Welding at any joint shall be completed uninterrupted. If this cannot be followed for
some reason, the weld shall be insulated for slow and uniform cooling.
(iv) Welding shall be done by manual oxyacetylene or manual shielded metal arc process.
Automatic or semi-automatic welding processes may be done only with the specific
approval of Employer/ Consultant.
(v) As far as possible welding shall be carried out in flat position. If not possible, welding
shall be done in a position as close to flat position as possible.
(vi) No backing ring shall be used for circumferential butt welds.
(vii) Welding carried out in ambient temperature of 5°C or below shall be heat-treated.
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(viii) Tack welding for the alignment of pipe joints shall be done only by qualified welders.
Since tack welds form part of final welding, they shall be executed carefully and shall be
free from defects.
Defective welds shall be removed prior to the welding of joints. Electrodes size for tack
welding shall be selected depending upon the root opening.
(ix) Tacks should be equally spaced as follows:
for 65 NB and smaller pipes : 2 tacks
for 80 NB to 300 NB pipes : 4 tacks
for 350 NB and larger pipes : 6 tacks
(x) Root run shall be made with respective electrodes/filler wires. The size of the
electrodes/filler wires. The size of the electrodes shall not be greater than 3.25 mm (10
SWG) and should preferably be 2.3 mm (12 SWG). Welding shall be done with direct
current values recommended by the electrode manufacturers.
(xi) Upward technique shall be adopted for welding pipes in horizontally fixed position. For
pipes with wall thickness less than 3 mm, oxyacetylene welding is recommended.
(xii) The root run of butt joints shall be such as to achieve full penetration with the complete
fusion of root edges. The weld projection shall not exceed 3 mm inside the pipe.
(xiii) On completion of each run craters, weld irregularities, slag etc. shall be removed by
grinding or chipping.
(xiv) Fillet welds shall be made by shielded metal arc process regardless of thickness and class
of piping. Electrode size shall not exceed 10 SWG. (3.25 mm). At least two runs shall be
made on socket weld joints.
7.6 Tests at Works
a) Pipes
(i) Mechanical and chemical tests shall be performed as required in the codes/standards.
(ii) All pipes shall be subjected to hydrostatic tests as required in the codes/standards.
(iii) 10% spot Radiography test on welds of buried pipes shall be carried out as per ASME
VIII.
b) Valves
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(i) Mechanical and chemical tests shall be conducted on materials of the valve as required in
the codes/standards.
(ii) All valves shall be tested hydrostatically for the seat as well as required in the
code/standards for a period of ten minutes.
(iii) Air test shall be conducted to detect seat leakage.
(iv) Visual check on the valve and simple operational test in which the valve will be operated
thrice from full open to full close condition.
(v) No repair work on CI valve body, bonnet or wedge shall be allowed.
c) Strainers
(i) Mechanical and chemical tests shall be conducted on materials of the strainer.
(ii) Strainers shall be subjected to a hydrostatic test pressure of 1.5 times the design pressure
or 10 kg/cm2g whichever is higher for a period of one hour.
d) Hydrant valves and Indoor Hydrant Valves (Internal Landing Valves)
(i) The stand post assembly along with the hydrant valve (valve being open and outlet
closed) shall be pressure tested at a hydrostatic pressure of 21 kg/cm2g to detect any
leakage through defects of casting.
(ii) Flow test shall be conducted on the hydrant valves at a pressure of 7 kg/cm2g and the
flow through the valve shall not be less than 900 litres/min.
(iii) Leak tightness test of the valve seat shall be conducted at a hydrostatic test pressure of 14
kg/cm2g.
e) Hoses, Nozzles, Branch Pipes and Hose Boxes
Reinforced rubber-lined canvas hoses shall be tested hydrostatically.
Following tests shall be included as per IS:636.
a) Hydrostatic proof pressure test at 21.4 kgf/cm2g
b) Internal diameter
The branch pipe, coupling and nozzles shall be subjected to a hydrostatic test pressure of 21
kg/cm2g for a period of 21/2 minutes and shall not show any sign of leakage or sweating.
Dimensional checks shall be made on the hose boxes and nozzle spanners.
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8.0 AIR VESSELS
8.1 Air vessels shall be designed and fabricated of mild steel as class-II vessels as per IS:2825 for a
pressure of 14kg/cm2 and shall be minimum 3 m3 capacity.
8.2 Inside surface of the tank shall be protected by anti-corrosive paints/coatings/linings as required.
8.3 Outside surfaces of the vessels shall be provided with one (1) coat of red lead primer with two (2)
coats of synthetic enamel paint of approved colour and characteristics.
8.4 Tests & Inspection
i) Air vessels shall be hydraulically tested at 21kg/cm2 for a period not less than one (1) hour.
ii) All materials used for fabrication shall be of tested quality and test certificates shall be
made available to the Owner.
iii) Welding procedure and Welder's qualification tests will be carried out as per relevant IS
Standard.
iv) NDE tests, which will include 100% Radiography on longitudinal seams and spot
Radiography for circumferential seams, for pressure vessel will be carried out.
9.0 HEAT DETECTORS/FIRE DETECTORS AND SPRAY NOZZLES
9.1 Intent of Specification
This specification lays down the requirements of the smoke detectors, heat detectors and spray
nozzles for use in various sub-systems of the fire protection system.
9.2 Codes and Standards
All equipment supplied shall conform to internationally accepted codes and standards. All
equipment offered by Bidders should be TAC approved or have been in use in installations which
have been approved by TAC.
9.3 Heat Detectors, Quartzoid bulb type. (Used in HVW spray system)
a) Heat detectors shall be of any approved and tested type. Fusible chemical pellet type heat
detectors are however not acceptable.
b) Temperature rating of the heat detector shall be selected by the Bidder taking into
consideration the environment in which the detectors shall operate. Minimum set point
shall, however, be 79°C.
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c) Heat detectors shall be guaranteed to function properly without any maintenance work for a
period of not less than twenty five (25) years.
d) The heat detectors shall be mounted on a pipe network charged with water at suitable
pressure. On receipt of heat from fire, the heat detector will release the water pressure from
the network. This drop in water pressure will actuate the Deluge valve.
9.4 HVW Spray Nozzles (Projectors)
High velocity water spray system shall be designed and installed to discharge water in the form of
a conical spray consisting of droplets of water travelling at high velocity which shall strike the
burning surface with sufficient impact to ensure the formation of an emulsion. At the same time
the spray shall efficiently cut off oxygen supply and provide sufficient cooling. Integral non-
ferrous strainers shall be provided in the projectors ahead of the orifice to arrest higher size
particle, which are not allowed to pass through the projectors.
9.5 Fire Detectors (Used in fire detection and alarm system)
i) Fire detectors shall be approved by FOC-London or similar international authorities.
ii) Both smoke and heat type fire detectors shall be used. Bidder shall clearly indicate the
mode of operation of detectors in his proposal.
iii) The set point shall be selected after giving due consideration for ventilating air velocity and
cable insulation.
iv) Fire detectors shall be equipped with an integral L.E.D. so that it shall be possible to know
which of the detectors has been operated. The detectors, which are to be placed in the space
above the false ceiling or in the floor void shall not have the response indicators on the
body but shall be provided with remote response indicators.
v) Approval from Department of Atomic Energy (DAE), Government of India shall be made
available for ionisation type smoke detectors. All accessories required to satisfy DAE shall
also be included in the scope of supply.
vi) Fire detectors shall be guaranteed to function properly without any maintenance work for a
period of not less than ten (10) years.
10.0 PORTABLE AND WHEEL/ TROLLEY MOUNTED FIRE EXTINGUISHERS
10.1 This specification lays down the requirement regarding fire extinguishers of following types:
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Portable fire extinguishers.
a) Pressurised water type.
b) Dry chemical powder type
c) Carbon Dioxide type
Wheel/ Trolley mounted fire extinguishers.
a) Mechanical foam type
10.2 All the extinguishers offered by the Bidder shall be of reputed make and shall be ISI marked.
10.3 Design and Construction
i) All the portable extinguishers shall be of freestanding type and shall be capable of
discharging freely and completely in upright position.
ii) Each extinguisher shall have the instructions for operating the extinguishers on its body
itself.
iii) All extinguishers shall be supplied with initial charge and accessories as required.
iv) Portable type extinguishers shall be provided with suitable clamps for mounting on walls or
columns.
v) All extinguishers shall be painted with durable enamel paint of fire red colour conforming
to relevant Indian Standards.
vi) Pressurisation of water type fire extinguishers shall either be done by compressed air or by
using gas cartridge. The constant air pressure type shall conform to IS:6234 and the gas
pressure type shall conform to IS:940. Both these extinguishers shall be ISI marked.
vii) Dry chemical powder type portable extinguisher shall conform to IS: 2171.
viii) Carbon Dioxide type portable extinguisher shall conform to IS:2878.
ix) Wheel/ trolley mounted fire extinguishers of 50 litre capacity Mechanical foam type shall
conform to IS:13386
10.2 Tests and Inspection
i) A performance demonstration test at site of five (5) percent or one (1) number whichever is
higher, of the extinguishers shall be carried out by the Contractor. All consumable and
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replaceable items require for this test would be supplied by the Contractor without any
extra cost to Employer.
ii) Performance testing of extinguisher shall be in line of applicable Indian Standards. In case
where no Indian Standard is applicable for a particular type of extinguisher, the method of
testing shall be mutually discussed and agreed to before placement of order for the
extinguishers.
10.3 Painting
Each fire extinguisher shall be painted with durable enamel paint of fire red colour conforming to
relevant Indian Standards.
11.0 INSTRUMENTS
11.1 Intent of Specification
The requirements given in the sub-section shall be applicable to all the instruments being
furnished under this specification.
11.2 All field mounted instruments shall be weather and dust tight, suitable for use under ambient
conditions prevalent in the subject plant. All field mounted instruments shall be mounted in
suitable locations where maximum accessibility for maintenance can be achieved.
11.3 Local Instruments
Pressure/ Differential Gauges & Switches.
1) The pressure sensing elements shall be continuous 'C' bourdon type.
2) The sensing elements for all gauges/switches shall be properly aged and factory tested to
remove all residual stresses. They shall be able to withstand atleast twice the full scale
pressure/vacuum without any damage or permanent deformation.
3) For all instruments, connection between the pressure sensing element and socket shall be
braced or hard soldered.
4) Gauges shall be of 150 mm diameter dial with die-cast aluminium, stoved enamel black
finish case, aluminium screwed ring and clear plastic crystal cover glass. Upper range
pointer limit stop for all gauges shall be provided.
5) All gauges shall be with stainless steel bourdon having rotary geared stainless steel
movements.
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6) Weatherproof type construction shall be provided for all gauges. This type of construction
shall be fully dust tight, drip tight, weather resistant and splash proof with anti-corrosive
painting conforming to NEMA- 4.
7) All gauges shall have micrometer type zero adjuster.
8) Neoprene safety diaphragm shall be provided on the back of the instruments casing for
pressure gauges of ranges 0-10 Kg/cm2 and above.
9) Scales shall be concentric, white with black lettering and shall be in metric units.
10) Accuracy shall be + 1.0 percent of full range or better.
11) Scale range shall be selected so that normal process pressure is approximately 75 percent of
full scale reading. For pressure gauges and pressure switches, the range shall not be less
than 0 -16 Kg/cm2
12) All gauges shall have 1/2 inch NPT bottom connection.
13) All instruments shall conform to IS: 3624 - 1966.
14) All instruments shall be provided with 3 way gauge isolation valve or cock. Union nut,
nipple and tail pipe shall be provided wherever required.
15) Switch element contact shall have two (2) NO and two (2) NC contacts rated for 240 Volts,
10 Amperes A.C. or 220 Volts, 5 Amperes D.C. Actuation set point shall be adjustable
throughout the range. ON-OFF differential (difference between switch actuation and de-
actuation pressures) shall be adjustable. Adjustable range shall be suitable for switch
application.
16) Switches shall be sealed diaphragm, piston actuated type with snap action switch element.
Diaphragm shall be of 316 SS.
17) Necessary accessories shall be furnished.
11.4 Timers
i) The timers shall be electro-mechanical type with adjustable delay on pick-up or reset as
required.
ii) Each timer shall have two pairs of contacts in required combination of NO and NC.
11.5 Level Gauges/Indicator/Switches
a) Level Gauges
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i) Gauge glasses shall be used for local level indication wherever shown in the flow diagram.
ii) Gauge glasses, in general, shall be flag glass type with bolted cover. Body and cover
material shall be of carbon steel with rubber lining.
iii) Level coverage shall be in accordance with operating requirements. Maximum length of a
single gauge glass shall not exceed 1.4 M. Should a larger gauge glass be required, multiple
gauges of preferably equal length shall be used with 50 mm overlap in visibility.
iv) Reflex type gauge glasses shall be used for colourless liquids and transparent type gauge
glasses shall be used for all liquids having colour.
v) Each gauge glass shall be complete with a pair of offset valves. Valves shall have union
bonnet, female union level connection, flanged tank connection, and vent and drain plug.
vi) Offset valves shall have corrosion resistant ball-check to prevent fluid loss in the event of
gauge glass breakage. Valve body shall have a working pressure of 200 percent of the
maximum static pressure at the maximum process fluid temperature. Valve body materials
shall be of carbon steel with rubber lining.
b) Level Indicators
i) Float type mechanical level gauges with linear scale type indicator shall be offered for
measuring level of tanks wherever shown in the flow diagram.
ii) AISI-316 stainless steel float, guide rope and tape shall be used. Housing shall be of mild
steel painted with anti-corrosive painting.
iii) The scale indicator shall be provided at a suitable height for ease of reading.
iv) Accuracy shall be + 1% of scale range or better.
c) Level Switches
i) Level switches shall be of ball float operated magnetic type complete with cage.
ii) Materials of construction shall be suitable for process and ambient conditions. The float
material shall be AISI-316 stainless steel.
iii) Actuating switches shall be either hermetically sealed mercury type or snap acting micro-
switches. Actuation set point shall be adjustable. ON-OFF differential (difference between
switch actuation and de-actuation levels) shall be adjustable. Adjustable range shall be
suitable for switch application. All switches shall be repeatable within + 1.0 percent of
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liquid level change required to activate switch. Contacts shall be rated for 50 watts resistive
at 240 V A.C. Number of contacts shall be two NO and two NC for each level switch.
11.6 Solenoid Valves
i) The body of the valves shall be Forged brass or stainless steel.
ii) The coil shall be continuous duty, epoxy moulded type Class-F, suitable for high
temperature operation.
iii) The enclosure shall be watertight, dust-tight and shall conform to NEMA-4 Standard.
11.7 The valves shall be suitable for mounting in any position.
11.8 Switches, Lamps, Meters Etc.
All electrical components on the panel namely push buttons, switches, lamps, meters etc. shall
meet the requirements of sub-section Electrical enclosed with the specification.
11.9 All local instruments shall be inspected by Employer/Consultant as per the agreed quality plan.
11.10 Makes of control panel and local instruments, accessories shall be as per Employer's approval.
12.0 ELECTRIC MOTORS
12.1 General
i) This clause covers the requirements of three phase squirrel cage induction motors and
single-phase induction motors.
ii) The motors to be furnished, erected and commissioned as covered under this specification
shall be engineered, designed, manufactured, erected, tested as per the requirements
specified herein. These requirements shall however be read along with the requirements of
the respective driven equipment being supplied under the specification of which this
specification forms a part.
iii) The motor supplied under this specification shall conform to the standards specified in
GTR.
iv) Terminal point for all motors supplied under this specification shall be at the respective
terminal boxes.
v) Materials and components not specifically stated in this specification but are necessary for
satisfactory operation of the motor shall be deemed to be included in the scope of supply of
this specification.
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vi) Notwithstanding anything stated in this motor specification, the motor has to satisfy the
requirement of the mechanical system during normal and abnormal conditions. For this the
motor manufacturer has to coordinate with the mechanical equipment supplier and shall
ensure that the motor being offered meets the requirements.
12.2 Codes & Standards
i) The design, manufacture, installation and performance of motors shall conform to the
provisions of latest Indian Electricity Act and Indian Electricity Rules. Nothing in these
specifications shall be construed to relieve the Contractor of his responsibility.
ii) In case of contradiction between this specifications and IS or IEC, the stipulations of this
specification shall be treated as applicable.
iii) National Electrical code for hazardous location and relevant NEMA standard shall also be
applicable for motors located in hazardous location.
12.3 Design Features
12.3.1 Rating and type
(i) The induction motors shall be of squirrel cage type unless specified otherwise.
(ii) The motors shall be suitable for continuous duty in the specified ambient temperature.
(iii) The MCR KW rating of the motors for 50oC ambient shall not be less than the power
requirement imposed at the motor shaft by the driven equipment under the most onerous
operation conditions as defined elsewhere, when the supply frequency is 51.5 Hz (and the
motor is running at 103% of its rated speed).
(iv) Motors shall be capable of giving rated output without reduction in the expected life span
when operated continuously in the system having the following particulars:
a) Rated terminal voltage
From 0.2 to 200 KW 415V (3 Phase, solidly earthed)
Below 0.2 KW 240 V (1 Phase, solidly earthed)
Variation in voltage ± 6%.
b) Frequency 50 Hz ± 3%.
c) Any combination of (a) & (b)
12.3.2 Enclosure
Volume-II (Section-P), Fire Protection System 369
Motors to be installed outdoor and semi-outdoor shall have hose proof enclosure
equivalent to IP-55 as per IS: 4691. For motors to be installed indoor, the enclosure shall
be dust proof equivalent to IP-54 as per IS: 4691.
12.3.3 Cooling method
Motors shall be TEFC (totally enclosed fan cooled) type.
12.3.4 Starting requirements
(i) Induction motor
a) All induction motors shall be suitable for full voltage direct on-line starting. These
shall be capable of starting and accelerating to the rated speed alongwith the driven
equipment without exceeding the acceptable winding temperature even when the
supply voltage drops down to 80% of the rated voltage.
b) Motors shall be capable of withstanding the electro-dynamic stresses and heating
imposed if it is started at a voltage of 110% of the rated value.
c) The starting current of the motor at rated voltage shall not exceed six (6) times the
rated full load current subject to tolerance as given in IS : 325.
d) Motors when started with the driven equipment imposing full starting torque under
the supply voltage condition specified under Clause 12.3.1 (iv) (a) shall be capable of
withstanding at least two successive starts with coasting to rest between starts and
motor initially at the rated load operating temperature. The motors shall also be
suitable for three equally spread starts per hour, the motor initially at a temperature
not exceeding the rated operating temperature.
e) The locked rotor withstand time under hot condition at 110% of rated voltage shall be
more than the starting time with the driven equipment at minimum permissible
voltage (clause 12.3.4 (i) (a) by at least two seconds or 15% of the accelerating time
whichever is greater. In case it is not possible to meet the above requirement the
Bidder shall offer centrifugal type speed switch mounted on the motor shaft which
shall remain closed for speeds lower than 20% and open for speeds above 20% of the
rated speed. The speed switch shall be capable of withstanding 120% of the rated
speed in either direction of rotation.
Volume-II (Section-P), Fire Protection System 370
12.3.5 Running requirements
(i) When the motors are operating at extreme condition of voltage and frequency given
under clause no.12.3.1 (iv) the maximum permissible temperature rise over the ambient
temperature of 50°C shall be within the limits specified in IS : 325 after adjustment due to
increase ambient temperature specified herein.
(ii) The double amplitude of motor vibration shall be within the limits specified in IS: 4729.
Vibration shall also be within the limits specified by the relevant standard for the driven
equipment when measured at the motor bearings.
(iii) All the induction motors shall be capable of running at 80% of rated voltage for a period
of 5 minutes with rated load commencing from hot condition.
(iv) Induction motors shall be so designed as to be capable of withstanding the voltage and
torque stresses developed due to the difference between the motor residual voltage and
incoming supply voltage during fast changeover of buses. The necessary feature
incorporated in the design to comply with this requirement shall be clearly indicated in
the proposal.
(v) Motors shall be capable of developing the rated full load torque even when the supply
voltage drops to 70% of rated voltage. Such operation is envisaged for a period of one
second. The pull out torque of the induction motors to meet this requirement shall not be
less than 205% of full load torque.
(vi) The motors shall be capable of withstanding for 10 seconds without stalling or abrupt
change in speed (under gradual increase of torque) an excess torque of 60 percent of their
rated torque, the voltage and frequency being maintained at their rated value.
(vii) Guaranteed performance of the motors shall be met with tolerances specified in
respective standards.
12.4 Construction Features
12.4.1 Stator
(i) Stator frame
The stator frames and all external parts of the motors shall be rigid fabricated steel or of
casting. They shall be suitably annealed to eliminate any residual stresses introduced
during the process of fabrication and machining.
Volume-II (Section-P), Fire Protection System 371
(ii) Stator core
The stator laminations shall be made from suitable grade magnetic sheet steel varnished
on both sides. They shall be pressed and clamped adequately to reduce the core and teeth
vibration to minimum.
(iii) Insulation and winding
All insulated winding conductor shall be of copper. The overall motor winding insulation
for all 415 volts motors shall be of epoxy thermosetting type i.e., class 'F' but limited to
class-B operating from temperature rise consideration. Other motors may be of
conventional class-B type.
The windings shall be suitable for successful operation in hot, humid, tropical climate
with the ambient temperature of 50°C.
12.4.2 Rotor
(i) Rotors shall be so designed as to keep the combined critical speed with the driven
equipment away from the running speed by atleast 20%.
(ii) Rotors shall also be designed to withstand 120% of the rated speed for 2 minutes in either
direction of rotation.
12.4.3 Terminal box leads
(i) For motors of 415 Volts and below a single terminal box may be provided for power and
accessories leads.
(ii) Terminal boxes shall be of weatherproof construction designed for outdoor service. To
eliminate entry of dust and water, gaskets of neoprene or approved equivalent shall be
provided at cover joints and between box and motor frame.
(iii) Terminal box shall be suitable for top and bottom entry of cables.
(iv) Unless otherwise approved, the terminal box shall be capable of being turned through
360° in steps in 90°.
(v) The terminals shall be complete with all accessories for connecting external cables. They
shall be designed for the current carrying capacity and shall ensure ample phase to phase
to ground clearances.
Volume-II (Section-P), Fire Protection System 372
(vi) Suitable tinned brass compression type cable glands and cable lugs shall be supplied by
the Contractor to match Employer's cable.
(vii) Terminal box for single core cable shall be of non- magnetic material.
(viii) Marking of all terminals shall be in accordance with IS: 4728.
12.4.4 Rating Plates
(i) Rating plates shall be provided for all motors giving the details as called for in IS:325
(for three phase squirrel cage induction motors).
(ii) In addition to above, the rating plate shall indicate the following :
a) Temperature rise in °C under normal working conditions.
b) Phase sequence corresponding to the direction of rotation for the application.
c) Bearing identification number (in case of ball/ roller bearing) and recommended
lubricants.
12.4.5 Other Constructional Features
(i) Two independent earthing points shall be provided on opposite sides of the motor for
bolted connection of Employer's earthing conductor to be specified to the successful
Bidder.
(ii) Motor weighing more than 25 kg. shall be provided with eyebolts, lugs or other means to
facilitate lifting.
12.5 Paint and Finish
12.5.1 Motor external parts shall be finished and painted to produce a neat and durable surface,
which would prevent rusting and corrosion. The equipment shall be thoroughly
degreased, all sharp edges and scales removed and treated with one coat of primer and
two coats of grey enamel paint.
12.5.2 Motor fans shall also be painted to withstand corrosion.
12.5.3 All fasteners used in the construction of the equipment shall be either of corrosion
resistant material or heavy cadmium plated.
12.5.4 Current carrying fasteners shall be either of stainless steel or high tensile brass.
Volume-II (Section-P), Fire Protection System 373
12.6 Tests at Manufacturers Works
12.6.1 Motors shall be subject to routine tests in accordance with IS: 325 & IS : 4029 standards.
12.6.2 In addition, the following tests shall also be carried out:
a) 20% over speed test for 2 minutes on all rotors.
b) Measurement of vibration.
c) Measurement of noise level.
d) Phase sequence and polarity checks relative to mechanical rotation.
12.6.3 Tests after installation at site
(i) After installation and commissioning at site, the motors alongwith the driven equipment shall be
subject to tests to ascertain their conformity with the requirement of this specification and those of the
driven equipment specification and the performance data quoted by the Bidder.
(ii) In case of non-conformity of the motor with these specifications and performance requirement, the
Engineer may at his discretion reject or ask for necessary rectification/replacement.
13.0 BATTERY & BATTERY CHARGERS
This clause covers the design, performance, manufacturing, construction features and testing of
Battery and Battery charger used primarily for starting the diesel engine driving the fire water
pumps. Battery Chargers shall be housed in Diesel Engine Panel.
13.1 General Information
i) The equipment specified hereinafter are required for starting the diesel engines and other
operation of the plant as required.
ii) For each diesel engine there shall be two (2) sets of Battery and two (2) sets of Battery
Charger.
iii) The D.C. voltage shall be obtained normally after necessary rectification by battery
charger. The Battery Charging system shall be capable of meeting the following
requirements :
a) Float charging the Battery.
b) Boost Charging the Battery.
Volume-II (Section-P), Fire Protection System 374
vi) The battery shall be large enough to crank the engine 3 times without charging in
between and without getting drained to an extent which will affect its life.
vii) The Bidder shall indicate the battery voltage and battery capacity in Ampere- Hour at ten
(10) hour discharge rate. The battery voltage at any time during operation shall not be
less than the minimum voltage required for operation of the D.C. loads.
13.2 General Design
The Battery shall be located indoor
13.2.1 Battery
(i) The cells shall be lead-acid type. The Battery shall be automotive type.
(ii) The cells shall be sealed in type with anti-splash type vent plug.
(iii) The cell terminal posts shall be provided with connector bolts and nuts, effectively coated
with lead to prevent corrosion. Lead or lead coated copper connectors shall be furnished
to connect up cells of battery set.
(iv) Positive and Negative terminal posts shall be clearly and indelibly marked for easy
identification.
(v) The electrolyte shall be of battery grade Sulphuric Acid conforming to IS : 226-2962.
Water for storage batteries conforming to IS: 1069 shall be used in the preparation of the
electrolyte.
13.2.2 Battery Charger
(i) The Bidder shall furnish the battery charging scheme complete with all necessary
accessories such as transformers, switches, fuses, starters, contactors, diodes, ammeters,
voltmeters and other devices as required for trouble free operation. All devices and
equipment shall conform to relevant Indian Standard or shall be Superior to it.
(ii) The scheme of the battery charger shall be such that the battery can be charged
automatically as well as manually.
(iii) The boost charger shall have sufficient capacity to restore a fully discharged Battery to a
state of full charge in eight (8) hours with some spare margin over maximum charging
Volume-II (Section-P), Fire Protection System 375
rate. Suitable provision shall be kept so that, for a particular engine, any of the two (2)
charger units can be used for charging any of the two (2) batteries.
(iv) The instruments, switches and lamps shall be flush/semi-flush mounted on the front
panel. Name plate of approved type shall be provided for each of these equipment.
(v) The panel shall be complete with internal wiring and input-output terminal block.
Terminal blocks shall be clip on type of suitable rating. All equipment and wire terminals
shall be identified by symbols corresponding to applicable schematic/wiring diagram.
(vi) Space heaters of adequate capacity shall be provided to prevent moisture condensation in
the panel.
13.3 Testing
i) The Battery Charger shall also be subjected to the following tests at manufacturer's works as per
IS - 4540
ii) Insulation test.
iii) Connection checking.
iv) Measurement of voltage regulation.
v) Auxiliary of devices.
vi) Alternating current measurement.
vii) Performance test.
viii) Temperature rise test.
ix) Following acceptance tests shall be carried out in batteries as per IS:1651.
a) Marking and packing
b) Verification of dimensions
c) Test for capacity
d) Test for voltage during discharge
Battery and battery charger shall be checked for auto charging and providing sufficient power for
three consecutive starting kicks to diesel engine within five minutes with A.C. supply switched
off.
14.0 CONTROL & ANNUNCIATION PANELS
Volume-II (Section-P), Fire Protection System 376
14.1 Intent of Specification
The following requirement shall be applicable to the control and annunciation panels furnished
under these specifications.
14.2 General Information
i) The equipment specified herein are required for controlling, metering, monitoring and indication
of electrical systems of the plant offered.
ii) The selection and design of all the equipment shall be so as to ensure reliable and safe operation
of the plant and shall be subjected to approval by the Employer.
iii) The reference ambient temperature outside the panel shall be taken as 50°C and relative humidity
100%.
14.3 Equipment to be Furnished
Control & annunciation panels shall be furnished complete with all accessories and wiring for
safe and trouble free operation of the plant.
14.4 Constructional Details
i) The panel frames shall be fabricated using suitable mild steel structural sections or pressed and
shaped cold-rolled sheet steel of thickness not less than 2.5 mm. Frames shall be enclosed in cold-
rolled sheet steel of thickness not less than 1.6 mm. Stiffeners shall be provided wherever
necessary.
ii) Panels shall be of free standing type and shall be provided with hinged door with locking
arrangement. The access doors, cutest and covers shall be equipped with neoprene/synthetic
rubber gaskets (conforming to IS 11149-1984) all around and the latches sufficiently strong to
hold them in alignment when closed. The panels to be installed outdoor or semi outdoor shall
have a degree of protection of IP:55 and those installed indoor shall have a degree of protection
of IP:52 as per IS:13947 Part-1.
iii) If a panel consists of a number of panels, each panel should be mounted side by side and bolted
together to form a compact unit, when two panels meet, the joints shall be smooth, close fittings
and unobstructive.
iv) Removable eye bolt or lifting lugs shall be provided on all panels to facilitate easy lifting.
v) The heights of all operating equipment on the panel shall be between 800 mm to 1600 mm from
the finished floor level. The proper supporting arrangement shall be provided by the Contractor.
Volume-II (Section-P), Fire Protection System 377
vi) Cable entries to the panel may be from bottom or top. The cable entry required will be intimated
to the successful Bidder. A suitable removable gland plate of 3 mm thick shall be mounted not
less than 200 mm above the floor level.
vii) All equipment mounted on the front face of the panels shall be flush or semi-flush type. All
equipment shall be so located that their terminal and adjustment are readily accessible for
inspection or maintenance and their removal and replacement can be done without interruption of
service to other equipment. The contractor shall submit the panel general arrangement drawings
clearly bringing out internal mounting details, dimensions of equipment, clearance between the
equipment and the edges of the panel, for approval.
14.5 Name Plates and Labels
i) Each panel shall be provided with prominent, engraved identification plates for all front mounted
equipment. Panel identification name plate shall be provided at front and rear as required.
ii) All name plates shall be of non-rusting metal or 3 ply lamicold, with white engraved lettering on
black background. Inscription and lettering sizes shall be subjected to Employer's approval.
iii) Suitable plastic sticker labels shall be provided for easy identification of all equipment located
inside the panel. These labels shall be positioned so as to be clearly visible and shall give the
device number, as mentioned in the wiring drawings.
14.6 AC/DC Power Supply
i) The Employer will provide one feeder each for AC and DC to the panel. The Contractor shall
make for his own arrangements for providing these power supplies to different panels.
ii) The Contractor shall provide suitable isolating switch fuse unit in the control panel for receiving
the above incoming AC and DC supplies. Fuse and link shall be provided for isolating of
individual circuit without disturbing other circuits.
14.7 Wiring
i) All inter panel wiring and connections between panels (if there is group of panels) including all
bus wiring for AC & DC supplies shall be provided by the Contractor.
ii) All internal wiring shall be carried out with 1100 V grade, single core, 1.5 square mm or larger
stranded copper wires having colour-coded PVC insulation. CT circuits shall be wired with 2.5
square mm copper wires, otherwise similar to the above.
iii) Extra-flexible wire shall be used for wiring to devices mounted on moving parts such as doors.
Volume-II (Section-P), Fire Protection System 378
iv) Spare contacts of auxiliary relays, timers and switches shall be wired out to the terminal blocks as
required by the Employer/Engineer at the time of detailed engineering.
14.8 Terminal Blocks
i) Terminal Blocks shall be of 650V grade, rated for 10 Amps and in onepiece moulding. It shall be
complete with insulating barriers, clip-ontype terminals, and identification strips. Marking on
terminal strip shall correspond to the terminal numbering on wiring diagrams. It shall be similar
to 'Elmex-Standard' type terminals.
ii) Terminal blocks shall be arranged with at least 100 mm clearance between two sets of terminal
block.
iii) The terminal blocks shall have at least 20% spare terminals.
14.9 Grounding
A continuous copper bus 25 x 3 mm size shall be provided along the bottom of the panel
structure. It shall run continuously throughout the length of the panel and shall have provision at
both ends for connection to the station grounding grid (25 x 6 mm MS Flat).
14.10 Space Heater and Lighting
i) Space heaters shall be provided in the panels for preventing harmful moisture condensation.
ii) The space heaters shall be suitable for continuous operation on 240V AC, 50 Hz, single phase
supply and shall be automatically controlled by thermostat. Necessary isolating switches and
fuses shall also be provided.
iii) Free standing panel shall have a 240V AC, plug point and a fluorescent light operated by door
switch.
14.11 Control and Selector Switches
i) Control and selector switches shall be of rotary type, with escutcheon plates clearly marked to
show the function and positions.
ii) Control/selector switches shall be spring return or stay put type as per the requirements. Handles
of control/selector switches shall be black in colour. Shape and type of handles shall be to the
approval of the Employer.
iii) The contact ratings shall be at least the following :
a) Make and carry continuously 10 Amp.
Volume-II (Section-P), Fire Protection System 379
b) Breaking current at 240V DC 1Amp. (Inductive)
c) Breaking current at 240V DC 5 Amp. at 0.3 p.f. lagging
14.12 Push Buttons
i) Push buttons shall be spring return, push to actuate type and rated to continuously carry and break
10A at 240V AC and 0.5A (Inductive) at 220V DC. The push buttons shall have at least 1 NO
and 1 NC contact. All contact faces shall be of silver or silver alloy.
ii) All push buttons shall be provided with integral escutcheon plates marked with its function.
iii) The colour of buttons shall be as follows :
Green For motor START, Breaker CLOSE, Valve/ damper OPEN.
Red For motor TRIP, Breaker OPEN, Valve/ damper CLOSE.
Black For all annunciation functions, overload reset and miscellaneous.
iv) Red push buttons shall always be located to the left of green push buttons. In case of clinker
grinder etc. the push buttons would be blackred- green from left to right.
14.13 Indicating Lamps
i) Indicating lamps shall be of the panel mounting, filament type and of low-watt consumption.
Lamps shall be provided with series resistors preferably built-in- the lamps assembly. The lamps
shall have escutcheon plates marked with its function, wherever necessary.
ii) Lamp shall have translucent lamp covers of the following colours :
Red For motor OFF, Valve/damper OPEN, Breaker CLOSED.
Green For motor ON, Valve/damper CLOSED, Breaker OPEN.
White For motor AUTO-TRIP.
Blue For all healthy conditions (e.g. control supply, lub oil pressure and also for spring
charged).
Amber For all ALARM conditions (e.g. pressure low, over load and also for 'service' and
'Test' position indication).
iii) Bulbs and lamps covers shall be easily replaceable from the front of the panel.
Volume-II (Section-P), Fire Protection System 380
iv) Indicating lamps should be located directly above the associated push button/control switches.
Red lamps shall variably be located to the right of the green lamp. In case a white lamp is also
provided, it shall be placed between the red and green lamps. Blue and amber lamps should
normally be located above the red and green lamps.
14.14 Fuses
i) All fuses shall be of HRC cartridge plug-in-type and shall be of suitable rating, depending upon
circuit requirements.
ii) All fuses shall be mounted on fuse carriers, which shall be mounted on fuse-bases.
14.15 Contactors
i) Contactors shall be of air break, electromagnetic type rated as per requirement. These shall be of
utilisation category AC 3 as per IS:2959.
ii) Operating coils of AC contactors shall be of 240V AC or 220V DC as required. AC contactors
shall operate satisfactorily between 85% to 110% of the rated voltage. The Contactor shall not
drop out at 70% of the rated voltage.
iii) DC contactors shall have a coil voltage of 220V DC and shall be suitable for satisfactory
continuous operation at 80% to 110% of the rated voltage.
14.16 Relays and Timers
i) All auxiliary relays & timers shall be of proven design and of reputed make. Contacts of relays
and timers shall be of solid silver or silver cadmium oxide or solid silver faced. Timers shall have
the provision to adjust the delay on pick-up or reset as required.
ii) All relays and timers shall have at least two NO and two NC contacts.
iii) All relays and timers shall be suitable for 240V AC and 220V DC as required. DC relays shall
operate satisfactorily between 70% to 110% and AC relays shall be suitable for voltage variation
between 80% to 110%.
14.17 Indication Instruments
i) All indicating and integrating meters shall be flush mounted on panel front. The instruments shall
be of at least 96 mm square size with 90 degree scales and shall have an accuracy class of 2.0 or
better. The covers and cases of instruments and meters shall provide a dust and vermin proof
construction.
Volume-II (Section-P), Fire Protection System 381
ii) All instruments shall be compensated for temperature errors and factory calibrated to directly
read the primary quantities. Means shall be provided for zero adjustment removing or dismantling
the instruments.
iii) All instruments shall have white dials with black numerals and lettering. Black knife edge pointer
with parallax free dials will be preferred.
iv) Ammeters provided on motor feeders shall have a compressed scale at the upper current region to
cover the starting current.
14.18 Annunciation System
i) The annunciation system shall be complete with all necessary relays, flashers and other
accessories required for the proper operation of the equipment and shall be completely solid state.
The control circuit shall be mounted on plug-in type glass epoxy printed circuit boards. Audible
alarms for the system shall be mounted inside the panel. One set of acknowledge, test and reset
push buttons shall be mounted on the panel.
ii) Indications shall be engraved on Acrylic inscription plate window and shall be visible clearly
when the indication lamp is lighted (black letters on white background). Each window shall be
provided with two lamps.
iii) Audible hooter shall sound when a trouble contact operates and shall continue to sound until the
acknowledge button is pressed. In addition to the hooters provided on annunciation panels, a
hooter shall be provided outside FFPH which shall sound in any fire alarm condition.
iv) Indication lamps shall flash when trouble contact operates and shall continue flashing until
acknowledge button is pressed.
v) After acknowledge button is pressed, the hooter and flashing shall stop but the indication lamp
shall remain lighted.
vi) After trouble is cleared indication lamps shall be ready and shall go off only when reset.
vii) Silencing the hooter in conjunction with one trouble contact shall not stop and hooter sounding if
another trouble contact operates.
viii) When test button is pressed, all lamps shall flash and hooter shall sound.
ix) Annunciator systems shall operate on 220V DC Systems.
x) The annunciation system shall include alarm for AC control system failure (working on DC
supply), DC supply failure (working on AC supply) and test facilities for these alarms.
Volume-II (Section-P), Fire Protection System 382
xi) List of annunciations required on the panels has been listed elsewhere.
The Contractor shall also provide additional annunciations if desired by the Employer/Engineer
during Vendor drawing review stage and for such additional annunciations no extra charges shall
be claimed by the Contractor, if the number of such additions are within 10% of the number
stipulated in this specification.
xii) 20% spare windows shall be provided on the panel.
14.19 Painting
All sheet steel work shall be pre-treated, in tanks, in accordance with IS:6005, Degreasing shall
be done by alkaline cleaning. Dust and scale shall be removed by pickling, the parts shall be
washed in running water. Then these shall be rinsed in slightly alkaline hot water and dried. The
phosphate coating shall be "Class-C" as specified in IS:6005. The phosphated surfaces shall be
rinsed and passivated prior to application of stoved lead oxide primer coating.
After primer application, two coats of finishing synthetic enamel paint on panels shall be applied.
Electrostatic painting shall also be acceptable. Finishing paint on panels shall be shade 692
(smoke grey) of IS:5 unless required otherwise by the Employer. The inside of the panels shall be
glossy white. Each coat of finishing shall be properly stoved. The paint thickness shall not be less
than 50 microns. Finished parts shall be coated by peelable compound by spraying method to
protect the finished surface from scratches, grease, dirt and oily spots during testing,
transportation handling and erection.
14.20 Tests
i) Following tests/inspection shall be carried out by the Contractor in the presence of Employer's
representative:
(A) Factory Tests
1. Compliance with approved drawings, data and specification.
2. Visual check for workmanship.
3. Wiring continuity and functional checks.
4. Calibration of instruments, relays and metres wherever required by inspector.
5. HV test
6. Insulation resistance measurement before and after HV test.
Volume-II (Section-P), Fire Protection System 383
(B) Inspection/Testing at site :
1. IR test before and after HV test
2. HV Test
3. Functional Testing.
(C)
1. The Fire detection and annunciation panel shall be subjected to functional tests.
2. The Annunciation System shall be routine tested
Appendix-1
TECHNICAL DATA SHEETS
DATA SHEET FOR DELUGE VALVE
1.0 Manufacturer Owner Approved make
2.0 Number & size As per approved system drawings.
3.0 Type. Differential Diaphragm type
4.0 Rating
4.1 Flow in M3/hr. 1. 150 mm ø 2. 100 mm ø
170 to 650 50 to 225
4.2 Pressure Working Pressure – 12.3 kg/cm2 Test Pressure - 25 kg/cm2.
4.3 Pressure drop in equivalent length 1. 150 mm ø 2. 100 mm ø
19M 11M
5.0 Material of construction
5.1 Body CI IS:210 Gr. FG 260
5.2 Valve internal Cast Bronze – IS:318-LTB 2
5.3 Seat Seal Neoprene Rubber
5.4 Diaphragm Neoprene Rubber
6.0 Differential pressure required for operation
Differential Ratio – 50%
7.0 Water Motor Gong provided Yes
7.1 Type Hydraulic type
7.2 Material of Construction:
Volume-II (Section-P), Fire Protection System 384
7.2.1 Housing Al. Alloy-IS:617
7.2.2 Cover/Rotor./Gong Aluminium to IS:737
7.2.3 Manual actuation lever provided? Yes 8.0 Remote actuation with Solenoid
Valve provided? Yes
9.0 Resetting type Manual resetting type
10.0 Deluge valve complete with test and drain valves, manual operation arrangement, supporting structures and all necessary accessories.
Yes
11.0 Approval of Deluge Valve. FM of USA, UL of USA, LPCB of U.K. or VDS of Germany
DATASHEET FOR HVW SPRAY NOZZLE
1.0 Make Owner Approved make
2.0 Type High velocity water spray type
3.0 Working pressure 3.5 bar to 5 bar
4.0 Material Brass
5.0 K factor As per approved design & drawings
6.0 Quantity As per approved design & drawings
7.0 Integral non-ferrous strainer provide Yes
8.0 Approval of HVW spray Nozzle FM of USA, UL of USA, LPCB of U.K. or VDS of Germany
DATA SHEET FOR QUARTZOID BULB DETECTORS
1.0 Make Owner Approved make
2.0 Type Quartzoid bulb type
3.0 Rated pressure 12.3 kg/ cm2 (175 PSI).
4.0 Hydrotest pressure 30kg/cm2
5.0 Material of construction Brass
5.1 Frame Bronze
5.2 Bulb Glass
5.3 Deflector Copper
6.0 Temperature rating 79°C
7.0 Quantity As per approved drawings
8.0 Approval of Detector FM of USA, UL of USA, LPCB of
Volume-II (Section-P), Fire Protection System 385
U.K. or VDS of Germany
DATA SHEET FOR OPTICAL SMOKE DECTECTOR
1.0 Manufacturer Owner Approved make
2.0 Principle of operation Light scattering by smoke particles.
3.0 Max. recommended spacing
9 m.
4.0 Normal operating temperature -10°C to 60°C
5.0 Guaranteed to function properly without any maintenance work for a period of not less than ten (10) years
Yes. Accumulated dust to be removed periodically by blowing air.
6.0 Approval of detector FM of USA, UL of USA, LPCB of U.K. or VDS of Germany
5.2 Cabling. 2C x 1.5 sq.mm. Un-armoured PVC insulated FR cables conforming to IS 1554 (Part 1).
DATA SHEET FOR HEAT DECTECTOR
1.0 Manufacturer Owner Approved make
2.0 Principle of operation Rate of rise-cum-fixed temperature type.
3.0 Max. recommended spacing
6 m.
4.0 Normal operating temperature -20°C to 70°C
5.0 Guaranteed to function properly without any maintenance work for a period of not less than ten (10) years
Yes. Accumulated dust to be removed periodically by blowing air.
6.0 Set point of operation 5°C per minute / 55°C
7.0 Approval of detector FM of USA, UL of USA, LPCB of U.K. or VDS of Germany
8.0 Cabling. 2C x 1.5 sq.mm. Un-armoured PVC insulated FR cables conforming to IS 1554 (Part 1).
DATA SHEET FOR IONISATION SMOKE DECTECTOR
1.0 Manufacturer Owner Approved make
2.0 Principle of operation Ionisation of air by Radio-active source.
Volume-II (Section-P), Fire Protection System 386
3.0 Max. recommended spacing
9 m.
4.0 Normal operating temperature -10°C to 60°C
5.0 Guaranteed to function properly without any maintenance work for a period of not less than ten (10) years
Yes. Accumulated dust to be removed periodically by blowing air.
7.0 Approval of detector FM of USA, UL of USA, LPCB of U.K. or VDS of Germany
8.0 Cabling. 2C x 1.5 sq.mm. Un-armoured PVC insulated FR cables conforming to IS 1554 (Part 1).
DATA SHEET FOR 2C x 1.5sq.mm Un-armoured cable.
1 Manufacturer Owner Approved make
2 Type Control Cable
3 Number of cores
Two (2)
4 Size 1.5 sq. mm.
5 Voltage Grade 1.1 kV
6 Applicable standard IS:1554 Part 1
7 Conductor Material Plain annealed electrolytic copper
8 Conductor construction Stranded
9 Conductor resistance. 12.1 Ohms/kM at 20° C
10 Insulation material PVC insulation Type A as per IS:5831
11 Insulation thickness 0.8 mm Nominal
12 Identification Red & Black
13 Inner sheath material PVC compound Type ST1 as per IS:5831
14 Inner sheath thickness 0.3 mm Minimum
15 Outer sheath material PVC compound Type ST2 as per IS:5381,FR.
16 Outer sheath thickness 1.8 mm Nominal.
17 Outer Sheath Colour Grey
18 Overall Diameter As per manufacturer design data
DATA SHEET FOR MANUAL CALL POINT
1 Manufacturer Owner Approved make
Volume-II (Section-P), Fire Protection System 387
2 Construction Deep drawn sheet steel
3 Type Break glass with push button.
4 Operating Voltage 24V DC ± 10%
5 Type of control Pole- NO/NC
6 Degree of protection IP 52
7 Material of housing. M.S. 18 Gauge
8 Colour FIRE RED
9 Accessories Hammer & Chain assembly
DATA SHEET FOR MANUAL CALL POINT
1 Manufacturer Owner Approved make
2 Construction Deep drawn sheet steel
3 Type Break glass with push button.
4 Operating Voltage 24V DC ± 10%
5 Type of control Pole- NO/NC
6 Degree of protection IP 52
7 Material of housing. M.S. 18 Gauge
8 Colour FIRE RED
9 Accessories Hammer & Chain assembly
DATA SHEET FOR FIRE ALARM SOUNDER (HOOTER)
1 Manufacturer Owner Approved make
2 Construction Deep drawn sheet steel
3 Type Dual tone/ Single tone
4 Operating Voltage 24V DC ± 10%
5 Output
Not less than 80dB(A) but not more than 120dB(A) at 1.5m distance.
6 Output frequency range 500Hz. to 1000 Hz.
Material of housing M.S. 18 Gauge
7 Operating time 50 minutes (Minimum)
8 Colour FIRE RED
10 Marking FIRE ALARM.
Volume-II (Section-P), Fire Protection System 388
DATA SHEET FOR GLOBE VALVE.
1 Nominal size in mm 15 TO 40
2 Make Owner Approved make
3 Type Globe
4 Number As per approved system drawings
5 Material of construction
i) Body Bronze to IS 318 Grade LTB 2
ii) Hand wheel Grey cast iron, grade FG200 of IS 210
iii) Bonnet & Bonnet Wedge Bronze to IS 318 Grade LTB 2
iv) Trim Bronze to IS 318 Grade LTB 2
6 End connection Screwed
7 Standard IS:778
8 Rating PN 1.6
9 Hydrostatic test pressure
i) Body 24 kg/cm2
ii) Seat 16 kg/cm2
DATA SHEET FOR GUN METAL GATE/ SLUICE VALVE
1 Nominal size in mm 15 TO 40
2 Make Owner Approved make
3 Type Globe
4 Number As per approved system drawings
5 Material of construction
i) Body Bronze to IS 318 Grade LTB 2
ii) Hand wheel Grey cast iron, grade FG200 of IS 210
iii) Bonnet & Bonnet Wedge Bronze to IS 318 Grade LTB 2
iv) Trim Bronze to IS 318 Grade LTB 2
6 End connection Screwed
7 Standard IS:778
8 Rating PN 1.6
9 Hydrostatic test pressure
i) Body 24 kg/cm2
Volume-II (Section-P), Fire Protection System 389
ii) Seat 16 kg/cm2
DATA SHEET FOR FLOAT OPERATED VALVE
1 Manufacturer Owner Approved make
2 Size 100 MM
3 Type Float operated valve
4 Quantity 2 nos. 24V DC ± 10%
5 Material of construction
i) Body Cast Iron (IS:210 FG:200)
ii) Seat Ring Gun Metal (IS:318, LTB-2)
iii) Disc Ring Gun Metal (IS:318, LTB-2)
iv) Spindle 13% Cr. Stainless steel
v) Piston Cast Iron (IS:210, FG:200)
vi) Lever Mild Steel (IS:226)
vii) Float Tin Coated Copper
viii) Fulcrum Mild Steel (IS:226)
ix) Pilot Valve Stainless Steel (AISI-304)
x) Gland Packing Graphited Asbestos Rope
xi) Bonnet Cast Iron (IS:210, FG:200)
6 Hydrostatic test pressure
i) Body 15 kg / cm2
ii) Seat 10 kg / cm2
7 End connection Flanged connection
DATA SHEET FOR CHECK VALVES (NON-RETURN VALVES)
1 Make Owner Approved make
2 Type Swing Check Type
3 Standard followed IS:5312
4 Rating PN 1.6
5 Material of construction, Dimensions As per IS:5312
6 Inlet Outlet details Flanged
7 Hydraulic test pressure, kg/cm2
i) Body 24
ii) Seat 16
Volume-II (Section-P), Fire Protection System 390
VENDOR LIST FOR FIRE PROTECTION PACKAGE
1 Pumps
(Horizontal Centrifugal)
KBL/M&P/B&C
2 Motors (L.T.) RAJENDRA ELECT.IND./GEC SIEMENS/ ABB/CROMPTON
3 Diesel Engine Ruston & Hornsby (Greaves)/ KIRLOSKAR OIL ENGINE LTD
4 Air Compressor KGK/ELGI/INGERSOL RAND
5 Batteries EXIDE/AMCO/AMARA RAJA
6 M.S./G.I Pipes
JINDAL/PRAKASH/ SAIL/ LLOYD METALS & ENGINEERS LTD
7 C. I. Valves (Gate & Check)
H. Sarkar/Venus/Kalpana
8 Gun Metal Valves (Globe) Leader
9 Float operated Gate Valve Levcon/Sigma
10 Deluge Valve ACE Turnkey/H.D. Fire
11 Strainer (Y-Type & Basket Type) Grandprix/Jaypee/Multitex/ Gujarat Otofilt
12 Hume pipe Indian Hume Pipe/Pargate Concrete Udyog Delhi
13 H. V. Spray Nozzles H.D. Fire/ACE Turnkey
14 Q. B. Detectors H.D Fire/ACE Turnkey
15 Pressure Gauge H. Guru/General Instrument
16 Pressure Switches Indfos/Switzer/Verma Trafag
17 Level Switches Levcon/Sigma
18 Level Indicator Levcon/Sigma
19 Level Gauge Levcon/Sigma
20 Hydrant Valves & Accessories Sukan/Shah Bhogilal
21 Hoses (Flax Canvas) Jayshree Calcutta/Newage
22 Solenoid Valves AVCON/ROTEX
23 Heat & Smoke Detectors Apollo, U.K. /Pyrotonics / System Sensor/ Nittan
24 Cables Polycab/PRWE/GEMSCAB/ KEI/PARAMOUNT
25 Fire Extinguishers Nitin/Vijay Fire/Lightex/ Zenith/ Minimax
26 Fire alarm Panels ECD
27 Annunciators Peacon/Piri/Procon
28 Dished Ends Anoop Engg./Motilal/Kanara
Volume-II (Section-P), Fire Protection System 391
29 Local control panels & Annunciation panels
Suchitra/ Vikas Engg./UNILEC/JASPER/ MIKA/ Bose corporation.
30 Response Indicators/Hooters Break Glass Units
M.C. Engineering Delhi/ Maths, Bombay/ Mehta & Associates, Ahmedabad.
Volume-II (Section-Q), Air Conditioning System 392
SECTION- (Q)
TECHNICAL DETAILS FOR AIR CONDITIONING SYSTEM
1.0 GENERAL
This specification covers supply, installation, testing and commissioning and handing over to
OWNER of Air conditioning system for the control room building and switchyard panel rooms.
Air conditioning units for control room building shall be set to maintain the inside DBT at 24.4°C
± 2°C and the air conditioning system for switchyard panel rooms shall be designed to maintain
DBT inside switchyard panel rooms below 24°C.
2.0 AIR CONDITIONING SYSTEM FOR CONTROL ROOM BUILDING
2.1 The following rooms shall be air conditioned.
i. Control room
ii. Conference Room
iii. Officer’s room
iv. Battery room
v. Electronics test lab
vi. PLCC Room
2.2 Air conditioning requirement of rooms indicated at clause no.2.1 shall be met using split AC
units. High wall type split AC units of 2TR capacity each with high wall type indoor evaporator
unit shall be used for all rooms.
2.3 SCOPE
The scope of the equipment to be furnished and services to be provided under the contract are
outlined hereinafter and the same is to be read in conjunction with the provision contained in
other sections/ clauses. The scope of the work under the contract shall be deemed to include all
such items, which although are not specifically mentioned in the bid documents and/or in Bidder's
proposal, but are required to make the equipment/system complete for its safe, efficient, reliable
and trouble free operation.
2.3.1 Suitable number of high wall type split AC units of 2TR capacity each complete with air
cooled outdoor condensing unit having hermetically sealed compressor and high wall
type indoor evaporator unit with cordless remote controller.
Volume-II (Section-Q), Air Conditioning System 393
2.3.1 Copper refrigerant piping complete with insulation between the indoor and remote
outdoor condensers as required.
2.3.3 PVC drain piping from the indoor units upto the nearest drain point.
2.3.4 Power and control cabling between the indoor unit and outdoor unit and earthing.
2.3.5 MS Brackets for outdoor condensing units, condensers as required.
2.4 SPECIFICATION FOR SPLIT AC UNITS
2.4.1 The split AC units will be complete with indoor evaporator unit, outdoor condensing
units and cordless remote control units.
2.4.2 Outdoor unit shall comprise of hermetically sealed reciprocating/ rotary compressors
mounted on vibration isolators, propeller type axial flow fans and copper tube aluminium
finned coils all assembled in a sheet metal casing. The casing and the total unit shall be
properly treated and shall be weatherproof type. They shall be compact in size and shall
have horizontal discharge of air.
2.4.3 The indoor units shall be high wall type. The indoor unit shall be compact and shall have
elegant appearance. They shall have low noise centrifugal blowers driven by special
motors and copper tube aluminium finned cooling coils. Removable and washable
polypropylene filters shall be provided. They shall be complete with multi function
cordless remote control unit with special features like programmable timer, sleep mode
and soft dry mode etc.
2.4.4 The Split AC units shall be of Carrier, Voltas, Blue Star, Hitachi, Daikin, LG, National,
O’General or Samsung make.
3.0 AIR CONDITIONING SYSTEM FOR SWITCHYARD PANEL ROOMS
3.1 Air conditioning system shall be provided in the switchyard panel rooms used for housing control
and protection panels. These panel rooms will be located in the switchyard area and generally
unmanned. Therefore, the air-conditioning system shall be rugged, reliable, maintenance free and
designed for long life.
3.2 Air conditioning system is required for maintaining the temperature for critical sub-station control
and protection panels. This shall be achieved by providing adequate number of Environmental
control units (ECU) to maintain the temperature below 24°C. The system
Volume-II (Section-Q), Air Conditioning System 394
shall be designed for 24 Hours, 365 Days of the year operation to maintain the inside Switchyard
panel rooms temperature for proper operation of the critical equipment.
3.3 ENVIRONMENTAL CONTROL UNITS (ECU)
3.3.1 Each Environmental control unit (ECU) shall comprise of two nos. of air conditioners (1
main + 1 standby), working in conjunction through a micro processor based controller for
desired operation. One of the air-conditioner shall be running at a time and shall maintain
the required temperature. On failure of the running air-conditioner or as described
hereunder, the other air-conditioner shall start automatically. To ensure longer life of the
system, the redundant airconditioner shall also be running in cyclic operation through the
controller. However, during running of one air-conditioner, if inside temperature of the
room reaches 35°C due to any emergency condition, the other air-conditioner shall start
running to maintain the temperature less than 24°C and gives alarm for such situation.
After achieving this temperature, the other unit shall again shut off. The ECU shall be
switched off if the temperature falls below 20°C. No heating or humidification is
envisaged for the air conditioning system inside the Switchyard panel rooms.
3.4 AIR CONDITIONERS USED IN ECU
3.4.1 Construction
The air conditioner shall be completely self-contained. All components of the units shall
be enclosed in a powder coated cabinet. The unit shall be assembled, wired, piped,
charged with refrigerant and fully factory tested as a system to ensure trouble free
installation and start up. Suitable isolation or other by-passing arrangement shall be
provided such that any unit/component could be maintained/ repaired without affecting
the running standby unit. The maintenance of unit shall be possible from outside the
Switchyard panel room.
3.4.2 Sequence of Operation
Suitable arrangement shall be made to operate the unit in the following order. However,
the actual operation arrangement shall be finalised during detailed engineering.
1. Evaporator Fan
2. Condenser Fan
3. Compressor
3.4.3 Required Features of Various Components
Volume-II (Section-Q), Air Conditioning System 395
The compressor shall be very reliable, trouble free and long life i.e. hermetically sealed
Scroll type of reputed make suitable for continuous operation. Compressor should be
installed on vibration isolated mountings or manufacturer’s recommended approved
mounting. Valve shall be provided for charging/topping up of refrigerant. The bidder
shall furnish details of their compressor indicating the MTBF, life of compressor and
continuous run time of compressor without failure. The contractor shall also furnish
details of all accessories i.e. refrigeration system, evaporator coil, condenser coil,
evaporator blower filter, cabinet, indoor supply and return grill etc. during detailed
engineering.
Volume-II (Section-R), Diesel Generator 396
SECTION- (R)
TECHNICAL DETAILS FOR DIESEL GENERATOR SET
1.1 SCOPE OF SUPPLY
1.1.1 The scope covers supply of. Diesel Generator set of stationary type having a net electrical
output of 250kVA capacity at specified site conditions of 50°C ambient temperature and
100% relative humidity on FOR site basis. DG set shall be equipped with:
(i) Diesel engine complete with all accessories.
(ii) An alternator directly coupled to the engine through coupling, complete with all
accessories.
(iii) Automatic voltage regulator.
(iv) Complete starting arrangement, including two nos. batteries & chargers.
(v) Base frame, foundation bolts etc.
(vi) Day tank of 990 Litre capacity.
(vii) Engine Cooling and lubrication system.
(viii) Engine air filtering system.
(ix) Exhaust silencer package.
(x) Set of GI pipes, valves, strainers, unloading hose pipes as required for fuel transfer
system from storage area to fuel tank including electrically driven fuel pump.
(xi) All lubricants, consumable, touch up paints etc. for first filing, testing & commissioning
at site. The fuel oil for first commissioning will also be provided by the contractor.
(xii) AMF panel for control, metering and alarm.
(xiii) Enclosure for silent type D.G. Set
1.2 SCOPE OF SERVICE
1.2.1 The Contractor shall provide following services:
a) Design, manufacture, shop testing including assembly test.
b) Despatch, transportation to site.
Volume-II (Section-R), Diesel Generator 397
c) Erection, testing & commissioning with all equipments/materials required for the
purpose.
d) Drawings, data, design calculations and printed erection, operation & maintenance
manual.
e) Certification and compliance for meeting noise level & emission parameters and other
requirements in accordance with latest Notification of MOEF.
1.3. TECHNICAL REQUIREMENTS
1.3.1 The rating of DG sets are as follows:
i) DG set net out put after considering deration for engine and alternator separately due to
temperature rise in side the enclosure and on account of power reduction due to
auxiliaries shall be 250kVA, 1500RPM, 0.8Pf, 415V, 3 phase, 50Hz. The above ratings
are the minimum requirements. However for 132kV substations the net output of DG Set
shall be 100kVA.
ii) DG sets shall also be rated for 110% of full load for 1 hour in every twelve hrs of
continuous running.
1.3.2 The output voltage, frequency and limits of variation from open circuit to full load shall be
as follows :
a) Voltage variation +5% of the set value provision shall exist to adjust the set value
between 90% to 110% of nominal Generator voltage of 415V.
b) Frequency 50Hz +2%
1.3.3. The Diesel Generator and other auxiliary motor shall be of H class with temperature rise
limited to Class-F for temperature rise consideration.
1.3.4. NOISE LEVEL & EMISSION PARAMETERS: These shall be as per latest Notification
of MOEF
1.4. PLANT DESIGN
1.4.1. DIESEL ENGINE
i) The engine shall comply with the IS 10002/BS 5514/ISO 3046; latest edition
ii) Diesel engine shall be turbo charged multicylinder V-type in line type with mechanical
fuel injection system.
Volume-II (Section-R), Diesel Generator 398
iii) The engine with all accessories shall be enclosed in a enclosure to make it work silently
(within permissible noise level) without any degradation in its performance.
iv) The Diesel Engines shall be directly water cooled. Cooling of water through radiator and
fan as envisaged.
v) The fuel used shall be High Speed Diesel oil (HSD) or Light Diesel Oil (LDO) as per
IS:1460.
1.4.2. Air Suction & Filtration
i) Suction of air shall be from indoor for ventilation and exhaust flue gasses will be let out
to outside atmosphere, Condensate traps shall be provided on the exhaust pipe.
ii) Filter shall be dry type air filter with replaceable elements.
1.4.3 FUEL AND LUBRICATING OIL SYSTEM
The engine shall have closed loop lubricating system. No moving parts shall require
lubrication by hand prior to the start of engine or while it is in operation.
1.4.4. ENGINE STARTING SYSTEM
Automatic electric starting by DC starter motor shall be provided.
1.4.5. FUEL INJECTION AND REGULATOR
i) The engine shall be fitted with electronic governor suitable for class A-1 as per IS 10000.
ii) The engine shall be fitted with a heavy, dynamically balanced fly wheel suitable for
constant speed governor duty.
1.4.6. ALTERNATOR
i) The alternator shall comply with BS 2613/IS 4722/IEC 34; latest edition.
ii) The alternator shall be of continuously rated duty, suitable for 415 V, 3 phase, 50 Hz.
Power development having brush-less, synchronous, self-excited, self-regulating system.
iii) The alternator shall be drip-proof, screen protected as per IP-23 degree of Protection.
iv) The rotor shall be dynamically balanced to minimize vibration.
v) The alternator shall be fitted with shaft mounted centrifugal fan.
vi) It shall have the winding of class H but limited to Class-F for temperature rise
consideration.
Volume-II (Section-R), Diesel Generator 399
vii) The Alternator regulator shall be directly coupled to the engine and shall be complete
with the excitation system, automatic voltage regulation of +/- 1%, voltage adjusting
potentiometer and under/over speed protection.
viii) Terminal Box
a) Six (6) output terminals shall be provided in alternator terminal box. Terminals shall
be Suitable for 1 No. of single core, 630 mm2 XLPE cables per phase for 250kVA
DG set and 3½Core 300 mm2 XLPE cable for 100kVA DG set. The neutral shall be
formed in AMF panel. The generator terminal box shall be suitable to house
necessary cables and should be made of non-magnetic material.
b) The alternator with all accessories shall be enclosed in a enclosure to make it work
Silently (within permissible noise level)
1.4.7. COUPLING
i) The engine and alternator shall be directly coupled by means of self-aligning flexible
flange coupling to avoid misalignment.
ii) The coupling shall be provided with a protecting guard to avoid accidental contract.
1.4.8. MOUNTING ARRANGEMENT
i) The engine and alternator shall be mounted on a common heavy duty, rigid fabricated
steel base frame constructed from ISMC of suitable sections.
ii) Adequate number of anti-vibration mounting pads shall be fixed on the common base
frame on which the engine and the alternator shall be mounted to isolate the vibration
from passing on to the common base frame or the foundation of the D.G. Set.
1.4.9. PERIPHERALS
i) FUEL TANK
a) The Fuel tank of 990 Litre capacity shall be provided on a suitably fabricated steel
platform. The tank shall be complete with level indicator marked in litres, filling inlet
with removable screen, an outlet, a drain plug, an air vent, an air breather and
necessary piping. The tank shall be painted with oil resistant paint and shall be
erected in accordance with Indian explosive act of 1932. Fuel tank shall be kept
outside of enclosure. The fuel piping shall be carried out to connect the D.G set kept
inside.
Volume-II (Section-R), Diesel Generator 400
b) For transferring fuel to Fuel tank transfer pump is envisaged. The capacity of transfer
pump shall be adequate to fill the day tank in about 30 minutes. Fuel pump shall be
electrically driven.
ii) BATTERY and BATTERY CHARGER
a) Two nos. 24V batteries complete with all leads, terminals and stand shall be
provided. Each battery shall have sufficient capacity to give 10 nos. successive
starting impulse to the diesel engine.
b) The battery charger shall be complete with transformer, suitable rating (415 V, 3 Ph.,
50 Hz./230V, 1Ph., 50 Hz) rectifier circuit, charge rate selector switch for
“trickle”/’boost’ charge, D.C. ammeter & voltmeter, annunciation panel for battery
charge indication / loading / failures.
c) The charger shall float and Boost Charge the battery as per recommendation of
manufacturer of battery. The charger shall be able to charge a fully discharged
battery to a state of full charge in 8 Hrs. with 25% spare capacity.
d) Manual control for coarse and fine voltage variation shall be provided. Float charger
shall have built-in load limiting features.
e) Ripple shall not be more than 1%(r.m.s) to get smooth DC voltage shall be provided.
f) Charger shall be provided with Out-put Voltmeter & Ammeter.
g) Changeover scheme for selecting battery and battery charger by changeover switch
should be provided.
1.5. CONTROL AND INSTRUMENTATION
1.5.1. Each D.G. Set shall be provided with suitable instruments, interlock and protection
arrangement, suitable annunciation and indications etc. for proper start up, control,
monitoring and safe operation of the unit. One local AMF control panel alongwith each
D.G. set shall be provided by the Supplier to accommodate these instruments, protective
relays, indication lamps etc. The AMF Panel shall have IP-52 degree of Protection as per
IS:12063.
1.5.2. The D.G. sets shall be provided with automatic start facility to make it possible to take
full load within 30 seconds of Power Supply failure.
1.5.3. Testing facility for automatic operation of D.G.Set shall be provided in AMF panel.
Volume-II (Section-R), Diesel Generator 401
1.5.4. A three attempt starting facility using two impulse timers and summation timer for engine
shall be proved and if the voltage fails to develop within 40 sec. from receiving the first
impulse, the set shall block and alarm to this effect shall be provided in the AMF panel.
1.5.5. Following instruments shall be provided with Diesel Engine
a) Lub oil pressure gauge
b) Water temperature thermometers
c) Engine tachometer/HR
d) Any other instruments necessary for DG Set operation shall be provided.
1.5.6. DG set shall be capable of being started/ stopped manually from remote as well as local.
(Remote START/STOP push button shall be provided in 415V ACDB). However,
interlock shall be provided to prevent shutting down operation as long as D.G. Circuit
breaker is closed.
1.5.7. The diesel generator shall commence a shutdown sequence whenever any of the
following conditions appear in the system :
a) Overspeed
b) Overload
c) High temperature of engine and cooling water.
d) High temperature inside enclosure
e) Low lube oil pressure
f) Generator differential protection
g) Short circuit protection
h) Under voltage
i) Over voltage
j) Further interlocking of breaker shall be provided to prevent parallel operation of DG set
with normal station supply.
Volume-II (Section-R), Diesel Generator 402
1.5.8. Following indication lamps for purposes mentioned as under shall be provided in AMF
panel :
i) Pilot indicating lamp for the following:
a) Mains ON
b) Alternator ON
c) Charger ON/OFF
d) Breaker ON/OFF
e) Main LT Supply ON/OFF
ii) Visual annunciation shall be provided for set shut down due to :
a) Engine overheating
b) Low oil pressure
c) Lack of fuel
d) Set failed to start in 30 secs after receiving the first start impulse
e) High cooling water temperature
f) Low level in daily service fuel tank
g) Overspeed trip
h) Audio & visual Annunciation for alternator fault.
1.5.9. Thermostatically controlled space heaters and cubicle illumination operated by Door
Switch shall be provided in AMF panel. Necessary isolating switches and fuses shall also
be provided.
1.5.10. AMF panel shall have facility for adjustment of speed and voltage including fine
adjustments in remote as well as in local mode.
Following shall also be provided in AMF panel:
a) Frequency meter
b) 3 Nos. single phase CT's for metering
Volume-II (Section-R), Diesel Generator 403
c) 3 Nos. (Provided by LT swgr manufacturer) single phase CT's with KPV 300V &
RCT 0.25 ohm for differential protection of DG Set on neutral side only for
250kVA.
d) One (1) DC Ammeter (0-40A)
e) One (1) DC Voltmeter (0-30V)
f) One (1) Voltmeter Selector switch
g) One (1) AC Ammeter
h) One (1) AC Voltmeter
i) Three (3) Timers (24V DC)
j) Two (2) Auto/Manual Selector Switch
k) Two (2) Auto/test/Manual Selector Switch
l) Eleven (11) Aux. Contactors suitable for 24V DC
m) One (1) Motorised potentiometer for voltage adjustment
n) Two (2) Set Battery charger as specified in Technical details
o) One (1) Set Phase & Neutral busbars.
p) Any other item required for completion of Control scheme shall be deemed to be
included.
1.6. D.G. SET Enclosure
1.6.1. General requirements
i) Diesel engine, alternator, AMF panel, Batteries and Chargers shall be installed outdoor in
a suitable weather-proof enclosure which shall be provided for protection from rain, sun,
dust etc. Further, in addition to the weather proofing, acoustic enclosures shall also be
provided such that the noise level of acoustic enclosure DG set shall meet the
requirement of MOEF The diesel generator sets should also conform to Environment
(Protection) Rules, 1986 as amended. An exhaust fan with louvers shall be installed in the
enclosure for temperature control inside the enclosure. The enclosure shall allow
sufficient ventilation to the enclosed D.G. Set so that the body temperature is limit to
50°C. The air flow of the exhaust fan shall be from inside to the outside the shelter. The
exhaust fan shall be powered from the DG set supply output so that it starts with the
Volume-II (Section-R), Diesel Generator 404
starting of the DG set and stops with the stopping of the DG set. The enclosure shall have
suitable viewing glass to view the local parameters on the engine.
ii) Fresh air intake for the Engine shall be available abundantly; without making the Engine
to gasp for air intake. A chicken mess shall be provided for air inlet at suitable location in
enclosure which shall be finalised during detailed engineering.
iii) The Enclosure shall be designed and the layout of the equipment inside it shall be such
that there is easy access to all the serviceable parts.
iv) Engine and Alternator used inside the Enclosure shall carry their manufacturer’s
Warranty for their respective Models and this shall not degrade their performance.
v) Exhaust from the Engine shall be let off through Silencer arrangement to keep the noise
level within desired limits. Interconnection between silencer and engine should be
through stainless steel flexible hose/ pipe.
1.6.2. All the Controls for Operation of the D.G. Set shall be easily assessable. There should be
provision for emergency shutdown from outside the enclosure.
1.6.3. Arrangement shall be made for housing the Battery set in a tray inside the Enclosure.
1.6.4. Construction Features:
i) The enclosure shall be fabricated from at least 14 Gauge CRCA sheet steel and of
Modular construction for easy assembling and dismantling. The sheet metal components
shall be pre-treated by Seven Tank Process and Powder coated (PURO Polyester based)
both-in side and out side – for long life. The hard-ware and accessories shall be high
tensile grade. Enclosure shall be given a lasting anti-rust treatment and finished with
pleasant environment friendly paint. All the hardware and fixtures shall be rust proof and
able to withstand the weather conditions.
ii) Doors shall be large sized for easy access and provided with long lasting gasket to make
the enclosure sound proof. All the door handles shall be lockable type.
iii) The Enclosure shall be provided with anti-vibration pads (suitable for the loads and
vibration they are required to carry) with minimum vibration transmitted to the surface
the set is resting on.
iv) High quality rock wool of required density and thickness shall be used with fire retardant
thermo – setting resin to make the Enclosure sound proof.
Volume-II (Section-R), Diesel Generator 405
1.6.5. Provision for Neutral/Body Earthing
Points shall be available at two side of the enclosure with the help of flexible copper
wires from alternator neutral, and electrical panel body respectively. The earthing point
shall be isolated through insulator mounted on enclosure.
1.7. INSTALLATION ARRANGEMENT
1.7.1. DG set enclosed in enclosure shall be installed on Concrete Pedestal 300mm above FGL
1.8. DOCUMENTS
1.8.1. Following drawings and data sheet shall be submitted for approval by Contractor:
(i) Data sheet for Engine, Alternator, Battery, AMF panel and Enclosure
(ii) GA drawing of DG set
(iii) Layout of DGset in the enclosure along with sections
(iv) GA and schematic of AMF panel
(v) Arrangement of inclined roof and pedestal.
1.8.2. The D G Set shall be supplied with
(i) D G Set test certificate
(ii) Engine Operation & maintenance Manual.
(iii) Engine Parts Catalogue.
(iv) Alternator Operation, maintenance & Spare parts Manual.
(v) Alternator test certificate.
1.9. TESTS
a) The Diesel generator sets shall be tested for routine and acceptance tests as per the
relevant IS/IEC standards.
b) For the new makes type test reports as per relevant standard shall be submitted for
purchaser’s approval.
Volume-II (Section-R), Diesel Generator 406
1.10. Commissioning Checks
In addition to the checks and test recommended by the manufacturer, the Contractor shall
carryout the following commissioning tests to be carried out at site.
1. Load Test
The engine shall be given test run for a period of atleast 6 hours. The set shall be subjected to the
maximum achievable load as decided by Purchaser without exceeding the specified DG Set
rating:
During the load test, half hourly records of the following shall be taken :
a) Ambient temperature.
b) Exhaust temperature if exhaust thermometer is fitted.
c) Cooling water temperature at a convenient point adjacent to the water output from
the engine jacket.
d) Lubricating oil temperature where oil cooler fitted.
e) Lubricating oil pressure.
f) Colour of exhaust gas
g) Speed
h) Voltage, wattage and current output.
i) Oil tank level
The necessary load to carry out the test shall be provided by the purchaser.
2. Insulation Resistance Test for Alternator
Insulation resistance in mega-ohms between the coils and the frame of the alternator when tested
with a 500V megger shall not be less than IR=2x(rated voltage in KV)+1
3. Check of Fuel Consumption
A check of the fuel consumption shall be made during the load run test. This test shall be
conducted for the purpose of proper tuning of the engine.
Volume-II (Section-R), Diesel Generator 407
4. Insulation Resistance of Wiring
Insulation resistance of control panel wiring shall be checked by 500V Megger. The IR shall not
be less than one mega ohm.
5. Functional Tests
a) Functional tests on control panel.
b) Functional test on starting provision on the engine.
c) Functional tests on all Field devices.
d) Functional tests on AVR and speed governor.
6. Measurement of Vibration
The vibration shall be measured at load as close to maximum achievable load and shall not
exceed 250microns.
7. Noise Level check as per relevant standard
8. The tests shall be carried out with the DG set operating at rated speed and at maximum
achievable load. Necessary correction for Test environment condition & background noise will be
applied as per IS:12065.
Volume-II (Section-S), Civil 408
SECTION- (S)
TECHNICAL DETAILS OF CIVIL
1.0 GENERAL
The intent of this technical specification covers the following:
All civil works shall be carried out as per design/drawings standardised by the Owner and these
specification provided by the Owner. In case any item is not covered under specification then the
same shall be carried out as per CPWD specification and applicable Standards and Codes. Any
item for which specification is not provided herein and is not covered under CPWD specification
shall be executed as per manufacturer guidelines. All materials shall be of best quality
conforming to relevant Indian Standards and Codes. In case of any conflict between Standards/
Code and Technical Specification, the provisions of Technical Specification shall prevail.
The Contractor shall furnish all labour, tools, equipment, materials, temporary works,
constructional plant and machinery, fuel supply, transportation and all other incidental items not
shown or specified but as may be required for complete performance of the Works in accordance
with drawings, specifications and direction of Owner.
All materials including cement, reinforcement steel and structural steel etc. shall be arranged by
the Contractor. All testing required shall be arranged by the Contractor at his own cost. The
contractor shall execute the work as per the Field Quality Plan (FQP) attached with this
document. The bidder shall fully appraise himself of the prevailing conditions at the proposed
site. Climatic conditions including monsoon patterns, local conditions and site specific
parameters and shall include for all such conditions and contingent measures in the bid, including
those which may not have been specifically brought out in the specifications.
2.0 Drawings
Bidder should provide construction drawings for the following:
i) Building
ii) Roads & rail cum Road
iii) Chain link fencing
iv) Soak pit and gate Septic tank
v) Fire fighting pump house building and fire water tank.
vi) Rain water harvesting
Volume-II (Section-S), Civil 409
2.3 Tower & equipment foundations
Drawings for any non-standard tower or equipment foundation, if required, shall be designed by
the Owner and made available to the Contractor during detailed Engineering. Foundations for any
miscellaneous requirements like electric poles, marshalling box, control cubicles, etc. shall be
engineered by the Contractor and the design and drawings shall be submitted for owner’s
approval.
Drawings for transformer, reactor foundations and fire wall are not enclosed and shall be made
available to the contractor by the owner during detailed engineering.
In case the site conditions warrant any special type of foundations to be used, the same shall be
designed and issued by the owner to the contractor during detailed engineering.
2.4 Drains
The contractor shall develop an overall drainage layout for the new sub-station/ extension of
substation during detailed engineering. The type of drains used shall be of the sections
standardized.
2.5 Under Ground Water Tank
The scope includes supplying and erection of 2 numbers ISI marked centrifugal water pump
(Monoblock) at 415 Voltage 3 phase 50 cycle/per second of 7.5 HP along with all necessary
accessories.
2.6 External Sewage System of Township
The drawing for the Sewage system consisting of glazed stoneware pipes Grade-A with all round
cement grade 1:5:10 including manholes, road crossing, gali trap connections etc for connecting
each fittings with the septic tank shall be developed by the Contractor and submitted to Engineer-
in-Charge for approval before execution. Manholes of suitable size as per CPWD standard design
and depth shall be provided at all turning points and junction with spacing between 2 manholes
not exceeding 30m. Heavy duty covers shall be provided for the manholes in case it comes on the
2.7 External water supply from bore-well to fire water tank
The drawing for the water supply from bore-well to fire water tank shall be developed by the
contractor and submitted to owner for approval. Water supply will be made available to the
Contractor from a bore-well by the Owner at any one location within the substation. 80 mm dia
GI pipe shall be provided by the Contractor from the bore-well to the fire water tank. From this a
Volume-II (Section-S), Civil 410
25 mm dia tap off shall be connected by the Contractor to the roof water tank provided for the
control room building.
2.8 Stone spreading and antiweed treatment
The layout of the area where anti-weed treatment and stone spreading is to be provided shall be
made available to the contractor during detailed engineering.
3.0 SITE PREPARATION:
Levelled/sloped site shall be handed over to the contractor. The finished ground level (FGL) shall
be the finished formation level furnished by the owner. The layout and levels of all structure etc
shall be made by the Contractor at his own cost from the general grids of the plot and benchmarks
set by the Contractor and approved by the Owner. The Contractor shall provide all assistance in
instruments, materials and personnel to the Owner for checking the detailed layout and shall be
solely responsible for the correctness of the layout and levels.
3.1 SCOPE
This clause covers the execution of the work for site preparation, such as clearing of the site, the
supply and compaction of fill material, excavationand compaction of backfill for foundation, road
construction, drainage, trenches and final topping by stone (broken hard stone).
3.2 GENERAL
1) Material unsuitable for founding of foundations shall be removed and replaced by suitable fill
material and to be approved by the Owner.
2) Backfill material around foundations or other works shall be suitable for the purpose for
which it is used and compacted to the density described under Compaction. Excavated
material not suitable or not required for backfill, shall be disposed off in area's as directed by
Owner up to a maximum lead of 2 km.
3.3 EXCAVATION AND BACKFILL
1. Excavation and backfill for foundations shall be in accordance with the relevant code.
2. Whenever water table is met during the excavation, it shall be dewatered and water table shall
be maintained below the bottom of the excavation level during excavation, concreting and
backfilling.
3. Embankments adjacent to abutments, culverts, retaining walls and similar structures shall be
constructed by compacting the material in successive uniform horizontal layers not exceeding
Volume-II (Section-S), Civil 411
20 cm in thickness. (of loose material before compaction). Each layer shall be compacted as
required by means of mechanical tampers approved by the Owner. Rocks larger than 10 cm
in any direction shall not be placed in embankment adjacent to structures.
4. Earth embankments of roadways and site areas adjacent to buildings shall be placed in
successive uniform horizontal layers not exceeding 20 cm in thickness in loose stage
measurement and compacted to the full width specified. The upper surface of the
embankment shall be shaped so as to provide complete drainage of surface water at all times.
3.4 COMPACTION
1. The density to which fill materials shall be compacted shall be as per relevant IS and as per
direction of Owner. All compacted sand filling shall be confined as far as practicable.
Backfilled earth shall be compacted to minimum 95% of the Standard Proctor’s density at
OMC. The subgrade for the roads and embankment filling shall be compacted to minimum
95% of the Standard Proctor’s density at OMC. Cohesion less material subgrade shall be
compacted to 70% relative density (minimum).
2. At all times unfinished construction shall have adequate drainage. Upon completion of the
road’s surface course, adjacent shoulders shall be given a final shaping, true alignment and
grade.
3. Each layer of earth embankment when compacted shall be as close to optimum moisture
content as practicable. Embankment material which does not contain sufficient moisture to
obtain proper compaction shall be wetted. If the material contains any excess moisture, then it
shall be allowed to dry before rolling. The rolling shall begin at the edges overlapping half
the width of the roller each time and progress to the center of the road or towards the building
as applicable. Rolling will also be required on rockfills. No compaction shall be carried out in
rainy weather.
3.5 REQUIREMENT FOR FILL MATERIAL UNDER FOUNDATION
The thickness of fill material under the foundations shall be such that the maximum pressure from
the footing, transferred through the fill material and distributed onto the original undisturbed soil
will not exceed the allowable soil bearing pressure of the original undisturbed soil. For expansive
soils the fill materials and other protections etc. to be used under the foundation is to be got
approved by the Owner.
Volume-II (Section-S), Civil 412
4.0 ANTIWEED TREATMENT & STONE SPREADING
4.1 SCOPE OF WORK
The Contractor shall furnish all labour, equipment and materials required for complete
performance of the work in accordance with the specification and direction of the Owner.
Stone spreading along with cement concrete layer shall be done in the areas of the switchyard
under present scope of work. However the stone spreading along with cement concrete layer in
future areas within fenced area shall also be provided in case step potential without stone layer is
not well within safe limits.
4.2 GENERAL REQUIREMENT
The material required for site surfacing/stone filling shall be free from all types of organic
materials and shall be of standard quality, and as approved by the Owner.
4.2.1 The material to be used for stone filling/site surfacing shall be uncrushed/crushed/broken
stone of 40mm nominal size (ungraded single size) conforming to Table 2 of IS:383–
1970. Hardness, flakiness shall be as required for wearing courses are given below:
(a) Sieve Analysis limits (Gradation)
(IS : 383 – Table – 2)
Sieve Size % passing by weight
63mm 100
40mm 85-100
20mm 0-20
10mm 0-5
“One Test” shall be conducted for every 500 cu.m.
(b) Hardness
Abrasion value (IS:2386 Part-IV) – not more than 40%
Impact value (IS:2386 Part-IV) – not more than 30% and frequency shall be one test per
500 cu.m. with a minimum of one test per source.
Volume-II (Section-S), Civil 413
(c) Flakiness Index
One test shall be conducted per 500 cu.m. of aggregate as per IS:2386 Part – I and
maximum value is 25%.
4.2.2 After all the structures/equipments are erected, antiweed treatment shall be applied in the
switchyard where ever stone spreading along with cement concrete is to be done and the
area shall be thoroughly de-weeded including removal of roots. The recommendation of
local agriculture or horticulture department may be sought where ever feasible while
choosing the type of chemical to be used. The antiweed chemical shall be procured from
reputed manufacturers. The doses and application of chemical shall be strictly done as per
manufacturer’s recommendation. Nevertheless the effectiveness of the chemical shall be
demonstrated by the contractor in a test area of 10MX10M (appx) and shall be sprinkled
with water at least once in the afternoon everyday after forty eight hours of application of
chemical. The treated area shall be monitored over a period of two to three weeks for any
growth of weeds by the Engineer – in- charge. The final approval shall be given by
Engineer – in –charge based on the results.
4.2.3 Engineer-in-charge shall decide final formation level so as to ensure that the site appears
uniform devoid of undulations. The final formation level shall however be very close to
the formation level indicated in the approved drawing.
4.2.4 After antiweed treatment is complete, the surface of the switchyard area shall be
maintained, rolled/compacted to the lines and grades as decided by Engineer-incharge.
The sub grade shall be consolidated by using half ton roller with suitable water sprinkling
arrangement to form a smooth and compact surface. The roller shall run over the sub
grade till the soil is evenly and densely consolidated and behaves as an elastic mass.
4.2.5 In areas that are considered by the Engineer-in-Charge to be too congested with
foundations and structures for proper rolling of the site surfacing material by normal
rolling equipments, the material shall be compacted by hand, if necessary. Due care shall
be exercised so as not to damage any foundation structures or equipment during rolling
compaction.
4.2.6 The sub grade shall be in moist condition at the time the cement concrete is placed. If
necessary, it should be saturated with water for not less than 6 hours but not exceeding 20
hours before placing of cement concrete. If it becomes dry prior to the actual placing of
Volume-II (Section-S), Civil 414
cement concrete, it shall be sprinkled with water and it shall be ensured that no pools of
water or soft patches are formed on the surface.
4.2.7 Over the prepared sub grade, 75mm thick base layer of cement concrete in 1:5:10 (1
cement :5 fine/coarse sand : 10 burnt brick aggregate. shall be provided in the area
excluding roads, drains, cable trenches. For easy drainage of water, the slope of 1:1000 is
to be provided from the ridge to the nearest drain. The ridge shall be suitably located at
the centre of the area between the nearest drains. The above slope shall be provided at the
top of base layer of cement concrete in 1:5:10. A layer of cement slurry of mix 1:6 (1
cement: 6 fine sand) shall be laid uniformly over cement concrete layer. The cement
consumption for cement slurry shall not be less than 150 kg. Per 100 sq.m.
4.2.8 A final layer of 100mm thickness of uncrushed/crushed/broken stone of 40 nominal size
(ungraded size) shall be spread uniformly over cement concrete layer after curing is
complete.
5.0 RAINWATER HARVESTING:
5.1 In addition to drainage of rainwater, the contractor shall make arrangement for rainwater
harvesting also.
5.2 Rainwater harvesting shall be done by providing two numbers recharge structures with bore
wells. The recharge structures shall be suitably located within the substation. Branch drains from
the main drain carrying rainwater from entire switchyard shall be connected to the recharge
structures.
5.3 The internal diameter of recharge shafts shall be 4.5 meter with 230mm thick lining of brick work
upto a depth of 2.0 meter from ground level and 345mm thick brickwork below 2.0 meter depth.
The brickwork shall be constructed with cement mortar 1:6 (1 cement : 6 coarse sand). The
overall depth of shaft shall be 5.0 meter below invert level of drain. The shaft shall be covered
with RCC slab for a live load of 300 kg. per sq.m. Two openings of size 0.7 x 0.7 meter shall be
provided in the RCC cover slab. An iron cover made of 5mm thick chequered plate with hinges
shall be provided on the openings. Galvanized M.S. rungs of 20mm diameter at spacing of 300
mm shall be provided in the wall of shaft below the opening in the RCC slab to facilitate cleaning
of shaft.
5.4 A 300 mm diameter bore well shall be drilled in the centre of the shaft. The depth of bore well
shall be 5.0 meter more than the depth of sub soil water.
Volume-II (Section-S), Civil 415
5.5 A 100 mm dia medium duty MS pipe conforming to IS 1161 shall be lowered in the bore well
keeping bail plug towards bottom of bore well. The pipe shall have 1.58mm holes for 4.0 meter
length starting from 1.0 meter from bottom of bore well. Holes of 3.0mm dia shall be provided
for a length of 2.0 meter starting from the bottom level of coarse sand and down wards. The
overall length of pipe shall be equal to total depth of bore well plus depth of shaft.
5.6 Gravel of size 3mm to 6mm shall be filled around 100 dia MS pipe in the borewell.
The shaft shall be filled with 500 mm thick layers each from the bottom of shaft with boulders of
size 50mm to 150mm, gravel of size 5mm to 10mm, coarse sand having particle size 1.5mm to
2.0mm and boulders of size not less than 200mm respectively.
6.0 ROADS AND CULVERTS
6.1 All the roads in the scope of contract shall be of concrete road.
6.2 There would be two types of Roads. The wider road shall be 5.5m wide and the other road shall
be 3.75m wide.
The road outside the switchyard fenced area shall have shoulder of 1.75m in case of 5.5m wide
road and 1.3 m in case of 3.75m wide road with kerb stone at the two side ends of the road.
Interlocking tiles shall be laid on this shoulder. Kerb stone with channel are to be provided at both
the side of the roads. The kerb stone on both side of the roads shall be painted yellow and black
alternatively.
In case of switchyard road the shoulder would be compacted earth 600mm wide on the sides of
both types of road.
6.3 Layout of the roads shall be shown in the General Arrangement drawing for the substation.
Adequate turning space for vehicles shall be provided and bend radii shall be set accordingly.
Road to the Autotransformer/Reactor shall be as short and straight as possible.
6.4 The road shall have 100mm thick RCC (1:1.5:3 nominal mix with reinforcement of 8mm dia. 300
C/C bothways) on the top. Below it 100mm thick PCC (1:4:8) shall be provided. 300mm thick
water bound macadam (WBM) in three equal layers of 100mm each at the bottom.
PCC and WBM shall extend upto the shoulder width on both sides of the road outside switchyard
area. In case of road within the switchyard PCC and WBM shall placed only upto the width of the
road. Polythene sheet of 125 microns shall be placed between the RCC and PCC slab. Expansion
joint (12mm thick) shall be provided at every 8.0 m. In addition, in case of 5.5 m wide road,
Volume-II (Section-S), Civil 416
expansion joint shall also be provided longitudinally at the center. 100mm dia RCC hume pipe
(NP-3) shall be provided at every 100m interval across the length of the road for cable crossing.
The concrete shall be laid and finished with screed board, vibration, vacuum dewatering process
and finishing by floating brooming with wire brush etc.
6.5 The shoulder of the road in case of extension shall match with the shoulder of the existing road.
7.0 FOUNDATION /RCC CONSTRUCTION
7.1 GENERAL
1. Work covered under this Clause of the Specification comprises the construction of
foundations and other RCC constructions for switchyard structures, equipment supports,
trenches, drains, jacking pad, pulling block, control cubicles, bus supports,
Autotransformer/Reactors, marshalling kiosks, auxiliary equipments & systems buildings,
tanks or for any other equipment or service and any other foundation required to complete
the work. This clause is as well applicable to the other RCC constructions.
2. Concrete shall conform to the requirements mentioned in IS:456 and all the tests shall be
conducted as per relevant Indian Standard Codes as mentioned in Standard field quality
plan appended with the specification. However, a minimum grade of M20 concrete (1: 1.5:
3 nominal volumetric mix) shall be used for all structural/load bearing members
3. If the site is sloping, the foundation height will be adjusted to maintain the exact level of
the top of structures to compensate such slopes. The switchyard foundation’s plinths and
building plinths shall be minimum 300mm and 500mm above finished ground level
respectively.
5. Minimum 75mm thick lean concrete (1:4:8) shall be provided below all underground
structures, foundations, trenches etc. to provide a base for construction.
6. Concrete made with Portland slag cement shall be carefully cured and special importance
shall be given during the placing of concrete and removal of shuttering.
7. The design and detailing of foundations shall be done based on the approved soil data and
sub-soil conditions as well as for all possible critical loads and the combinations thereof.
The Spread footings foundation or pile foundation as may be required based on soil/sub-
soil conditions and superimposed loads shall be provided.
8. If pile foundations are adopted, the same shall be cast-in-situ bored or pre-cast or under
reamed type as per relevant parts of IS 2911. Only RCC piles shall be provided. Necessary
Volume-II (Section-S), Civil 417
initial load test shall be carried out by the Contractor at their cost to establish the piles
design capacity. Only after the design capacity of piles have been established, the
Contractor shall take up the job of piling. Routine tests for the piles shall also be conducted
as per IS-2911. All the testing work shall be planned in such a way that these shall not
cause any delay in project completion.
7.2 DESIGN
The following clauses shall be applicable only for the foundation / structure which the contractor
may have to design as mentioned at Clause 2.3.
1. All foundation shall be of reinforced cement concrete. The design and construction of RCC
structures shall be carried out as per IS:456 and minimum grade of concrete shall be M-20.
This M20 shall correspond to nominal volumetric mix of 1:1.5:3.
2. Limit state method of design shall be adopted unless specified otherwise in the
specification.
3. For detailing of reinforcement IS: 2502 and SP:34 shall be followed.
Cold twisted deformed bars (Fe=415 N/mm2) conforming to IS: 1786, or equivalent TMT
bars of equivalent or higher grade as per CPWD specifications shall be used as
reinforcement. However, in specific areas, mild steel (Grade I) conforming to IS: 432 can
also be used. Two layers of reinforcement (on inner and outer face) shall be provided for
wall & slab sections having thickness of 150 mm and above. Clear cover to reinforcement
shall be as per IS:456 (latest).
4. RCC water retaining structures like storage tanks, etc. shall be designed as uncracked
section in accordance with IS:3370 (Part I to IV) by working stress method. However,
water channels shall be designed as cracked section with limited steel stresses as per
IS:3370 (Part I to IV) by working stress method.
5. The procedure used for the design of the foundations shall be the most critical loading
combination of the steel structure and or equipment and/or superstructure and other
conditions which produces the maximum stresses in the foundation or the foundation
component and as per the relevant IS Codes of foundation design. Detailed design
calculations shall be submitted by the bidder showing complete details of piles/pile groups
proposed to be used.
Volume-II (Section-S), Civil 418
6. Design shall consider any sub-soil water pressure that may be encountered following
relevant standard strictly.
7. Necessary protection to the foundation work, if required shall be provided to take care of
any special requirements for aggressive alkaline soil, black cotton soil or any other type of
soil which is detrimental/harmful to the concrete foundations.
8. RCC columns shall be provided with rigid connection at the base.
9. All sub-structures shall be checked for sliding and overturning stability during both
construction and operating conditions for various combinations of loads. Factors of safety
for these cases shall be taken as mentioned in relevant IS Codes or as stipulated elsewhere
in the Specifications. For checking against overturning, weight of soil vertically above
footing shall be taken and inverted frustum of pyramid of earth on the foundation should
not be considered.
10. Earth pressure for all underground structures shall be calculated using co-efficient of earth
pressure at rest, co-efficient of active or passive earth pressure (whichever is applicable).
However, for the design of substructures of any underground enclosures, earth pressure at
rest shall be considered.
11. In addition to earth pressure and ground water pressure etc., a surcharge load of 2T/Sq.m
shall also be considered for the design of all underground structures including channels,
sumps, tanks, trenches, substructure of any underground hollow enclosure etc., for the
vehicular traffic in the vicinity of the structure.
12. Following conditions shall be considered for the design of watertank in pumps house,
channels, sumps, trenches and other underground structures:
a) Full water pressure from inside and no earth pressure & ground water pressure &
surcharge pressure from outside (application only to structures which are liable to be
filled up with water or any other liquid).
b) Full earth pressure, surcharge pressure and ground water pressure from outside and no
water pressure from inside.
c) Design shall also be checked against buoyancy due to the ground water during
construction and maintenance stages.
Minimum factor of safety of 1.5 against buoyancy shall be ensured ignoring the
superimposed loadings.
Volume-II (Section-S), Civil 419
13. Base slab of any underground enclosure shall also be designed for empty condition during
construction and maintenance stages with maximum ground water table (GWT). Minimum
factor of safety of 1.5 against buoyancy shall be ensured ignoring the super-imposed
loadings.
14. Base slab of any underground enclosure like water storage tank shall also be designed for
the condition of different combination of pump sumps being empty during maintenance
stages with maximum GWT. Intermediate dividing piers of such enclosures shall be
designed considering water in one pump sump only and the other pumps sump being empty
for maintenance.
15. The foundations shall be proportioned so that the estimated total and differential
movements of the foundations are not greater than the movements that the structure or
equipment is designed to accommodate.
16. The foundations of transformer/reactor and circuit breaker shall be of block type
foundation. Minimum reinforcement shall be governed by IS: 2974 and IS:456.
17. The tower and equipment foundations shall be checked for a partial factor of safety of 2.2
for normal condition and 1.65 for short circuit condition.
18 The Contractor shall provide a RCC Rail cum road system integrated with the
Autotransformer / Reactor foundation to enable installation and the replacement of any
failed unit. The transfer track system shall be suitable to permit the movement of any failed
unit fully assembled (including OLTC, bushings) with oil. This system shall enable the
removal of any failed unit from its foundation to the nearest road. If trench/drain crossings
are required then suitable R.C.C. culverts shall be provided in accordance with I.R.C.
standard / relevant IS.
The Contractor shall provide a pylon support system for supporting the fire fighting system.
Each Autotransformer/Reactor including oil conservator tank and cooler banks etc. shall be
placed in a self-sufficient pit surrounded by retaining walls (Pit walls). The clear distance
of the retaining wall of the pit from the Autotransformer/Reactor shall be 20% of the
Autotransformer/Reactor height or 0.8m whichever is more. The oil collection pit thus
formed shall have a void volume equal to 200% volume of total oil in the
Autotransformer/Reactor. The minimum height of the retaining walls shall be 15 cm above
the finished level of the ground to avoid outside water pouring inside the pit. The bottom of
the pit shall have an uniform slope towards the sump pit.
Volume-II (Section-S), Civil 420
While designing the oil collection pit, the movement of the autotransformer / reactor must
be taken into account. The grating shall be made of MS flat of size 40mmx 5mm placed at
30mm centre to centre and 25mmx5mm MS flat at an spacing of 150mm at right angle to
each other. Maximum length of grating shall be 2000mm and width shall not be more than
500mm. The gratings, supported on ISMB 150mm, shall be placed at the formation level
and will be covered with 100mm thick layer of broken/crushed/non-crushed stone having
size 40mm to 60mm which acts as an extinguisher for flaming oil.
Each oil collection pit shall be drained towards a sump pit of size 1000X750mm and
500mm deep below the floor level within the collection pit whose role is to drain water and
oil due to leakage within the collection pit so that collection pit remains dry.
19. FIRE PROTECTION WALLS
Fire protection walls shall be provided, if required The firewall shall have a minimum fire
resistance of 4 hours. The partitions, which are made to reduce the noise level, shall have
the same fire resistance. The walls of the building, which are used as firewalls, shall also
have a minimum fire resistance of 4 hours.
The firewall shall be designed to protect against the effect of radiant heat and flying debris
from an adjacent fire. The firewall shall extend 600 mm on each side of the
Autotransformer / Reactors and 600 mm above the conservator tank or safety vent. A
minimum of 2.0meter clearance shall be provided between the equipments e.g.
Autotransformer/Reactors and firewalls. In case of space constraints, these dimensions can
be reduced as per the approval of owner. The building walls, which act as firewalls, shall
extend at least 1 m above the roof in order to protect it. The firewall will be made of
reinforced concrete (1:1.5:3 nominal mix).
7.3 ADMIXTURES & ADDITIVES
1. Only approved admixtures shall be used in the concrete for the Works. When more than
one admixture is to be used, each admixture shall be batched in its own batch and added to
the mixing water separately before discharging into the mixer. Admixtures shall be
delivered in suitably labelled containers to enable identification.
2. Admixtures in concrete shall conform to IS:9103. The water proofing cement additives
shall conform to IS:2645. Concrete Admixtures/ Additives shall be approved by Owner.
Volume-II (Section-S), Civil 421
3. The Contractor may propose and the Owner may approve the use of a water-reducing set-
retarding admixture in some of the concrete. The use of such an admixture will not be
approved to overcome problems associated with inadequate concrete plant capacity or
improperly planned placing operations and shall only be approved as an aid to overcoming
unusual circumstances and placing conditions.
4. The water-reducing set-retarding admixture shall be an approved brand of Ligno-
sulphonate type admixture.
5. The water proofing cement additives shall be used as required/ advised by the Owner.
8.0 Chainlink Fencing and Gate:
Fencing and Gate shall be provided at the suitable locations. Separate gate shall be provided for
men and equipment. Fence shall also be provided for the various equipments (if) mounted on
ground or a height lower than 2.5m. Necessary gates shall be provided for each area so
surrounded.
Chain link galvanised fence fabric with 3.15mm dia wire and 75mm mesh size conforming to IS:
2721 shall be used. MS tube used shall be of grade YST22 and conform to IS: 1161. All other
structural steel shall conform to IS: 2062.
The whole assembly of tubular post shall be hot dip galvanized. The zinc coating shall be
minimum 610 gram per sq. meter. The purity of zinc shall be 99.95% as per IS: 209. Frame of
panels of chain link fencing shall be painted with two or more coats of approved standard
synthetic enamel paint over approved standard steel primer. The gate shall be made of medium
duty M.S. pipe with welded joints. The main frame (outer frame) of the gate shall be made of
40mm dia pipe and vertical pipes of 15mm dia @ 125mm spacing (maximum) shall be welded
with the main frame. Gate shall be painted with one coat of approved steel primmer and two or
more coats of synthetic enamel paint to give an even shade. The height of the fencing shall be
1500mm on a toe wall of 300mm.
9.0 WATER SUPPLY (EXTERNAL)
(i) Water shall be made available by Owner (unless stated otherwise elsewhere) at any feasible point
near scope boundary at single point to the contractor. Contractor shall state the total water
requirement both in terms of quantity and head to the Owner.
(ii) The contractor shall carry out all the external plumbing/erection works required for supply of
water to the control room building beyond the single point as at (i).
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(iii) The contractor shall carry out all the plumbing/erection works required for supply of water to fire
water tank beyond the single point as at (i).
(v) A scheme shall be prepared by the contractor indicating the layout and details of water supply
which shall be got approved from the
Owner before actual start of work including all other incidental items not shown or specified but
as may be required for complete performance of the works.
(vi) Bore well is not in the scope of contractor.
10.0 TECHNICAL DETAILS OF THE BUILDINGS
1. 12mm cement plaster of mix 1:6 ( 1 cement : 6 coarse sand ) shall be provided on the smooth side
of internal walls.
2. 6 mm cement plaster of mix 1:3 (1 cement : 3 fine sand) to all ceiling.
3. 18mm Cement plaster of mix (1 cement: 5Coarse Sand) with under layer 12mm thick and top
layer of 6mm thick for external plaster.
4. 12 mm thick pre-laminated three layer medium density (exterior grade) particle board Grade-I,
Type II conforming to IS:12823 bonded with phenol formaldehyde synthetic resin, of approved
brand and manufacture shall be provided in panelling fixed in aluminium doors, windows shutters
and partition frames with C.P brass/stainless steel screws etc. for control room.
5. Distempering on all internal walls and ceilings with oil bound washable distemper of approved
brand and manufacture to give an even shade ( two or more coats ) over and including priming
coat with cement primer for control room.
6. Plaster of Paris (Putty) of 2mm thickness over the plaster surface to prepare the surface even and
smooth complete with distempering with first quality acrylic washable distemper (ready mix) of
approved manufacturer with two or more coats of new work of required shade and colour
complete as per manufacturer’s specification.
7. Enamel Painting with synthetic enamel paint of approved brand and manufacture of required
colour to give an even shade shall be provided on the steel glazed doors, windows, ventilators and
rolling shutters in various buildings. Two or more coats over an under coat of suitable shade with
primer paint of approved brand and manufacture.
8. Two or more coats of French spirit polishing with a coat of wood filler shall be provided on the
wooden doors.
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9. Cement plaster skirting (up to 15 cm height) with cement mortar 1:3 (1 cement: 3 coarse sand)
mixed with metallic concrete hardener in same ratio as for floor finished with a floating coat of
neat cement. 21 mm thick in ACDB/DCDB room
10. Polished vitrified tiles in 60x60 cm size (thickness to be specified by the manufacturer) in
flooring and skirting, with water absorption’s less than 0.08% and conforming to IS: 15622 of
approved make in all colours and shades, laid on cement mortar 20mm thick for flooring &
12mm thick for skirting 1:4 (1 cement: 4coarse sand) including grouting the joints with white
cement and matching pigments etc., complete.
11 Glazed Ceramic floor tiles 300x300mm (thickness to be specified by the manufacturer) of 1st
quality conforming to IS:15622 of approved make in colours as approved by Engineer-in-charge
in toilet and pantries area on 20mm thick cement mortar 1:4 (1 cement : 4coarse sand) including
grouting the joints with white cement and matching pigments etc., complete.
12. Ceramic glazed wall tiles of 1st quality conforming to IS;15622 (thickness to be specified by the
manufacture) of approved make in all colours, shades as approved by Engineer-in-Charge in
skirting, risers of steps and dados over 12mm thick bed of cement Mortar 1:3 (1 Cement: 3
Coarse sand) and jointing with grey cement slurry @ 3.3kg per sqm including pointing in white
cement mixed with pigment of matching shade complete.
13. Pre-cast terrazzo tiles 20mm thick with graded marble chips of sizes upto 12mm laid in floors,
landings, skirting and riser of light shade using white cement jointed with neat cement slurry mix
with pigment to match the shade of the tiles including rubbing and polishing complete with pre-
cast tiles on Cement mortar 1:4 ( 1 cement : 4 coarse sand) with (20mm thick for flooring and
12mm thick for skirting).
14. Rajnagar plain white marble/Udaipur Grade Marble/Zebra black marble work gang socket (Polish
and machine cut) of thickness 18mm for staircase in cement mortar 1:3 (1 Cement : 3 coarse
sand) including rubbing, curing, pointing with an additional mixture of pigment to match the
marble shade.
15. 18mm polished granite in cement mortar 1:4, 20mm thick made to a level cut to size shall be
provided. The joints are filled with jointing compound matching to the tiles.
Wherever granite tiles are specified for the floor, 100mm granite skirting shall be provided with
the walls. The granite outer surface shall be flushed to the plaster finish of the wall.
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16. Granite counter shall be provided and fixed with 18mm granite slab mounted on 75mm RCC slab
supported by 115mm brick wall plastered on all sides. The shelves shall be made of 18mm thick
well cut and polished white marble slabs. The outer side of the brick wall and the RCC slab
visible in the front shall be finished with 18mm granite with edges moulded on the exposed end.
17. All Brickwork shall be provided with cement mortar 1:6 (1cement: 6 coarse sand). Half brick
work masonry shall be provided with cement mortar 1:4 (1cement: 4coarse sand). FPS Bricks of
clay/Fly ash used shall be of class – 75.
18. Anti termite treatment shall be carried out for all buildings.
19. M.S. Rolling shutters shall be provided and fixed interlocked together through their entire length
and jointed together at the end by end locks mounted on specially designed pipe shaft with
brackets along with ball bearing for rolling shutter, side guides and arrangements for inside and
outside locking with push & pull operation including the cost of providing and fixing necessary
27.5 cm long wire springs grade No. 2 and M. S top cover of required thickness for rolling
shutters. 80 x 1.25 mm M. S laths with 1.25 mm thick top cover.
20. Circular/hexagonal M.S. sheet ceiling fan box shall be provided in the ceiling with clamp of
internal dia. 140 mm, 73 mm height, 3 mm thick rim, top and bottom lid of 1.5 mm M.S. Sheet.
Lids shall be screwed in to M. S. box by means of 3 mm round headed screws, clamps shall be
made of 12 mm dia. M. S. bar bent to shape with overall length as 80 cm.
21. Powder Coated (minimum thickness 50 micron) aluminum work for doors, windows, ventilators
and partitions shall be provided and fixed in building with extruded built up standard tubular and
other sections of approved make conforming to IS:733 and IS : 1285, fixed with rawl plugs and
screws or with fixing clips, or with expansion hold fasteners including necessary filling up of
gaps at junctions at top, bottom and sides with required PVC/neoprene felt etc and joined
mechanically wherever required including cleat angle, Aluminium snap beading for glazing /
panelling, C.P. brass/ stainless steel screws including glazing and fittings as specified. All doors
except for toilet and kitchen shall have 100mm 6 lever CP Brass mortice latch and lock with a
pair of lever handle. Sliding door bolt of ISI marked (300x16mm) size shall be provided for toilet,
kitchen and main door of control room/residential buildings.
22. Cement based water proofing treatment of roofs, balconies, terraces etc. shall be provided with
average thickness of 120mm and minimum thickness at Khurra as 65mm and laid consisting of
following operations:
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(a) A slurry coat of neat cement using 2.75 kg/m2 of cement admixed with proprietary water
proofing compounds conforming to IS: 2645 shall be applied and grouted over the RCC slab
including cleaning the surface before treatment.
(b) Plain Cement concrete 1:5:10 (1 Cement: 5 fine sand: 10 burnt brick aggregate of 40mm
nominal size) admixed with proprietary water proofing compound conforming to IS: 2645
over 20mm thick layer of cement mortar of min 1:5 (Cement: 5 coarse sand) admixed with
proprietary water proofing compound conforming to IS: 2645 to required slope and treating
similarly the adjoining walls upto 300mm height including rounding of junctions of walls
and slabs.
(c) After two days of proper curing , a second coat of cement slurry admixed with proprietary
water proofing compound conforming to IS: 2645 shall be applied.
(d) The surface shall be finished with 20mm thick joint less cement mortar of mix 1:4 (1 cement
: 4 course sand) admixed with proprietary water proofing compound conforming to IS: 2645
and finally the surface shall be finished with trowel with neat cement slurry and making of
300 x 300 mm square.
(e) The whole terrace so finished shall be flooded with water for a minimum period of two
weeks for curing and for final test. All above operations shall be done in order and as
directed and specified by the Engineer-in-charge.
23. Unplasticised rigid PVC rain water pipes of 110mm dia shall be provided and fixed on the wall
face conforming to IS:13592 type A including jointing with seal ring conforming to IS: 5382
leaving 10mm gap for thermal expansion single socketed pipes including all fittings like bends,
bat clamps gratings etc..
24. Unplasticised PVC Moulded fittings/accessories including 110mm bend and 110mm shoes shall
be provided and fixed for unplasticised rigid PVC rain water pipes conforming to IS:13592 type
A including jointing with seal ring conforming to IS: 5382 leaving 10mm gap for thermal
expansion.
25. Unplasticised PVC pipe clips of approved design shall be provided and fixed to unplasticised
110mm PVC rain water pipes by means of 50x50x50mm hard wood plugs, screwed with MS
screws of required length including cutting brick work and fixing in cement mortar1:4 (1 cement :
4 coarse sand) and making good the wall etc.
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26. Double action hydraulic floor spring of approved brand and manufacture IS:6315 marked
"hardwyn" make(Model 3000) or equivalent for doors shall be provided and fixed at the
following door including cost of cutting floors as required, embedding in floors and cover plates
with brass pivot and single piece MS sheet outer box with slide plate etc. as per the direction of
Engineer-in-charge.
With stainless steel cover plate :
a. Main Entrance to Control Room Building / Transit Camp/Recreation Centre.
b. DGM room in control room.
c. Conference Room
d. Control Room
27. Plinth protection 50 mm thick of cement concrete 1:2:4 (1 cement : 2 coarse sand : 4 graded
stone) aggregate 20 mm nominal size) shall be laid over 75 mm bed of dry brick ballast 40 mm
nominal size well rammed and consolidated and shall be grouted with fine sand including
finishing the top smooth.
28. Coloured vitreous china pedestal type water closet (European type)shall be provided with seat
and lid, 10 liter low level vitreous china flushing cistern & C.P. flush bend with fittings and C.I.
brackets, 40mm flush bend, overflow arrangement and mosquito proof coupling of including
painting of fittings and brackets, cutting and making good the walls and floors wherever required.
29. Providing and fixing coloured wash basin counter type of (630x450mm size) and flat back wash
basin of (550 x400mm size) with CI. Brackets 15mm C.P. brass pillar taps, close hole basin mixer
32mm C.P. brass waste and bottle trap of standard pattern, including painting of fittings and
brackets, cutting and making good the walls wherever required.
30. All urinals shall be coloured vitreous china flat back half stall urinal of 580x380x350mm with 10
litre PVC automatic flushing cistern, Parryware/ Hindware/ Seabird/ Orient (Coral) with fittings,
standard size C.P. brass flush pipe, spreaders with unions and clamps (all in C.P. brass) with
waste fitting as per IS: 2556 C.I. trap with outlet grating and other couplings in C.P. brass
including painting of fittings and cutting and making good the walls and floors wherever
required.
31. Following fittings shall be provided in the toilets:
i) Toilet paper roll holder.
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ii) Double type coat & hat hooks with flanges, fixed to wall / shutter, etc. with necessary
screws, washers & plugs.
iii) CP liquid soap holder of approved make fixed with each wash basin to the wall with
necessary CP brackets, CP screws, washers, plugs etc.
iv) 100mm dia vitreous chinaware half round channel of approved make fixed to correct grade,
level, opening for floor trap below urinals set in CM 1:3 & pointed using white cement etc .
v) CP brass bib cock 15mm nominal bore of approved quality conforming to IS :8931 .
vi) CP brass angle valve of 15mm nominal bore provided and fixed in position for basin and
cistern points of approved quality conforming IS :8931.
vii) Best quality marble partition slab provided and fixed in position for urinals, of size
610x1150mm, 20mm thick, polished on both sides & machine cut, exposed corners
rounded etc.
viii) Towel rail of approved make of 600mm length, 25mm dia with a pair of brackets or flanges
provided and fixed to wall beside each wash basin/set of wash basin with necessary screws,
plugs, etc.
ix) 6mm thick beveled edge mirror 1000x600mm shall be provided and fixed mounted on
12mm thick water proof plywood backing and hardwood beading all-round and mirror
fixed to the backing with 4 Nos. of CP cap screws & washers, including fixing the mirror to
the wall with necessary screws, plugs & washers etc, with each wash basin.
32. Stainless steel AISI 304 (18/8) Kitchen sink of 460x915 mm bowl with depth of 178mm with
drain board shall be provided and fixed as per IS 13983 with C.I brackets, and stainless steel plug
40mm with provision of 2 nos. CP brass long body bib cock conforming to IS Standard and
weighing not less than 650 gm for CP bottle trap etc. including painting of fittings and brackets,
cutting and making good the wall.
33. GI Pipe work for Internal and External works:
i) All GI types and fittings shall conform to IS-1239 Part I & II for medium grade. All
accessories shall be ISI Marked.
ii) All concealed GI pipe shall be painted with anticorrosive bitumastic paint including cutting
of chases and making good the wall.
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iii) All exposed GI pipes and fittings shall be painted with synthetic enamel paint of desired
shade over a ready mixed priming coat, both of approved quality for new work.
iv) Wherever GI pipes are buried the same shall be provided and laid in position including
trenching sand cushion and refilling, painted with anticorrosive bitumastic paint etc.
v) Gun metal ball valve with operating levers, non-return valves conforming to IS
specification shall be provided.
34. Masonry chamber for sluice valve shall be 600x600mm size in plan and depth 750mm, or
matching with the site condition inside with 50 class designation brick work in cement mortar 1:5
(1 cement : 5 fine sand) with CI surface box 100 mm. Top diameter, 160 mm bottom dia and 180
mm deep (inside) with chained lid and RCC top slab 1:2:4 mix (1cement : 2 coarse sand: 4 graded
stone aggregate 20 mm nominal size) necessary excavation foundation concrete 1:5:10 (1 cement
: 5 fine sand : 10 graded stone aggregate 40 mm nominal size) and inside plastering with cement
mortar 1:3 (1 cement : 3 coarse sand) 12 mm thick finished with a floating coat of neat cement
complete as per standard design with FPS bricks of class 75.
35. Polyethylene water storage tanks conforming to ISI: 12701 shall be provided of approved brand
and manufacture with cover and suitable locking arrangement, float valve and making necessary
holes for inlet, outlet and overflow pipes. Capacity of water tank shall be 2x2000 litres for control
room, 2000 litres for Transit Camp, 1000 litres for D type & Recreation Centre and 500 litres
each for other dwelling unit.
36. PVC floor traps of self cleansing design shall be provided & fixed in position with outlet size of
75mm diameter of approved make, including making connection with PVC soil/waste pipes using
rubber gaskets, embedding the trap in 150 mm thick PCC 1:2:4, providing & fixing of top tile &
strainer of CP or PVC on top of the trap etc.
37. Square-mouth SW gully trap grade 'A' 100x100mm size P type with FPS Bricks class designation
75 shall be provided and fixed complete with CI grating brick masonry chamber with water tight
C.I. cover with frame of 300X300mm size (inside) the weight of cover to be not less than 4.5 Kg
and frame to be not less than 2.70 Kg as per standard design
38. Brick Masonry road gully chamber of 50x45x60cm shall be provided with brick with cement
mortar 1:4 including 500x450mm pre cast RCC Horizontal/vertical grating with frame complete.
Volume-II (Section-S), Civil 429
39. Glazed stoneware pipes of 150mm diameter grade 'A' shall be provided, laid and jointed with stiff
mixture of cement mortar in the proportion of 1:1 (1cement :1 fine sand ) including testing of
joints etc. complete.
40. Cement concrete 1:5:10 (1 cement: 5 coarse sand: 10 graded stone aggregate 40 mm nominal
size) shall be provided and laid around S.W pipes including bed concrete.
41. Brick masonry manhole shall be constructed in cement mortar 1:4 ( 1 cement :4 coarse sand )
RCC top slab with 1:2:4 mix ( 1 cement : 2coarse sand : 4 graded stone aggregate 20 mm nominal
size ) foundation concrete 1:4:8 mix ( 1cement : 4 coarse sand :8 graded stone aggregate 40 mm
nominal size ) inside plastering 12 mm thick with cement mortar 1:3 (1 cement : 3 coarse sand )
finished with floating coat of neat cement and making channels in cement concrete 1:2:4 ( 1
cement: 2 coarse sand :4 graded stone aggregate 20 mm nominal size ) finished with a floating
coat of neat cement complete as per standard design.
a) Inside size shall be 90 x 80 cm and 60 cm deep including CI cover with frame (light duty)
455 x 610 mm internal dimensions total weight of cover and frame shall not be less than 38
kg (weight of cover 23 kg and weight of frame 15 kg) and shall be constructed with
F.P.S./fly ash bricks with class designation 75.
b) Inside size shall be 120 x 90 cm and 90 cm or more deep including CI cover with frame
(medium duty) 500mm internal diameter total weight of cover and frame to be not less than
116 kg (weight of cover 58 kg and weight of frame 58 kg) with FPS Bricks class
designation 75.
42. MS foot of 20 x 20mm square rests shall be provided and fixed in manholes with 20 x 20 x 10 cm
cement concrete blocks 1:3:6 ( 1 cement :3 coarse sand :6 graded stone aggregate 20 mm nominal
size ) as per standard design.
43. Steel glazed doors, windows and ventilators of standard rolled steel sections shall be provided
and fixed in Township pumphouse and FFPH building, jointed and welded with 15 x 3 mm lugs,
10cm long, embedded in cement concrete blocks 15 x 10 x10 cm of 1:3:6 (1 cement 3 coarse sand
: 6 graded stone aggregate 20mm nominal size) or with wooden plugs and screws or rawl plugs
and screws or with fixing clips or with bolts and nuts as required, including providing and fixing
of glass panes with glazing clips and special metal sash putty of approved make complete
including applying a priming coat of approved steel primer, necessary hinges or pivots as
required to complete the work.
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44. Pressed steel door frames manufactured from commercial mild steel sheet of 1.25mm thickness
shall be provided and fixed in Township pumphouse and FFPH building including hinges jamb,
lock jamb, bead and if required angle threshold of mild steel angle of section 50x25mm, or base
ties of 1.25 mm pressed mild steel welded or rigidly mixed together by mechanical means,
adjustable lugs with split end tail to each jamb including steel butt hinges 2.5mm thick with
mortar guards, lock strike-plate and shock absorbers as specified and applying a coat of approved
steel primer after pretreatment of the surface as directed by Engineer-in-Charge.
45. Asbestos cement 6mm thick corrugated sheets roofing shall be provided and fixed with G, I, J or
L hooks, bolts and nuts 8mm diameter G, I plain and bitumen washers complete excluding the
cost of purlins, rafters and trusses for water tank.
46. Water closet squatting pan (Indian type W.C. pan ) (white vitreous china Orissa pattern W.C. pan
of size 580x440mm with integral type foot rests) shall be provided with 100mm sand cast iron P
or S trap. 10 litre low level white P.V.C flushing cistern with manually controlled device (handle
lever) conforming to IS:7231, with all fittings and fixtures complete including cutting and making
good the walls and floors wherever required.
47. Coloured vitreous china pedestal type water closet (European type) shall be provided with seat
and lid, 10 litre low level white vitreous china flushing cistern & C.P. flush bend with fittings and
C.I. brackets, 40mm flush bend, overflow arrangement with specials of standard make and
mosquito proof coupling of approved municipal design complete including painting of fittings
and brackets, cutting and making good the walls and floors wherever required.
48. Coloured vitreous china flat back half stall urinal of size 580x380x350mm shall be provided with
5 litre PVC automatic flushing cistern, with fittings, standard size C.P. brass flush pipe, spreaders
with unions and clamps (all in C.P. brass) with waste fitting as per IS:2556 C.I. trap with outlet
grating and other couplings in C.P. brass including painting of fittings and cutting and making
good the walls and floors wherever required.
49. Wash basin counter type (630x450mm) and flat back wash basin (550 x400mm) shall be provided
with CI. Brackets 15mm C.P. brass pillar taps, close hole basin mixer 32mm C.P. brass waste and
bottle trap of standard pattern, including painting of fittings and brackets, cutting and making
good the walls wherever required.
50. Hardware fittings shall have 100mm CP brass handle, 50mm CP Brass cup-board locks, Nickel
Plated finishing, Piano hinges as per IS:3818, Magnetic catchers, heavy type hanger rods of
20mm dia, Anodized (Grade AC-10) Aluminium tower bolts(10o x10m) of ISI marked of
Volume-II (Section-S), Civil 431
required shade. All doors of recreation center and Transit Camp shall have tubular type Hydraulic
Door Closer conforming to IS-3564.
51. All doors except toilet and kitchen shall have 100mm 6 liver mortice lock and a pair of lever
handles with necessary screws complete etc.
52. Aluminium sliding door with ISI marked anodized transparent and dyed to required colour or
shade shall be provided at main entry door, toilets and kitchen.
53. Pelmet shall be provided 18mm thick 150mm wide of coir veneer board ISI marked including top
cover of 6mm of coir veneer board and lipping, Nickel plated MS pipe 20mm dia (heavy type0
curtain road with Nickel plated (including fixing with 25x 3mm MS flat 10cm long and rawl plug
all complete.
54. Cement Jaali of (1:2:4) ( 1 Cement: 2 fine aggregate : 4 coarse aggregate ) 50mm thick, shall be
reinforced with 1.6mm dia with Mild steel wire including centring and shuttering cleaning fixing
and furnishing with cement mortar 1:3).
55. Providing and fixing 15mm thick approximately 600 X 600mm Mineral fibre board panel along
with false ceiling and making cut-outs for electrical fixtures, AC diffusers, openable access etc
with silhouette profile system with 15mm wide flange incorporating 6mm central recess white /
black main runners at 1200mm centre-centre and not greater than 600mm from the adjacent wall.
The cross tees shall be provided to make a module of approximately 600mm X 600mm by fitting
600 mm long cross tees centrally placed between 1200 mm long cross tees .Cross tees also have
15mm wide flange incorporating 6mm central recess white/black.
The module formed above shall be anchored to the slab with channels or angles, suspenders as
per manufacturer’s specifications. It shall be provided in all the AC area of Control Room and in
the Transit Camp of Township.
56. The Tiles / Paver Blocks shall be made of white cement in order to accentuate the vibrancy of
colours and to ensure the increased natural sheen of the tile / block with regular use and
maintenance with an aggregate mix not leaner than 1:3 and shall be free from the use of
undesirable substitutes such as slag / red mud. Moreover the pigments used in each and every tile
/ block shall be imported Bayer pigments which have a higher colour consistency and fade
resistance. Moreover the pigments shall also have higher UV stability and should not fade / crack
in the exterior weather conditions.
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The Contractor shall ensure that the material is brought on site in a packed condition with
minimal / no damages or breakages in transit. The thickness of Floor Tiles shall be 22mm and
that of Flexi Paver Block shall be 60mm. The Concrete Tiles & Flexi Pavers shall be laid over
cement mortar 1:4 (1 cement: 4Coarse sand) over an average thickness of 25mm. The base shall
be 100mm thick PCC 1:4:8. The jointing shall be done with white cement mixed with pigment
matching to the tiles.
11.0 MODE OF MEASUREMENT
11.1 Earthwork
This shall include excavation in all kinds of soil including rock, all leads and lifts including back
filling, compacting, dewatering (if required) and disposal of surplus earth to a suitable location.
The quantity of excavation for foundations of towers, equipment structures, all transformers,
firewall, cable trenches, water tank, reactors, buildings and underground water tanks, covered car
parking shall only be measured. The quantity of excavation for roads, rail cum road, drains,
rainwater harvesting, septic tank, soak pit, external water supply system, site surfacing, chain link
fencing (including gate) shall not be measured separately and shall be deemed to be included in
the composite rates quoted by the bidder for the respective works. All other excavation required
for the completion of the work including fixing of lamp posts, plinth protection, flooring,
sewerage system, manholes, pipes, earthmat etc. shall also not be paid for. The measurement of
excavation of all concrete works shall be made considering dimension of the pit leaving 150mm
gap around the base pad (lean concrete) or actually excavated pit, whichever is less. The quantity
shall be measured in cubic metres.
11.2 PCC
Providing and laying Plain Cement Concrete of all types and at all locations including all leads
and lifts. The quantity shall be measured incubic meters as per lines and levels.
i) PCC 1:2:4 (1 cement : 2 sand : 4 coarse aggregate 20 mm nominal size) shall be
measured in flooring of buildings, plinth protection, fencing, transformer foundation,
reactor foundation, rail track, drain, culverts, septic tank, chain link fencing, gate etc.
ii) PCC 1:4:8 (1 cement : 4 coarse sand : 8 stone aggregate, 40mm nominal size) shall be
measured below all foundations of buildings, underground water tanks, covered car
parking cable trench, roads, under flooring, railcum- road, transformer foundation,
reactor foundation, drain, water tank, culverts, gate etc.
Volume-II (Section-S), Civil 433
iii) PCC 1:5:10 (1 Cement: 5 sand brick aggregate, 40mm nominal size) shall be provided for
site surfacing in switchyard, roof water proofing etc.
All other PCC required for the completion of the work including hold fasts of
doors/windows/rolling shutters, fixing of plumbing pipes, bedding concrete for sewer
lines, embedment of electrical conduits etc. shall not be measured and deemed included
in the composite rates quoted by the bidder for respective works. Water proofing
compound wherever specified shall be added without any extra cost.
11.3 RCC
Measurement of reinforced cement concrete at all locations shall be made and shall include all
leads, lifts, formwork, grouting of pockets and underpinning, (but shall exclude reinforcement),
of nominal mix 1:1.5:3 (1cement : 1.5 coarse sand : 3 stone aggregate 20mm nominal size). This
shall also include pre-cast RCC work and addition of water proofing compound wherever
required for which no additional payment shall be made. The quantity shall be measured in cubic
meters as per lines and levels. No deduction shall be made for volume occupied by
reinforcement/inserts/sleeves and for openings having crosssectional area up to 0.1 sq.m.
11.4 Steel Reinforcement
Reinforcement shall be measured in length including hooks, if any, separately for different
diameters as actually used in work, excluding overlaps. From the length so measured, the weight
of reinforcement shall be calculated in tones on the basis of sectional weights as adopted by
Indian Standards. Wastage, overlaps, couplings, welded joints, spacer bars, chairs, stays, hangers
and annealed steel wire or other methods for binding and placing shall not be measured and cost
of these items shall be deemed to be included in the rates for reinforcement.
11.5 Stone filling
Measurement of stone (40mm nominal size) for transformer foundations shall be made as per
theoretical volume of the space to be filled in the transformer foundation. This shall be measured
in cu.m.
11.6 Miscellaneous structural steel
Measurement for Supply, fabrication, transportation and erection of all miscellaneous structural
steel work for mono rails (RS joists), rails for transformers/ reactors, trusses, frame work, purlins,
gratings, steel tubes, built up sections along with all other steel fittings and fixtures, inserts and
embedment in concrete shall be made. The unit rate for this item shall be inclusive of cutting,
Volume-II (Section-S), Civil 434
grinding, drilling, bolting, welding, pre- heating of the welded joints, applying a priming coat of
steel primer and anti corrosive bitumastic paint/ synthetic enamel paint etc. (wherever specified),
setting of all types of embedment in concrete, etc. Steel required for foundation bolts, nuts and
bolt, doors, windows, ventilators, louvers, rolling shutters, chain link fencing, gratings in drains,
soil pipes, plumbing pipes, floor traps, embedment’s required for rainwater harvesting, septic
tank, soak pit, roof truss and purlins required for fire water tank, etc. shall not be considered for
payment and measurements.
Quantity shall be measured in Kg.
11.7 Roads
A) The measurement for the concrete road shall be made on the basis of area in square meter
(M2) of top concrete completed surface of the road and shall be deemed to include all items
such as excavation, compaction, rolling, watering, WBM, Kerb stone, grating, shoulder,
interlocking tiles etc but excluding concreting and reinforcement.
B) The measurement of bituminous road shall be made on the basis of area in square meter
(M2), of the top bituminous completed surface of the road and shall include all items such
as excavation, compaction, rolling, watering, sub base course, WBM, shoulder, premix
carpet etc.
11.9 Antiweed Treatment and Stone Spreading
The measurement shall be done for the actual area in square metres of stone spreading provided
in the switchyard and shall include antiweed treatment including material and providing and
spreading of 100mm thickness of uncrushed/crushed/broken stone of 40mm nominal size as per
the specification for the specified area.
11.10 Chain Link Fencing and gate
The measurement shall be made in running metres of the fence. The rate shall be including the
post, fencing, MS Flat etc. complete but excluding the concrete. The gate shall be measured in
numbers.
11.11 External Finishing:
This is a lump sum item. Contractor has to assess the quantity of Control room cum
administrative building, Fire Fighting Pump House, switchyard panel room, township buildings,
covered parking and quote for the same for each building separately. This shall include following
items.
Volume-II (Section-S), Civil 435
1) External plastering: 18 mm cement plaster of mix: 1:4 (1 cement: 4 coarse sand) including
all grooves as specified.
2) Providing and applying two or more coats with of Acrylic exterior flat paint over an under
coat of suitable primer on new cement plaster surfaces of the control room / FFPH building.
It shall be inclusive of required tools, scaffolding, materials and other painting accessories
etc. as per recommendations of manufacturer.
11.12 Hume Pipe
Hume pipe shall be measured diameter-wise and shall be measured in running metres. The item
shall be inclusive of excavation, laying, back filling, jointing etc. but excluding concrete and
reinforcement (if any).
11.13 Building
This is a lump sum item for each building. However, the quantity of excavation, concrete,
reinforcement below the plinth level shall be measured as per item nos. 11.1, 11.2, 11.3 & 11.4
described above. Quantity of concrete and reinforcement above the plinth level of the buildings
shall be measured and paid under item no. 11.2, 11.3 & 11.4 mentioned above respectively.
External Finishing shall be measured and paid as per item no. 11.11 mentioned above. The rest of
the entire work required to complete the building in all respect, shall be deemed to be included in
this lump sum rate.
11.14 Rain Water Harvesting
This is a lump sum item. The contractor shall be required to complete the work. All the items
including excavation, miscellaneous steel, brick work, fillings of boulders, gravel, sand, pipes etc.
shall be deemed to be included in this lump sum rate. However, the concrete (all types) and the
reinforcement shall be measured and paid under the item no. 11.2, 11.3 & 11.4 mentioned above.
11.15 Rail cum Road
The measurement for the rail cum road shall be made in square metres of top concrete completed
surface of the rail cum road and shall include all items such as excavation, compaction, rolling,
watering, WBM etc. but excluding concrete, reinforcement, structural steel and rails.
11.16 Septic Tank and Soak Pit
This is a lump sum item. All the items including excavation, masonry work, all types of fillings,
all types of pipes including plumbing and vent pipes, all type of fittings etc. shall be deemed to be
Volume-II (Section-S), Civil 436
included in this lump sum rate. However, the concrete (all types) and the reinforcement shall be
measured and paid under the item no. 11.2, 11.3 & 11.4 mentioned above.
11.17 Fire Water Tank
This is a lump sum item. All the items including excavation, compaction, brick work, roof truss,
corrugated AC Sheet roofing, all types of miscellaneous steel, internal and external plastering,
painting etc. shall be deemed to be included in this lump sum cost. However, the concrete (all
types), reinforcement and the steel embedments (except roof truss and purlins) shall be measured
and paid under the item no. 11.2, 11.3 and 11.6 mentioned above.
11.18 External water supply from Bore-well to Fire water tank, Control Room Building and
township buildings.
The external water supply from Bore-well shall be measured diameter-wise in running metres. It
shall include all the items such as excavation, piping, pipe fittings, painting, brickwork, sand
filling, concrete, valves, chambers cutting chases in walls, openings in RCC and repairs, etc.
required to complete the job.
11.19 External Sewage System of the township shall be measured diametric ways in running meters. It
shall include all the items such as excavation, piping, pipe fittings, manholes, gali trap, gali
chamber casing in concrete and repairs etc required to complete the job. Any modification in the
existing sewage system, if required, shall be done by the Contractor without any extra cost
implicated to Employer.
11.20 Township Pumphouse
This is a lump sum item including pumphouse, pumps & accessories, piping within pumphouse,
inserts in water pump etc. complete. However, the concrete (all types), reinforcement and the
steel embedments shall be measured and paid under the item no. 11.2, 11.3 11.4 and 11.6
mentioned above.
12.0 MISCELLANEOUS GENERAL REQUIREMENTS
12.1 Dense concrete with controlled water cement ratio as per IS-code shall be used for all
underground concrete structures such as pump-house, tanks, water retaining structures, cable and
pipe trenches etc. for achieving water-tightness.
12.2 All joints including construction and expansion joints for the water retaining structures shall be
made water tight by using PVC ribbed water stops with central bulb. However, kicker type
(externally placed) PVC water stops shall be used for the base slab and in other areas where it is
Volume-II (Section-S), Civil 437
required to facilitate concreting. The minimum thickness of PVC water stops shall be 5 mm and
minimum width shall be 230 mm.
12.3 All mild steel parts used in the water retaining structures shall be hot-double dip galvanised. The
minimum coating of the zinc shall be 750 gm/sq. m. for galvanised structures and shall comply
with IS:2629 and IS:2633. Galvanizing shall be checked and tested in accordance with IS: 2633.
The galvanizing shall be followed by the application of an etching primer and dipping in black
bitumen in accordance with BS: 3416.
12.4 FPS Bricks of clay/ fly ash having minimum 75 kg/cm2 compressive strength can only be used
for masonry work. Contractor shall ascertain himself at site regarding the availability of bricks of
minimum 75 kg/cm2 compressive strength before submitting his offer.
12.5 Angles 50x50x5 mm (minimum) with lugs shall be provided for edge protection all round cut
outs/openings in floor slab, edges of drains supporting grating covers, edges of RCC cable/pipe
trenches supporting covers, edges of manholes supporting covers, supporting edges of manhole
precast cover and any other place where breakage of corners of concrete is expected.
12.6 Anti termite chemical treatment shall be given to column pits, wall trenches, foundations of
buildings, filling below the floors etc. as per IS: 6313 and other relevant Indian Standards.
12.7 The protections required to be carried out for aggressive alkaline soil, black cotton soil or any
other type of soil which is detrimental/harmful to the concrete foundations shall be payable
separately.
12.8 For all civil works covered under this specification, nominal mix by volume batching as per
CPWD specification is intended. The relationship of grade of concrete and ratio of ingredients
shall be as below:
S.No.
Mix
Cement
Sand
Coarse aggregate of 20 mm down
grade as per IS 383
1. M 10 1 3 6
2. M 15 1 2 4
3. M 20 1 1.5 3
Volume-II (Section-S), Civil 438
The material specification, workmanship and acceptance criteria shall be as per approved
standard Field Quality Plan attached with this document. In case certain item is not covered in
FQP, it shall be constructed as per CPWD specification..
12.9 Ready mix concrete pertaining to M20 grade of reputed manufacturer such as Lafarge, ACC,
Ultra Tech, RMC Readymix India etc. or manufacturer of similar repute shall also be accepted for
use in construction activity. Materials specification, workmanship and acceptance criteria of
readymix concrete shall be as per IS-456.
12.10 Items/components of buildings not explicitly covered in the specification but required for
completion of the project shall be deemed to be included in the scope.
13.0 INTERFACING
The proper coordination & execution of all interfacing civil works activities like fixing of
conduits in roofs/walls/floors, fixing of foundation bolts, fixing of lighting fixtures, fixing of
supports/embedment, provision of cut outs etc. shall be the sole responsibility of the Contractor.
He shall plan all such activities in advance and execute in such a manner that interfacing activities
do not become bottlenecks and dismantling, breakage etc. is reduced to minimum.
14.0 STATUTORY RULES
14.1 Contractor shall comply with all the applicable statutory rules pertaining to factories act (as
applicable for the State). Fire Safety Rules of Tariff Advisory Committee. Water Act for pollution
control etc.
14.2 Statutory clearance and norms of State Pollution Control Board shall be followed as per Water
Act for effluent quality from plant.
14.3 Requirement of sulphate resistant cement (SRC) for sub structural works shall be decided in
accordance with the Indian Standards based on the findings of the detailed soil investigation.
14.4 All building/construction materials shall conform to the best quality specified in CPWD
specifications if not otherwise mentioned in this specification.
14.5 All tests as required in the standard field quality plans have to be carried out.
VOLUME-III
Following formats should be filled by the Bidder.
Section-A Guaranteed Technical Particulars Section-B Schedule of Deviations Section-C. Bill Of Quantity
Section-A
Guaranteed Technical Particulars
CIRCUIT BREAKER ----------------------------- (Bidder’s Name)
1. Name of the Manufacturer & Address 1. ……………………………… 2. a) Type of Circuit Breaker 2.a.)…………………………… b) Type of tank (Live / Dead) b) ……………………………… 3. Manufacturer's type designation 3. ……………………………… 4. Standards Applicable 4. ……………………………… 5. Rated Voltage ( kVrms ) 5. ……………………………… 6. Rated continuous current at design 6. ……………………………… temperature of 50 deg.C (Amps) 7. Rated frequency (Hz) 7. ……………………………… 8. Number of breaks per poles 8. ……………………………… 9. Whether 3 pole or single pole unit 9. ……………………………… 10. Rated short circuit breaking current 10. i) Symmetrical component at i) …………… ………………… highest system voltage (kA) ii) DC Component (%) ii) …………… ………………… iii) Asymmetrical breaking current at iii) ……………………………. highest system voltage (kA) 11. Rated Making Capacity 11. i) at higher rated voltage (kAp) i) ……………………….…… ii) at lower rated voltage ( kAp) ii) ……………………………… 12. i). Maximum total break time under any 12.i) …………………………… duty condition for any current upto rated breaking current with limiting conditions of voltage and pressure (ms)
Section-A
Guaranteed Technical Particulars
CIRCUIT BREAKER ----------------------------- (Bidder’s Name)
ii) Rated break time as per IEC condition (ms) ii) ……………………………… iii) Closing time (ms) iii) ……………………………… iv) Maximum opening time under any iv) ……………………………… condition with limiting voltage and pressures (ms) v) Maximum close open time under any (ms) v) ……………………………… condition with limiting voltages and pressures 13. First pole to clear factor 13. …………………………….. 14. Short time current rating for 1 second (kA) 14. ……………………………… 15. Rated operating duty 15. ……………………………… 16. Maximum line charging breaking current with 16. ……………………………… temporary over voltage upto 1.4 p.u (kA) 17.i) Maximum period between closing of first 17.i)……………………………… contact & last contact in a pole (ms) ii) Maximum pole discrepancy (ms) ii) ……………………………… 18. Small fault current breaking capacity (Amps) 18. ……………………………… 19. Maximum temperature rise for main contacts over 19. ……………………………… design ambient temperature of 50C (Deg. C) 20. Rated pressure and limits of pressure of 20. ……………
………………… extinguishing medium ( kg/sq.cm) 21. Minimum dead time for 21. i) Three phase reclosing (ms) i) ……………………………… ii) Single phase reclosing (ms) ii) …………………………… 22. Dielectric Withstand Voltage of Complete 22.
Breaker
Section-A
Guaranteed Technical Particulars
CIRCUIT BREAKER ----------------------------- (Bidder’s Name)
i) One minute dry & wet power frequency withstand voltage a) Between live terminal and ground (kV rms) a) ……………………………… b) Between terminals with breaker contacts b) ………………………………
Open ( kVrms)
ii) 1.2/50 micro second impulse withstand test voltage. a) Between live terminals and ground (kVp) a) ………………………………
b) Between terminals with breaker contacts b) ……………………………… Open (kVp)
iii) 250/2500 micro second switching surge
withstand test voltage a) Between live terminals and ground (kVp) a) ………………………………
b) Between terminals with breaker contacts b) ……………………………… Open (kVp)
iv) Corona extinction voltage ` iv) ……………
………………… v) Maximum radio interference voltage at 1.1 v) ………………………………
Ur/root 3 vi) Total creepage distance a) To ground a) ……………………………… b) Between terminals b) ……………………………… 23. Operating Mechanism 23.
a) Type of operating mechanism for
i) Closing i) ………………………………
Section-A
Guaranteed Technical Particulars
CIRCUIT BREAKER ----------------------------- (Bidder’s Name)
ii) Opening ii) ………………………………
24. SF6 Circuit Breakers 24.
a) Quantity of SF6 per pole at rated a) ……………………………… pressure (cu. m)
b) Guaranteed maximum leakage b) ……………………………… rate per year ( kg / sq. cm)
c) Rated pressure of SF6 in operating c) ……………………………… chamber ( kg / sq.cm)
d) Limits of pressure at which breaker d) ……………………………… operates correctly ( kg /sq.cm)
e) Mimimum time interval between each e) ……………………………… Make / break operation (ms)
25. General 25.
a) Weight of complete3 phase breaker a) ……………………………… for foundation design (kg) b) Impact loading Foundation design b) ……………………………… c) Seismic level for which Breaker is designed (g) c) ……………………………… d) Min. safety clearance from earthed objects d) ……………………………… e) Noise level in Base of the breaker (dB) e) ……………………………… and upto 50m distance from base f) Minimum clearance In air f) i) between live parts (mm) i) ……………………………… ii) live parts to earth (mm) ii) ……………………………… iii) live parts to ground level (mm) iii) ……………………………… g) Compliance to technical specification g) w.r.t parameters specified for
Section-A
Guaranteed Technical Particulars
CIRCUIT BREAKER ----------------------------- (Bidder’s Name)
i) Control Cabinet i) YES / NO ii) Bushing/support Insulator ii) YES / NO iii)Terminal connector. iii) YES / NO iv) SF6 Gas iv) YES / NO 26. Detailed Literature 26. a) Whether similar equipment are type a) ……………………………… tested as per IEC/IS and are in successful operation for atleast 2 (two) years (If yes, furnish type test reports) b) Furnish data on capabilities of circuit b) ……………………………… breaker in terms of time and number of operations at duties ranging from 100 % fault currents to load currents of the lowest possible value without requiring any maintenance or checks c) Furnish details of effect of non simultanity c) ……………………………… between contacts within a pole or between poles and also show how it is covered in the guaranteed rated break time. d) Overall General Arrangement drawing of d) …………… ………………… circuit breaker is to be enclosed.
Section-A
Guaranteed Technical Particulars
Isolators ----------------------------- (Bidder’s Name)
Name and address of the Manufacturer 1. ……………………………… 2. Manufacturer’s type designation 2. ……………………………… 3. Standard applicable 3. ……………………………… 4. Rated Voltage, Ur 4. ……………………………… 5. Rated Current under site 5. ……………………………… conditions at 50 deg.C ambient (Amps) 6. Rated frequency (Hz) 6. ……………………………… 7. Number of poles 7. ……………………………… 8. Whether all 3 poles are ganged /mechanically 8. Yes/No coupled. 9. Pole to pole spacing (mm) 9. ……………………………… 10. Rated short time current of isolator and 10. ……………………………… Earth switch for 1(one) second and dynamic current 11. Opening time of isolator and earth switch 11. ……………………………… 12. Closing time of isolator and earth switch 12. ……………………………… 13. Rated mechanical terminal load 13. ……………………………… 14. Dielectric withstand capacity 14. ……………………………… of completely assembled isolator/ earth switch 15. One minute dry power frequency withstand 15. test voltage
i) against ground (kVrms) i) ………………………………
ii) across isolating distance (kVrms) ii) ……………………………… 16. 1.2/50 micro sec impulse withstand test voltage 16. i) against ground (kVp) i) ………………………………
Section-A
Guaranteed Technical Particulars
Isolators ----------------------------- (Bidder’s Name)
ii) across isolating distance (kVp) ii) ……………………………… 17. Corona Extinction voltage (kVrms) 17. ……………………………… 18. Radio interference level at 1.1 Ur/ 18. ……………………………… root 3 (in micro volts) at 1 MHz 19. Operating Mechanism 19.
i) For main blades i) ……………………………… ii) For earth switches ii) ………………………………
20. Confirm whether similar equipment are type tested 20. as per IEC / IS and are in successful operation for at least 2 (two) years( furnish type test report) 21. Overall General Arrangement drawing of 21. ……………………………… Isolator/ Earthswitch is to be enclosed.
Section-A
Guaranteed Technical Particulars
Instrument Transformer ----------------------------- (Bidder’s Name)
1. Name and address of manufacturer 1 …………………………. 2. Standards applicable 2. ……………….………… 3. Type of CT ( Live or Dead Tank Type) 3. ………………………… 4. Rated frequency (Hz) 4. ………………………… 5. Rated voltage Ur (kV) 5. ………………………… 6. Rated current 6. i) Rated continuous current (Amps) i) ………………………… ii) Rated extended primary current (Amps) ii) ………………………… 7. Short time thermal current withstand for 7. ………………………… 1 sec(kA) 8. Dynamic current withstand (kAp) 8. ………………………… 9. 1.2/50 micro sec impulse withstand voltage (kVp) 9. …………..…………… 10. 250/2500 micro sec switching surge 10. …………… …………… withstand voltage (dry and wet) (kVp) 11. One minute dry and wet power frequency 11. …………… …………… withstand voltage (kV rms) 12. No. of primary winding 12. …………… …………… 13. No. of cores per CT 13. …………… …………… 14. Current ratio (for all cores) 14. …………… …………… 15. Output Burden (for all cores) 15. …………… …………… 16. Accuracy class (for all cores) 16. …………… …………… 17. Knee point voltage at different taps (V) 17. …………… …………… (for all cores) 18. Maximum exciting current at Knee 18. . …………. ……………
Section-A
Guaranteed Technical Particulars
Instrument Transformer ----------------------------- (Bidder’s Name)
point voltage at different ratios ( for all cores) (mA) 19. Secondary winding resistance for all ratios 19. .………………………… and cores. 20. Instrument security factor at different ratios 20. …………… …………… for metering cores 21. Radio interference voltage at 1.1 Ur/3 21. …………… …………… at 1.0 MHz (Micro Volts) 22. Corona extinction voltage (kV rms) 22. …………… …………… 23. Partial discharge level (PC) 23. …………… …………… 24. Standard to which oil conforms generally 24. …………… …………… 25. Total weight (kg) 25. …………… …………… 26. Confirm whether similar equipment are type tested 26. and in successful operation for at least 2 years ratios (for all cores) (Ohms) ( Furnish type test report ) 27. Overall General arrangement drawing of 27. .………………………… CT is to be enclosed.
Section-A
Guaranteed Technical Particulars
Instrument Transformer ----------------------------- (Bidder’s Name)
1. Name and address of Manufacturer 1. ………………………………….. 2. Manufacturer's type designation 2. ………………………………….. 3. Standards applicable 3. ………………………………….. 4. Rated primary voltage Ur (kV) 4. ………………………………….. 5. Rated secondary voltages (kV) 5. ………………………………….. 6. Number of secondaries 6. ………………………………….. 7. Rated frequency (Hz) 7. ………………………………….. 8. Rated output of each secondary winding (VA) 8. ………………………………….. 9. Total simultaneous burden (VA) 9. ………………………………….. 10. Rated total thermal burden (VA) 10. ……………………………….. 11. Highest system voltage (kV) 11. ……………………………….. 12. Rated voltage factor and corresponding 12. ……………………………….. rated time 13. Accuracy class of each secondary winding 13. ……………………………….. 14. Capacitance 14. i. of high voltage capacitor (pF) i) ………………………………….. ii. of intermediate voltage capacitor (pF) ii) ………………………………….. 15. Carrier frequency coupling (pF) 15. ……………………………….. 16. Band width (kHz) 16. ……………………………….. 17. One minute power frequency 17. ……………………………….. test voltage of secondary winding (kV rms) 18. One minute power frequency 18. ……………………………….. test voltage of H.F. terminal (kV rms)
Section-A
Guaranteed Technical Particulars
Instrument Transformer ----------------------------- (Bidder’s Name)
19. One minute power frequency test voltage 19. ……………………………….. of capacitor (kV rms) (dry & wet) 20. 1.2/50 micro sec impulse withstand 20. ……………………………….. test voltage of Capacitor (kVp) 21. Corona extinction voltage (kV rms) 21. ……………………………….. 22. Max. Radio Interference voltage at 1.1 Ur/ 22. …………………………………. Root 3 at 1.0 MHz (Micro volts) 23. Total weight (kg) 23. ……………………………….. 24. Quantity of oil (litres) 24. ……………………………….. 25. Whether CVTs are hermetically sealed. 25. ……………………………….. If so. Furnish arrangement of sealing. 26. Whether similar equipment is type 26. YES / NO tested as per IEC 186 and in successful operation for at least. 2 (two) years (Furnish type test report) 31. Overall General Arrangement drawing of 31. ……………………………….. CVT is to be enclosed.
Section-A
Guaranteed Technical Particulars
Surge Arrestor ----------------------------- (Bidder’s Name)
1. Name and address of Manufacturer 1. ………… ………… ………… 2. Manufacturer’s type designation 2. ………… ………… ………… 3. Applicable standards 3. ………… ………… ………… 4. Arrester class and type 4. ………… ………… ………… 5. Rated arrester voltage (kV) 5. ………… ………… ………… 6. Rated system voltage (kV) 6. ………… ………… ………… 7. Maximum continuous operating voltage 7. ………… ………… ………… (COV) at 50 deg.C ambient temperature (kV) 8. Nominal discharge current(8/20 micro 8. ………… ………… ………… sec.wave) (kA) 9. Minimum discharge capability ( kJ / kV) 9. ………… ………… ………… 10. a) Maximum residual voltage at nominal 10.a) ………… ………… ………… discharge current (kVpeak) b) Minimum residual voltage at nominal 10.b) ………… ………… ………… discharge current (kVpeak) 11. a) Maximum residual voltage at 50 % nominal 11.a) ………… ………… ………… discharge current (kVpeak) b) Maximum residual voltage at 200% nominal 11.b) ………… ………… ………… discharge current (kVpeak) 12. Steep fronted wave residual voltage 12. ………… …………………… at 1 KA (kVpeak) 13. Long duration discharge class 13. ………… ………… ………… 14. Impulse current withstand 14. a) High current short duration (4/10 a) ………… ………… ………… micro-sec wave) in kVpeak
b) Low current long duration b) ………… …………………… (2000 microsec.) 15. Current for pressure relief test (kA) 15. ………… ……………………
Section-A
Guaranteed Technical Particulars
Surge Arrestor ----------------------------- (Bidder’s Name)
16. Pressure relief class ( as per IEC 99) 16. ………… ………… ………… 17. One minute power frequency (dry) withstand 17. ………… …………………… voltage of arrester housing (kVrms) 18. Lightning Impulse withstand test voltage of 18. ………… ………… ………… arrester housing with 1.2/50 microsec wave (kVp) 19. Total creepage distance of whole arrester 19. ………… ………… …………
housing ( mm) 20. Cantilever strength of complete arrester (N) 20. ………… ………… ………… 21. Total height of the arrestor (mm) 21. ………… …………………… 22. Total weight of the arrestor (Kg) 22. ………… …………………… 23. Maximum radio interference voltage at 1.1 Ur/ 23. ………… ………… ………… root 3 voltage at 1 MHz ( microvolts) 24. Partial discharge at 1.05 continuous operating 24. ………… ………… ………… voltage (pC) 25. Minimum prospective symmetrical fault current 25. ………… ………… ………… (kArms) 26. ZnO block details 26………… …………………… a) Confirm whether equipment type tested a) with offered type of ZnO block 27. Confirm whether similar equipment are type 27……………………………… tested as per IEC/IS or equivalent standard and are in successful operation for at least two years. 28. Overall General Arrangement drawing of 28. ………… ……………………
Surge arrester is to enclosed.
Section-A
Guaranteed Technical Particulars
Battery And Battery Charger ----------------------------- (Bidder’s Name)
A: BATTERIES 1. Manufacturer’s Name and address 1. ------------------------------- 2. Confirm whether Manufacturers have 2. -------------------------------
manufactured, tested, supplied, installed and commissioned batteries of 220V, 600AH capacity similar to the offered batteries and are in operation for at least 2(Two) years
3. Type of battery 3. -------------------------------- 4. Capacity of battery at 27C 4. -------------------------------- 5. Confirm whether batteries are type tested as per IS 5. 6. Recommended value of float charging 6. -------------------------------- voltage BATTERIES CHARGERS 1. Manufacturer’s Name and address 1. -------------------------------- 2. Confirm whether Manufacturer’s have 2.
manufactured, tested, supplied, installed and commissioned battery Chargers to 10 Kw capacity similar to the
offered battery Chargers. 3. Capacity of battery chargers (AH) 3. -------------------------------- 4 Charger rate / output current 4. -------------------------------- 5. Float charging mode (A) 5. -------------------------------- 6. Boost Charging Mode (A) 6. --------------------------------- 7. Ripple content in output voltage (%) 7. -------------------------------- 8. Confirm whether battery chargers are 8. ---------------------------------
type tested as per specification
Section-A
Guaranteed Technical Particulars
LT Transformer ----------------------------- (Bidder’s Name)
1. Name & Address of Manufacturer 1. ………………………………… 2. Voltage Ratio 2. ………………………………… 3. Rating 3. ………………………………… 4. Standards applicable 4. ………………………………… 5. Rated frequency 5. ………………………………… 6. Number of phases 6. ………………………………… 7. Vector Group 7. ………………………………… 8. Type of cooling 8. ………………………………… 9. Tap changing equipment 9. i) Type i) ………………………………… ii) No. of steps & tap range ii) ………………………………… 10. Positive sequence 10. impedance at 75 C with 100% rating at
a) Principal tap a) ………………………………… b) Maximum tap b) …………………………………
c) Minimum tap c) …………………………………
11. Temperature rise over an ambient of 50 deg.C 11. a) Top oil deg.C a) …………………………………
b) Windings (by resistance measurement b) ………………………………… method ) deg.C
1 2. Guaranteed losses 12. a) Maximum no load loss on principal tap at a )………………………………….
rated voltage and frequency.(kW) b) Maximum load loss at rated current at b) …………………………………
Section-A
Guaranteed Technical Particulars
LT Transformer ----------------------------- (Bidder’s Name)
principal tap at 75 deg C(kW) 13. Withstand time for three phase short 13. ………………………………… circuit at terminals (secs.) 14. Insulation level 14.
a) Full wave lightning impulse withstanding a)
i. HV Winding (kVp) i. …………………………………
ii. LV Winding (kVp) ii. …………………………………
15. Confirm whether similar equipment are type tested 15. and are in successful operation for atleast two years. 16. Confirm whether similar equipment is tested 16. ………………………………… for dynamic short circuit withstand capability. ( furnish details)
Section-A
Guaranteed Technical Particulars
LT Switchgear ----------------------------- (Bidder’s Name)
1. Manufacturer’s Name & Address 1. ………………………………… 2. Confirm whether Manufacturer’s have 2. …………………………………
supplied 50 Nos drawout Air circuit breaker Panels out of which 5 Nos. are with CT and relaying scheme.
3. Confirm whether Manufacturer’s have 3. ………………………………….
supplied 50 Nos. MCC panels similar to the offered panels.
4. Confirm whether 100 nos.(at least) circuit 4………………………………….. breakers of the make and type being offered are already been operating satisfactorily. 5. Rated short circuit current 5. 5.1 Symmetrical short circuit 5.1. …………………………………
withstand current at rated voltage of switchgear cubicle
5.2 Peak short circuit withstand current 5.2. ………………………………… 6. Degree of protection 6. 6.1 Breaker/MCC/AC & DC 6.1. ………………………………… 6.2 Distribution Cubicles 6.2 ………………………………… 6.3 Busbar chamber 6.3 ………………………………… 7. Standard height, width & depth of typical panel 7. 7.1 Circuit Breaker Panel 7.1 ………………………………… 7.2 MCC panel 7.2 ………………………………… 7.3 AC/DC Distribution Board 7.3 ………………………………… 8. Width of cable alley 8. ………………………………… 9. Confirm whether equipment offered are from 9………………………………….. manufacturer and they are type tested as per IS/ International standard and are
Section-A
Guaranteed Technical Particulars
LT Switchgear ----------------------------- (Bidder’s Name)
in successful operation for two years.
Section-A
Guaranteed Technical Particulars
Power and Control Cable ----------------------------- (Bidder’s Name)
1. Manufacturer's name and address 1. …….… ……..… ……..…. 2. Type of cable 2. …….… ……..… ……..…. 3. Applicable standards 3. …….… ……..… ……..…. 4. Rated Voltage (Volts) 4. …….… ……..… ……..…. 5. Suitable for earthed or unearthed system? 5. …….… ……..… ……..…. 6. Continuous current rating when laid in air 6. …….… ……..… ……..…. in an ambient temp. of 50deg.C and for maximum conductor temp. of 70 deg.C for PVC cable 7. Short Circuit Capacity 7. i. Short Circuit Current (kArms) i. …….… ……..… ……..…. ii. Duration of short circuit. (Sec.) ii. …….… ……..… ……..….
iii. Conductor temp. allowed for the iii. …….… ……..………..…. short circuit duty ( Deg. C) iv. Formula relating short circuit current (rms) iv. …….… ……..… ……..…. and duration (Sec.)
8. Conductor 8. i. Material (Copper or aluminium) i. …….… ……..… ……..…. ii. Grade ii. …….… ……..… ……..…. iii. Normal cross section area (Sq.mm) iii. …….… ……..… ……..…. iv. Number and diameter of wire (No./mm) iv. …….… ……..… ……..…. 9. Insulation 9. i. Composition of insulation i. …….… ……..… ……..…. ii. Nominal thickness of insulation (mm) ii. …….… ……..… ……..…. 10. Inner Sheath 10.
Section-A
Guaranteed Technical Particulars
Power and Control Cable ----------------------------- (Bidder’s Name)
i. Material i. …….… ……..… ……..….
ii. Calculated diameter over the ii. …….… ……..… ……..…. laid up cores, (mm) iii. Thickness of Sheath (minimum) mm iii. …….… ……..… ……..…. 11. Armour 11. i. Type and material of armour i. …….… ……..… ……..…. (wire / strip)
ii. Calculated diameter under armour (mm) ii. …….… ……..… ……..….
iii. Nominal diameter of round armour wire iii. …….… ……..… ……..….
iv. Nominal size of wire / strip iv. …….… ……..… ……..…. v. Short circuit capacity armour v. …….… ……..… ……..…. alongwith formulae vi. Maximum D.C. resistance at 20deg.C vi. …….… ……..… ……..….
12. Outer Sheath 12. i. Material i. …….… ……..… ……..…. ii. Calculated diameter under sheath ii. …….… ……..… ……..…. 13. Safe pulling force when pulled by 13. …….… ……..… ……..…. pulling eye on the conductor (Kg) 14. Test Voltage 14. …….… ……..… ……..…. i. High Voltage test voltage (kV) i. …….… ……..… ……..…. ii. Water immersion test voltage (kV) ii. …….… ……..… ……..…. 15. Minimum bending radius permissible 15. …….… ……..… ……..…. 16. Confirm that are all the cables approved by 16. BIS or other international standard organizations and marked as such
Section-A
Guaranteed Technical Particulars
Power and Control Cable ----------------------------- (Bidder’s Name)
17. Whether the cables are type tested as per IS 17. Yes/No
/international Standard.
Section-A
Guaranteed Technical Particulars
Relay and Protection Panel ----------------------------- (Bidder’s Name)
1. Name and address of Manufacturer of panels 1.……………………………. 2. Manufacturer's type and designation 2..……………………………. 3. Type of construction (Simplex/duplex) 3. .……………………………. 4. Thickness of sheet steel 4. (i) Front i) .……………………………. (ii) Back ii) .……………………………
(iii) Sides iii) .…………………………… 5. Degree of protection 5. .……………………………. 6. Name of the manufacturer of relays 6. .……………………………. 7. DC voltage of the relays 7. ……………………………. 8. make and Model of static ( 0.2 accuracy class 8. .……………………………. type) energy meters 9. Confirm whether offered manufacturer of C&R 9. .……………………………. panels and protective relays have tested commissioned & they are in successful operation for at least two years in 400 kV system.
TRANSMISSION LINE PROTECTION
Numerical Distance protection Scheme -I
1. Name and address of Manufacturer 1………………………….. 2. Manufacturer's type and designation 2…………………………. 3. Switched or Non- switched type ( is 3…………………………. it with separate measurements for single/three phase faults) 4.. Setting range of offset feature 4…………………………. 5. Whether the relay is having self 5…………………………. monitoring feature 6. Whether relay is compatible for 6………………………… PLCC equipment and can be used for Permissive Under reach/over
Section-A
Guaranteed Technical Particulars
Relay and Protection Panel ----------------------------- (Bidder’s Name)
reach /Blocking scheme etc 7. Suitable for single and three phase Trip? 7……………………….. 8. Type of shaped characteristic 8…………………………… 9. No of tripping contacts with making 9……………………………
capacity of 30 amp for 0.2 seconds 10 In case 16 contacts as per above 10………………………….. clause are not available with the distance relay offered , type of tripping relay being offered 11 Maximum operating time for at 50% of the 11 reach setting of 2 ohms and 10/20 ohms (with CVT) including all trip relays ,if any (Bidder is required to enclose isochronic curve with CVT on line)
a) at SIR=4 a)………………………….. b) at SIR=15, (3 phase faults) b)…………………………. c) at SIR=15 (other faults) c)………………………….
12 IDMT earth fault relay Meeting Normal 12………………………… Inverse Characteristics as per IEC 60253
is being offered ass built in feature for 220 KV lines
13. If no, type of IDMT relay being offered 13………………………… 14. Built in features offered with the relay (YES/NO) 14.
a) Disturbance recorder a)…………………………. b) Fault locator b)…………………………
c) Over voltage (one stage only) c)………………………… d) Auto reclose along with Dead line d)………………………… charging and check synchronisng
Numerical Distance protection Scheme -II
1. Name and address of Manufacturer 1………………………….. 2. Manufacturer's type and designation 2………………………….
Section-A
Guaranteed Technical Particulars
Relay and Protection Panel ----------------------------- (Bidder’s Name)
3. Switched or Non- switched type ( is 3…………………………. it with separate measurements for single/three phase faults) 4.. Setting range of offset feature 4…………………………. 5. Whether the relay is having self 5…………………………. monitoring feature 7. Whether relay is compatible for 6………………………… PLCC equipment and can be used for Permissive Under reach/over reach /Blocking scheme etc 7. Suitable for single and three phase Trip? 7……………………….. 8. Type of shaped characteristic 8…………………………… 10. No of tripping contacts with making 9……………………………
capacity of 30 amp for 0.2 seconds 13 In case 16 contacts as per above 10………………………….. clause are not available with the distance relay offered , type of tripping relay being offered 14 Maximum operating time for at 50% of the 11 reach setting of 2 ohms and 10/20 ohms (with CVT) including all trip relays ,if any (Bidder is required to enclose isochronic curve with CVT on line)
a) at SIR=4 a)………………………….. b) at SIR=15, (3 phase faults) b)…………………………. d) at SIR=15 (other faults) c)………………………….
15 IDMT earth fault relay Meeting Normal 12………………………… Inverse Characteristics as per IEC 60253
is being offered ass built in feature for 220 KV lines
13. If no, type of IDMT relay being offered 13………………………… 14. Built in features offered with the relay (YES/NO) 14.
a) Disturbance recorder a)…………………………. b) Fault locator b)…………………………
c) Over voltage (one stage only) c)…………………………
Section-A
Guaranteed Technical Particulars
Relay and Protection Panel ----------------------------- (Bidder’s Name)
d) Auto reclose along with Dead line d)………………………… charging and check synchronisng
BACKUP DIRECTIONAL OVER CURRENT
AND EARTH FAULT PROTECTION SCHEME
1. Name and address of Manufacturer 1…………………………… 2. Manufacturer’s type and designation 2…………………….……. 3. Three over current and one E/F elements 3. …………………………. Are whether independent or composite unit 4. Type of relay (Elecromechanical/static/Numerical) 4………………………….. 5. Directional sensitivity 5……………………………. 6. Whether characteristic conform to IEC 255-3 6………………………….. 7. Over current unit setting range inverse time 7…………………………… 8. Earth fault unit setting range inverse time 8…………………………… 8. VT Fuse failure relay/ feature included 9…………………………… for alarm
LINE OVER VOLTAGE PROTECTION RELAY
1. Name and address of Manufacturer 1…………………………… 2. Manufacturer’s type and designation 2…………………….……. 3. Type of relay (Elecromechanical/static/Numerical) 3………………………….. 4. Operation indicator provided? 4…………………………… 5. Operating time 5……………………………. 6. Resetting time 6………………………….. 7. Whether monitors all three phases? 7…………………………… 9. Built in feature of Main1/Main 2 distance 8…………………………… relay is offered . If so , which stage is offered as built in
Section-A
Guaranteed Technical Particulars
Relay and Protection Panel ----------------------------- (Bidder’s Name)
DISTANCE TO FAULT LOCATOR
1. Name and address of Manufacturer 1……………………………. 2. Manufacturer’s type and designation 2……………………………. 3. Built in feature of Main1/Main 2 3…………………………..
distance relay is offered 4. Maximum registering time 4………………………….. 5. Whether direct display unit provided? 5………………………….. 6. Whether both phase to phase fault and 6…………………………..
phase to earth fault measuring units included? 7. Whether “On-Line” type 7……………………………. 8. Accuracy for the typical conditions defined 8……………………………… under technical specification
DISTURBANCE RECORDER
a. Acquisition unit
1. Name and address of Manufacturer 1………………………………. 2. Manufacturer's type and designation 2……………………………….. 3. No. of analogue channels 3……………………………….. 4. No. of digital recording channels 4………………………………. 8. Built in feature of Main1/Main 2 distance 5……………………………….
relay is offered 6. Pre-fault memory (milli seconds) 6……………………………….. 7. Post fault memory(seconds) 7………………………………. 8. Total storage memory in seconds 8……………………………….. 9. Sampling Frequency 9……………………………… 10. Resolution of the event channels (ms) 10…………………………….. 11. Time display present? 11…………………………….
Section-A
Guaranteed Technical Particulars
Relay and Protection Panel ----------------------------- (Bidder’s Name)
12. Data out put in COMTRADE is available 12.……………………………
b.Evaluation Unit
1 Name and address of Manufacturer 1………………………………. 2 Manufacturer's type and designation 2……………………………….. 3 No of acquisition unit that can be connected 3…..………………………. to One evaluation unit 4 Technical Parameters of evaluation unit 4 A Processor and speed A………………………….
B RAM and hard disk capacity B…………………………. C Additional facilities C…………………………. D Details of printer D………………………….
5. Details of power supply arrangement for 6…………………………..
Acquisition unit (including printer)
AUTO RECLOSE RELAY
1. Name and address of Manufacturer 1……………………………. 2. Manufacturer's type and designation 2……………………………. 3. Electromechanical /static/numerical 3……………………………. 3. Auto reclose relay along with Dead line 4…………………………….
charging and check synchronisng relay (For 132 KV lines) offered as a part of
distance relay 5. Suitable for single and three phase? 5……………………………. 6. Single phase dead time setting 6……………………………. Range 7. Three phase dead time setting range 7……………………………… 8. Reclaim time setting range 8………………………………
TRANSFORMER PROTECTION
Section-A
Guaranteed Technical Particulars
Relay and Protection Panel ----------------------------- (Bidder’s Name)
Differential relay 1. Name and address of Manufacturer 1…………………………….. 2. Manufacturer's type and designation 2…………………………….. 3. Second harmonic restraint provided 3…………………………….. 4. Whether three instantaneous units provided 4…………………………….. 5. Operating Current setting range 5…………………………….. 6. Bias setting range 6……………………………..
7. Operating time at 5X setting current 7……………………………..
8. Resetting time 8…………………………….. 9. How ratio / phase angle corrections are 9…………………………….. being done(inter posing transformer/internal feature in the relay)
Restricted Earth Fault Protection 1. Name and address of Manufacturer 1…………………………….. 2. Manufacturer's type and designation 2…………………………….. 3. Operating time at 2 x setting 3……………………………..
Over Fluxing relays
1. Name and address of Manufacturer 1…………………………….. 2. Manufacturer's type and designation 2…………………………….. 3. Whether inverse time operating characteristics 5…………………………….. 4. Maximum operating time 6…………………………….. 5. Accuracy of operating time 7…………………………….. 6. Resetting time 8……………………………..
Section-A
Guaranteed Technical Particulars
Relay and Protection Panel ----------------------------- (Bidder’s Name)
Directional O/C and E/F relays
1. Name and address of Manufacturer 1…………………………….. 2. Manufacturer's type and designation 2…………………………….. 3. Whether Characteristic will confirm to IEC255-3 4…………………………….. 4. Directional sensitivity 5…………………………….. 5. Over current unit setting range 6
a) Inverse time a) ……………………………. b) High set b) ……………………………..
6. Earth fault unit setting range 7
a) Inverse time a) …………………………….. b) High set b) …………………………..
GENERAL PROTECTION /MONITORING EQUIPMENT
Trip Circuit Supervision relay 1. Name and address of Manufacturer 1…………………………….. 2. Manufacturer's type and designation 2…………………………….. 3. Whether pre-closing and post closing 3…………………………….. supervision provided? 4. Time delay 4……………………………..
High Speed Trip Relays
1. Name and address of Manufacturer 1…………………………….. 2. Manufacturer's type and designation 2…………………………….. 3. Contact ratings 3.
a) Make and carry continuously a) ……………………………. b) Make and carry for 0.5 sec. b) …………………………….. c) Break c) ……………………………..
Section-A
Guaranteed Technical Particulars
Relay and Protection Panel ----------------------------- (Bidder’s Name)
i). Resistive load i) ……………………………..
ii) Inductive load ii) …………………………….. (With L/R=40milli sec.) 4. Operating time at rated voltage (maximum) 4…………………………….. 5. Resetting time 5…………………………….. 6. Whether supervisory relays included 6…………………………….. Local breaker back-up protection 1. Name and address of Manufacturer 1…………………………….. 2. Manufacturer's type and designation 2…………………………….. 3. Operating time 3…………………………….. 4. Resetting time 4…………………………….. 5. Setting ranges 5
a) Current a) …………………………….. b) Time b) ……………………………..
Bus bar Protection
1. Name and address of Manufacturer 1…………………………….. 2. Manufacturer's type and designation 2…………………………….. 3. Type of relay 3…………………………….. (Elecromechanical/static/Numerical) 4. Principle of operation(Biased/High impedance) 4…………………………….. 5. Operating time 5…………………………….. 6. Resetting time 6…………………………….. 7. Setting ranges 7. (i) Current i) ……………………………..
(ii) Time ii) ……………………………..
Section-A
Guaranteed Technical Particulars
Relay and Protection Panel ----------------------------- (Bidder’s Name)
8 Whether will it cause tripping for the differential 8…………………………….. current below the load current of heavily loaded feeder (Bidder shall submit application
check for the same )
Section-A
Guaranteed Technical Particulars
Relay and Protection Panel ----------------------------- (Bidder’s Name)
CONTROL PANEL EQUIPMENT
Bay Control unit
1. Name of Manufacturer 1…………………………….. 2. Manufacturer's type and designation 2…………………………….. 3. Type of mounting 3…………………………….. 4. Standards Applicable 4…………………………….. 5. Rated auxiliary voltage 5…………………………….. 6. No. of analog variable (specify voltage & 6…………………………….. current separately 7. Rated Frequency 7……………………………... 8. No. of binary inputs 8……………………………... 9. No. of outputs 9……………………………... 10. Language 10……………………………... 11. Type of communication protocol supported 11……………………………... 12. No. & Type of communication ports 12……………………………... 13. Operating temperature range 13……………………………... 14. System Response Time 14……………………………...
Recording Meter for voltage
1. Name of Manufacturer 1…………………………….. 2. Manufacturer's type and designation 2…………………………….. 3. Accuracy class 3……………………………..
4. Full span response time 4……………………………..
5. Is it strip type recorder /digital type 5…………………………….. 6. If it is digital type 6.
Section-A
Guaranteed Technical Particulars
Relay and Protection Panel ----------------------------- (Bidder’s Name)
i) No of channels being used i) ……………………………..
ii)Whether time tagged information is available ii) ……………………………..
iii)Whether EMC/EMI compatibility is tested iii) ……………………………..
Recording Meter for frequency
1. Name of Manufacturer 1…………………………….. 2. Manufacturer's type and designation 2…………………………….. 3. Accuracy class 3……………………………..
4. Full span response time 4……………………………..
5. Is it strip type recorder /digital type 5…………………………….. 6. If it is digital type 6
i) No of channels being used (i) ……………………………..
ii) Whether time tagged information is available (ii) ……………………………..
iii) Whether EMC/EMI compatibility is tested (iii) ……………………………..
Terminal Block
1. Name of Manufacturer 1. …………………………….. 2. Manufacturer's type and designation 2…………………………….. 3. Rated current 3…………………………….. 4. Rated voltage 4…………………………….. 5 Minimum no. of conductors of area 5…………………………….. 2.5 mm2 suitable for connection.
(i) All circuits except CT.Circuits (i) …………………………….. (ii) C.T. Circuits (ii) ……………………………..
Control Switches
Section-A
Guaranteed Technical Particulars
Relay and Protection Panel ----------------------------- (Bidder’s Name)
1. Name of Manufacturer 1…………………………….. 2. Manufacturer's type and designation 2…………………………….. 3. Number of positions provided 3…………………………….
(Trip/Normal after trip, close, normal after close) 4. No. of contacts 4…………………………….. 5. Type of handle 5…………………………….. 6. Rating of contacts 6.
a) Make and carry continuously a) …………………………….. b) Make and carry for 0.5 sec. b) …………………………….. c) Break resistive load, in Amps (d.c.) c) …………………………….. d )Break inductive load with L/R=40 m. sec d) …………………………….. in Amps. (d.c).
4. Life of switch in terms of million 7……………………………..
mechanical operations
Push Buttons
1. Name of Manufacturer 1…………………………….. 2. Manufacturer's type and designation 2…………………………….. 3. Contact ratings 3…………………………….. 4. No. of contacts 4……………………………..
Annunciators
1. Make 1…………………………….. 2. Type & Model No. 2…………………………….. 3. Static/electromechanical 3…………………………….. 4. No of lamps per window 4…………………………….. 5. Lamps 5
Section-A
Guaranteed Technical Particulars
Relay and Protection Panel ----------------------------- (Bidder’s Name)
a) Voltage (a) ……………………………..
b) Wattage (b) …………………………….. 6. Minimum duration of impulse for initiating 7……………………………..
contact in millisecond
8. Type of reset self/manual 8……………………………..
Section-A
Guaranteed Technical Particulars
SDH & PLCC ----------------------------- (Bidder’s Name)
A. COUPLING DEVICE (Phase to Phase Type)
1. Name of Manufacturer and Country
1…………………………...
2. Type, Model and Catalogue Number
2…………………………...
3. Nominal primary side impedance
3…………………………...
4. Nominal secondary side impedance
4…………………………...
5. Composite loss with in pass-band
5…………………………...
6. Return loss with in pass-band
6…………………………...
7. Available Bandwidth (with 4400/6600/8800 pF CVTS)
7…………………………...
8. Nominal Peak Envelope Power (with Distortion and Inter modulation Products 80 dB down)
8…………………………..
9. Maximum number of PLC terminals that can be connected in parallel: a) 20 W (PEP) PlC terminals b) 40 W (PEP)PLC terminals c) 100 W(PEP) PLC terminals
9…………………………... a)………………………….. b)………………………….. c)…………………………..
10. Power Frequency Impedance between primary terminal and Earth Terminals of Coupling Device.
10………………………….
11. No of H.F. terminals provided for carrier equipment connection
11………………………….
HIGH FREQUENCY CABLE
1. Name of Manufacturer and country
1…………………………...
2. Type, Model and Catalogue no.
2…………………………..
3. Applicable standards
3…………………………..
4. Maximum attenuation per km of cable for carrier Frequency range 40 to 500 kHz
4…………………………..
5. Maximum loop resistance/ km of cable 5…………………………..
Section-A
Guaranteed Technical Particulars
SDH & PLCC ----------------------------- (Bidder’s Name)
POWER LINE CARRIER TERMINAL FOR SPEECH AND DATA TRANSMISSION OR NETWORK PROTECTION
1. Name of Manufacturer and country
1…………………………...
2. Type, Model and Catalogue no.
2…………………………...
3. Type of Modulation 3…………………………... 4. Mode of transmission 4…………………………... 5. Carrier Frequency Range
5…………………………...
6. Nominal carrier frequency band in either direction of transmission
6…………………………...
7. Return loss within the nominal carrier frequency band
7…………………………..
8. Effectively transmitted V.F. band a) For speech b) For telephone signaling
8…………………………...
9. Return Loss within the effectively transmitted voice frequency band
9…………………………...
10. Maximum H.F Amplifier output with single /Multiple tone keying (Peak Envelope Power )
10………………………….
11. Nominal carrier frequency power (peak envelop power) at output terminals.
11………………………….
VF TRANSMISSION TERMINAL FOR NETWORK PROTECTION SIGNALS (PROTECTION COUPLER)
1. Name of Manufacturer and country
1…………………………..
2. Type, Model and catalogue number
2…………………………..
3. Whether equipment works on frequency shift principle of coded signal principle
3…………………………..
4. Whether Equipment is suitable for independently protecting two circuits
4…………………………...
Section-A
Guaranteed Technical Particulars
SDH & PLCC ----------------------------- (Bidder’s Name)
5. Frequencies used in the equipment for transmission of signal for un-coded signal transmission a) Guard frequency c) Working frequency (Trip system-I) d) Working frequency (Trip system-II) e) Working frequency (Trip system (I&II)
5………………………….. a) ……………………….. b) ……………………….. c) ……………………….. d) ………………………..
6. Criteria used for command transmission
6…………………………..
7. Transmission time corresponding to telegraph speed for transmission on PLCC channel of coded signal a) 600 Bds. b) 400 Bds. c) 200 Bds.
7………………………….. a)…………………………. b)…………………………. c)………………………….
8. Mode of transmission of guard signal
8…………………………..
9. Whether equipment is suitable for Direct circuit breaker tripping.
9…………………………..
10. Whether loop test is possible
10………………………….
11. Whether the equipment is suitable for transmitting and receiving more than two independent commands (please furnish details)
11………………………….
12. Whether receiver design provides protection against false tripping from random noise
12………………………….
LINE TRAPS
1. Name of Manufacturer and country
1…………………………...
2. Type & Model
2…………………………...
3. System Voltage Rating
3…………………………...
4. Continuous current rating at 50C ambient
4…………………………...
5. Continuous current rating at 65C 5…………………………...
Section-A
Guaranteed Technical Particulars
SDH & PLCC ----------------------------- (Bidder’s Name)
6. Maximum Symmetrical short circuit current rating for 1 sec. duration
6…………………………...
7. Asymmetric peak value of first half wave of rated short time current
7…………………………...
8. Rated Inductance
8…………………………...
9. Blocking Range
9…………………………...
10. Minimum Guaranteed Resistive component in blocking frequency range
10………………………….
11. Details of protection of capacitors and coils against voltage surges. Indicate type of protective device.
11………………………….
12. Rated voltage of the arrestor (protective device )
12………………………….
ELECTRONIC PRIVATE AUTOMATIC EXCHANGE (EPAX)
1. Name of manufacturer 1…………………………..
2. Type and model 2…………………………..
3. Capacity of exchange (Subscribers & trunk lines)
3…………………………..
4. Whether compatible to both i.e PLCC & DOT lines for communication
4…………………………..
Section-A
Guaranteed Technical Particulars
Illumination System ----------------------------- (Bidder’s Name)
Lighting Fixtures & Accessories A. 1. Manufacturer's Name and address 1. a) Fixtures a). ………………………………… b) Accessories b). ………………………………… 2 Applicable Standards for 2. a) Fixtures a). ………………………………… b) Accessories b). ………………………………… B. Conduits & Accessories B. (For each type & size) 1. Manufacturer's name and address 1. ………………………………… 2. Applicable standard 2. ………………………………… C. Junction Boxes C. (For each type & size) 1. Manufacturer's name and address 1. ………………………………… 2. Degree of protection for enclosure. 2. ………………………………… D. Lighting Panels D. (For each type & size) 1. Manufacturer's name and address 1. ………………………………… 2. Degree of Protection 2. ………………………………… E. Lighting Transformer E. 1. Manufacturer's name and address 1. ………………………………… 2. Rating (KVA) 2. ………………………………… 3. Standards Applicable 3. …………………………………
Section-A
Guaranteed Technical Particulars
Illumination System ----------------------------- (Bidder’s Name)
4. Degree of protection for enclosure 4. ………………………………… F. Lighting poles F. 1. Manufacturer's name and address 1. ………………………………… 2. Dimensions 2. ………………………………… G. Lighting Wires G. 1. Manufacturer's name and address 1. ………………………………… 2. Voltage grade 2. ………………………………… 3. Cross section of conductor 3. …………………………………
Section-A
Guaranteed Technical Particulars
Fire Protection System ----------------------------- (Bidder’s Name)
1. Name and Address of the fire protection system 1. ………………………………… supplier 2. Number of Fire Protection System executed 2. by the supplier and duration of successful operation as on date of bid opening for each type fire protection system a) Automatic HVW / MVW spray type a) …………………………………. fire protection system b) Automatic Hydrant type b) …………………………………. fire protection system 3. Confirm that fire protection system supplier have designed, erected, tested & commissioned fire protection system of each type as in 2(a), (b) & (c) above as per the recommendations of TAC of India or any other international reputed authority like (FOC, London or NFPA, USA et) and are in successful operation for at least two years.
Section-A
Guaranteed Technical Particulars
Air Conditioning ----------------------------- (Bidder’s Name)
1. Name and Address of Air Conditioning 1. ………………………………… system supplier 2. Number of A/C system executed 2. …………………………………. by the supplier and duration of successful operation as on date of bid opening . 3. Window type air conditioning Unit 3. a) Make & Model a) …………………………………. b) Nominal Capacity (TR/Kcal/Hr.) b) …………………………………. c) Nominal Air quantity (cu.m/hr -CFM) c) …………………………………. d) Number of units offered d) …………………………………. e) Guaranteed power consumption e)………………………………….. for each unit
Section-A
Guaranteed Technical Particulars
Diesel Generator ----------------------------- (Bidder’s Name)
1. Manufacturer’s Name and Address for 1. a) Diesel Engine alongwith accessories a) ……………………………………. b) Alternator b) ……………………………………. c) Exciter c) ……………………………………. d) Battery d) ……………………………………. e) Battery Charger e) ……………………………………. f) D.G.Set control Panel f) ……………………………………. 2. ENGINE: 2. a) Rating a) ……………………………………. b) RPM b) ……………………………………. c) No. of strokes c) ……………………………………. d) Time required for starting from cold d) ……………………………………. e) Type of Governor e) ……………………………………. f) Guaranteed fuel consumption f) i. At full load i. …………………………………….
Section-A
Guaranteed Technical Particulars
Diesel Generator ----------------------------- (Bidder’s Name)
ii. At ¾ load ii. ……………………………………. iii. At ½ load iii. ……………………………………. iv. At ¼ load iv. ……………………………………. g) Lubricating oil consumption g) ……………………………………. h) Mechanical efficiency (%) h) ……………………………………. i) Thermal efficiency (%) i) ……………………………………. j) Total weight (in Kg) j) ……………………………………. k) Space required including clearances k) ……………………………………. 3. ALTERNATOR 3. a) Rated KW capacity a) ……………………………………. b) Rated Terminal Voltage b) ……………………………………. c) Rated Power Factor c) ……………………………………. d) Rated Speed d) ……………………………………. e) Rated frequency e) ……………………………………. f) No. of phases f) …………………………………….
Section-A
Guaranteed Technical Particulars
Diesel Generator ----------------------------- (Bidder’s Name)
g) Efficiencies and power factor at g) ……………………………………. 110%, 100%, 75%, 50% and 25% of full load h) Permissible Temperature rise h) i. Armature winding i. ……………………………………. ii. Field winding ii. ……………………………………. i) Overload capacity i). ……………………………………. j) Applicable standards j) ……………………………………. 4. AMF ( Auto Mains Failure) PANEL a) Degree of Protection a) ……………………………………. b) Whether the offered DG is type tested b) YES / NO
S.No. Clause No. of specification Clause Details Deviation Taken
Name Of The Signatory:
SECTION-B
The following are the deviations from the specification:
DEVIATION SCHEDULE
Sign:
Name Of The Bidder/company:
HAPUR S/S G.NOIDA S/SSIKANDRABAD
S/SNEHTAUR S/S
NOTE:
a)
b)
SECTION-C
BILL OF QUANTITY
Sl. No.
Item Description Unit QUANTITY
For filling the BOQ format following may be noted:
A comprehensive BOQ shall be furmished. As an illustration for Circuit Breaker- Quantities for breakers with & without PIR, with & without controlled switching etc. should separately be mentioned seperately. Similarly, for isolators- quantities based on current ratings & on the basis of number of earth switches should be elaborated. The current & Voltage transformers should clearly indicate the cores & ratings. Other equipment details to be mentioned on similar lines.
Wherever single phase transformer are being used, spared transformer also would be taken. Necessary equipment and scheme should be clearly brought out in offers.
Sl.No. Description Unit Quantity/Substation
I SF6 Circuit Breaker
1.0
1 SF6 Gas Kg 2502 Trip coils with resistor Nos. 33 Closing coils with resistor Nos. 34 Terminal pad (if applicable) Nos. 35 Molecular filter for SF6 Circuit for 1 pole of CB Nos. 3
6Density/Pressure monitor, Pressure switches and Pressure gaugesalongwith their coupling devices (set consisting of replacement forone pole of CB)
Set 1
7 Corona rings(set consisting of 1 no. of each type) Set 1
8Relays, power contactors, switch fuse units, limit switches, pushbuttons, timers & MCB (set consisting of 1 no. of each type)
Set 1
9 Closing Coil Assembly (including valve wherever applicable) Nos. 1
10 Trip Coil Assembly (including valve wherever applicable) Nos. 111 Aux. contact assembly Nos. 212 Operation counter Nos. 2
13Micro Filter, if applicable (set consisting of replacement for onecomplete CB)
Set 1
14All types of coupling for SF6 gas (set consisting of replacement forone complete CB)
Set 1
15Pipe length for SF6 gas system (set consisting of replacement forone complete CB)
Set 1
16
One complete pole of 3150A CB(with closing resistor) withgrading capacitor complete with pole column and interrupter withoperating mechanism and mechanism box but without supportstructure
Nos. 1
17
One complete pole of 3150A CB(without closing resistor) withgrading capacitor complete with pole column and interrupter withoperating mechanism and mechanism box but without supportstructure
Nos. 1
1.1 Pneumatic operating mechanism (If applicable)(INDIVIDUAL COMPRESSOR UNIT)
1All types of Valves for Pneumatric operating mechanism (setconsisting of 1 no. of each type)
Set 1
2"O" rings, gaskets & Seals for operating mechanism (set consistingof requirement for one pole of CB)
Set 1
1.2 Hydraulic operating mechanism (If applicable)
1"O" rings, gaskets & Seals for operating mechanism (set consistingof replacement for one complete CB)
Set 1
2All types of Valves for Hydraulic operating mechanism (setconsisting of 1 no. of each type)
Set 1
3 Pressure Transducer No. 14 Accumulator No. 15 Hydraulic oil Lit 2506 Hydraulic filter (set consisting of 1 no. of each type) Set 3
7Hydraulic operating mechanism with drive motor (set consisting ofreplacement for one pole of CB)
Set 1
1.3 Spring operated mechanism (If applicable)1 Closing dashpot No. 1
SECTION-D
MANDATORY SPARES FOR AIS SUBSTATION
2 Opening dashpot No. 13 Opening Catchgear No. 14 Closing Catchgear No. 1
5Complete Spring operating Mechanism (set consisting ofreplacement for one pole of CB)
Set 1
II Isolators1 Copper contact fingers for female & male contacts
1.1for 3150A Isolator (set consisting of replacement for one completeIsolator)
Set 2
2
Relays, power contactors, MCBs, switch fuses, push buttons,resistors, timers, key interlock, limit switches and auxiliaryswitches for electrical control circuit as per approved schematic(Set consisting of 1 no. of each type)
Set 1
3Motor with bevel gear assembly (set consisting of 1 no. of eachtype)
Set 1
4 Corona Shield rings (set consisting of 1 no. of each type) Set 1
5One complete pole of 3150A Isolator with 1 E/S with operatingmechanism for main Isolator and Earth switch but without supportstructure
No. 1
III Relay and Protection panels
1.0 Breaker Relay panel spares1 Breaker failure relay(if stand alone) Nos. 12 Trip circuit supervision relay Nos. 23 Self reset trip relay (set consisting of 1 no. of each type) Set 14 Hand reset trip relay (set consisting of 1 no. of each type) Set 15 Timer relay (set consisting of 1 no. of each type) Set 1
6 DC Supervision relay (set consisting of 1 no. of each type) Set 1
7 Flag relays (set consisting of 1 no. of each type) Set 18 Auxiliary relays (set consisting of 1 no. of each type) Set 1
9Autoreclose relay with checksynchronizing relay and dead linecharging relay (if stand alone)
Nos. 1
2.0 Line Protection Panel Equipment spares
1Main-I Numerical distance relay (excluding external trip relay) withsoftware & cable for front panel communication to PC
Nos 1
2Main-II Numerical distance relay (excluding external trip relay)with software & cable for front panel communication to PC
Nos 1
3Disturbance Recorder comprising of acquisition unit and evaluationwith software(if stand alone)
Nos 1
4Distance to fault locator including mutual compensation unit(ifstand alone)
Nos 1
5Over Voltage Protection relay with timers(Stage-I & Stage-II) (ifstand alone)
Nos 1
3.0 Reactor Protection Panel spares
1Reactor differential protection relay including aux. CTs andassociated software in case of numerical relay
Nos. 1
2 Restricted Earth Fault protection relay with non-linear resistor Nos. 13 Reactor back-up impedance protection relay Nos. 1
4.0 Transformer Protection Panel spares
1Transformer differential protection relay including aux. CTs andassociated software in case of numerical relay with modem(if Nos. 1
2 Restricted Earth Fault protection relay with non-linear resistor Nos. 1
3 Back-up impedance protection relay with 3 O/C and E./F relay Nos. 14 CVT Selection relay Nos. 15 Over fluxing relay Nos. 16 Overload relay with timer Nos. 1
IV Sub-station Automation system1 Bay control unit (1 no. of each type) Set 1
1.2 Ethernet switch ( 1no. Of each type) Set 11.3 Fibre optic cable of longest length alongwith end terminations No. 1
V LT Switchgear1 Relays (set consisting of 1 no. of each type) Set 12 CT, PT (set consisting of 1 no. of each type) Set 1
3 Switches and meters (set consisting of 2 nos. of each type and size) Set 1
4 Push buttons (set consisting of 5 nos. of each type and color) Set 1
5TPN Switch/MCB/MCCB (set consisting opf 1 No. of each rating and type)
Set 1
6 LT CB spares for each rating a) Spring charging motor Nos. 1b) Aux. Contactor (set consisting of requirement for one CB) Set 2c) Bus bar seal off insulator Nos. 5d) Arc chutes Nos. 1e) Moving contact Nos. 1f) Arcing contact Nos. 1g) Bus bar insulator Nos. 5h) Inter phase barrier Nos. 2I) Spring (closing/opening) (each type) Nos. 1j) Closing coil Nos. 1k) Tripping coil Nos. 1l) Limit switch Nos. 1m) Jaw contact Nos. 1
n) Aux. Finger contacts (set consisting of requirement for one CB) Set 1
o) Bus bar strip 1mm (Al.) Mtr. 5
VI L.T.Transformer 800kVA Trf.
1All bushings with metal parts (Set consisting of requirement for onetransformer)
Set 1
2 Oil temperature indicator No. 13 Silicagel container No. 1
VII Fire Fighting System1 Quartzoid bulb detector No. 10% of total population2 Projectors (Nozzles) No. 10% of total population
VIII PLCC Equipments
1 Coupling Device (Ph to Ph) Nos. 02 Co-axial connector Nos. 0
3Set of cards for carrier equipment (set consisting of 1 no. of each type)
Set 0
4Set of cards for protection coupler (set consisting of 1 no. of each type)
Set 0
IX DG Set
1Set of filters (Lub oil/fuel/air) (Set consisting of complete requirement for DG set)
Set 1
2 Solenoid Coil assembly Nos. 1
3Self starter assembly with clutch engaging and disengaging arrangements complete with motor
Nos. 1
4 Lube oil pressure safety control Nos. 15 High water temp. safety control Nos. 16 Diode Nos. 27 AVR (Automatic Voltage Regulator)/AVR card Nos. 1
X
XI
5% spares of the actual quantities for Insulator strings & hardwares, clamps & connectors (including equipment connectors), spacers, corona bell, welding sleeves, QUAD AAC Bull, ACSR
Illumination system 5% of each type of lighting fixture supplied
Erection Hardware Items
No spares are to be considered for ACSR Moose conductor, 4" IPS Al tube, BMB, grounding conductors, cable tray, Pipes(GI/PVC/hume), angles, channels and Junction Boxes
SECTION-E
GENERAL STANDARDS AND CODES
The Indian Electricity Act 2003
Indian Electricity Rules
Indian Factories Act
IS-5, - Colors for Ready Mixed Paints and Enamels.
IS-335, - New Insulating Oils.
IS-617, - Aluminium and Aluminium Alloy Ingots and Castings for General
Engineering Purposes
IS-1448 (P1 to P 145) - Methods of Test for Petroleum and its Products.
IS-2071 (P1 to P3) - Methods of High Voltage Testing.
IS-12063 - Classification of degrees of protection provided by enclosures of
electrical equipment.
IS-2165
P1:1997 - Insulation Coordination.
P2:1983
IS-3043 - Code of Practice for Earthing
IS-6103 - Method of Test for Specific Resistance (Resistivity) of Electrical
Insulating Liquids
IS-6104 - Method of Test for Interfacial Tension of Oil against Water by the Ring
Method
IS-6262 - Method of test for Power factor & Dielectric Constant of
Electrical Insulating Liquids.
IS-6792 - Method for determination of electric strength of insulating oils.
IS-5578 - Guide for marking of insulated conductors.
IS-11353 - Guide for uniform system of marking & identification of
conductors & apparatus terminals.
IS-8263 - Methods for Radio Interference Test on High voltage Insulators.
IS-9224 (Part 1, 2 & 4) - Low Voltage Fuses
IEC-60 (Part 1 to P4) - High Voltage Test Techniques
IEC 66 - Environmental Test
IEC-117 - Graphical Symbols
IEC-156, - Method for the Determination of the Electrical Strength of
Insulation Oils.
IEC-270, - Partial Discharge Measurements.
IEC-376 - Specification and Acceptance of New Sulphur Hexafluoride
IEC-437 - Radio Interference Test on High Voltage Insulators.
IEC-506, - Switching Impulse Tests on High Voltage Insulators.
IEC-507 - Artificial Pollution Tests on High Voltage Insulators to be used
on AC Systems.
IEC-6094 - Common Specification for High Voltage Switchgear & Control
gear Standards.
IEC-815 - Guide for the Selection of Insulators in respect of Polluted
Conditions.
IEC-865 (P1 & P2) - Short Circuit Current - Calculation of effects.
ANSI-C.1/NFPA.70 - National Electrical Code
ANSI-C37.90A - Guide for Surge Withstand Capability (SWC) Tests
ANSI-C63.21, - Specification for Electromagnetic Noise and
C63.3 - Field Strength Instrumentation 10 KHz to 1 GHZ
C36.4ANSI-C68.1 - Techniques for Dielectric Tests
ANSI-C76.1/EEE21 - Standard General Requirements and Test Procedure for
Outdoor Apparatus Bushings.
ANSI-SI-4 - Specification for Sound Level Meters
ANSI-Y32-2/C337.2 - Drawing Symbols
ANSI-Z55.11 - Gray Finishes for Industrial Apparatus and Equipment No. 61
Light Gray
NEMA-107T - Methods of Measurements of RIV of High Voltage apparatus
NEMA-ICS-II - General Standards for Industrial Control and Systems part
ICSI 109
CISPR-1 - Specification for CISPR Radio Interference Measuring
Apparatus for the frequency range 0.15 MHz to 30 MHz
CSA-Z299.1-1978h - Quality Assurance Program Requirements
CSA-Z299.2-1979h - Quality Control Program Requirements
CSA-Z299.3-1979h - Quality Verification Program Requirements
CSA-Z299.4-1979h - Inspection Program Requirements
TRANSFORMERS AND REACTORS
IS:10028 (Part 2 & 3) - Code of practice for selection, installation & maintenance of Transformers
(P1:1993), (P2:1991), (P3:1991)
IS-2026 (P1 to P4) - Power Transformers
IS-3347 (part 1 to Part 8) - Dimensions for Porcelain transformer Bushings for use in lightly polluted
atmospheres.
IS-3639 - Fittings and Accessories for Power Transformers
IS-6600 - Guide for Loading of OIl immersed Transformers.
IEC-60076 (Part 1 to 5) - Power Transformers
IEC-60214 - On-Load Tap-Changers.
IEC-60289 - Reactors.
IEC- 60354 - Loading Guide for Oil - Immersed power trans formers
IEC-60076-10 - Determination of Transformer and Reactor Sound Levels
ANSI-C571280 - General requirements for Distribution, Power and Regulating Transformers
ANSI-C571290 - Test Code for Distribution, Power and Regulation Transformers
ANSI-C5716 - Terminology & Test Code for Current Limiting Reactors
ANSI-C5721 - Requirements, Terminology and Test Code for Shunt Reactors Rated Over
500 KVA
ANSI-C5792 - Guide for Loading Oil-Immersed Power Transformers upto and including
100 MVA with 55 deg C or 65 deg C Winding Rise
ANSI-CG,1EEE-4 - Standard Techniques for High Voltage Testing
CIRCUIT BREAKERS
IEC-62271-100 - High-voltage switchgear and controlgear - Part 100: Alternating current
Circuit-breakers
IEC-62271-101 - High-voltage switchgear and controlgear - Part 101: Synthetic testing
IEC-62155 - Hollow pressurized and unpressurized ceramic and glass insulators for use
in electrical equipment with rated voltages greater than 1000V
IEC-62271-110 - High-voltage switchgear and controlgear - Part 110: Inductive load
switching
IEC-62271-109 - High-voltage switchgear and controlgear - Part 110: Inductive load
switching
CURRENT TRANSFORMERS, VOLTAGE TRANSFORMERS AND COUPLING CAPACITOR
VOLTAGE TRANSFORMERS
IS-2705- (P1 to P4) - Current Transformers.
IS:3156- (P1 to P4) - Voltage Transformers.
IS-4379 - Identification of the Contents of Industrial Gas Cylinders
IEC-44-1 - Current transformers.
IEC-44-2 - Voltage Transformers.
IEC-358 - Coupling capacitors and capacitor dividers.
IEC-44-4 - Instrument Transformes: Measurement of Partial Discharges
IEC-481 - Coupling Devices for power Line Carrier Systems.
ANSI-C5713 - Requirements for Instrument transformers
ANSIC92.2 - Power Line Coupling voltage Transformers
ANSI-C93.1 - Requirements for Power Line Carrier Coupling Capacitors
BUSHING
IS-2099 - Bushings for Alternating Voltages above 1000V
IEC-137 - Insulated Bushings for Alternating Voltages above 1000V
SURGE ARRESTERS
IS-3070 (PART2) - Lightning arresters for alternating current systems :
Metal oxide lightning arrestors without gaps.
IEC-99-4 - Metal oxide surge arrestors without gaps
IEC-99-5 - Selection and application recommendation
ANSI-C62.1 - IEE Standards for S A for AC Power Circuits
NEMA-LA 1 - Surge Arresters
CUBICLES AND PANELS & OTHER RELATED EQUIPMENTS
IS-722, IS-1248, IS-3231, 3231 (P-3) - Electrical relays for power system protection
IS:5039 - Distributed pillars for Voltages not Exceeding 1000 Volts.
IEC-68.2.2 - Basic environmental testing procedures Part 2: Test B:
Dry heat
IEC-529 - Degree of Protection provided by enclosures.
IEC-158(upto P3-1985) - Low Voltage Control Gear: Contactors.
IEC-439 (P1 & 2) - Low Voltage Switchgear and control gear assemblies
ANSI-C37.20 - Switchgear Assemblies, including metal enclosed bus.
ANSI-C37.50 - Test Procedures for Low Voltage Alternating Current
Power Circuit Breakers
ANSI-C39 - Electric Measuring instrument
ANSI-C83 - Components for Electric Equipment
IS: 8623: (Part I to 3) - Specification for Switchgear & Control Assemblies.
NEMA-AB - Moulded Case Circuit and Systems
NEMA-CS - Industrial Controls and Systems
NEMA-PB-1 - Panel Boards
NEMA-SG-5 - Low voltage Power Circuit breakers
NEMA-SG-3 - Power Switchgear Assemblies
NEMA-SG-6 - Power switching Equipment
NEMA-5E-3 - Motor Control Centers
1248 (P1 to P9) - Direct acting indicating analogue electrical measuring
instruments & their accessories.
Disconnecting switches
IEC-60129 - Alternating Current Disconnectors (Isolators) and Earthing
switches
IEC-1129 - Alternating Current Earthing Switches Induced Current switching
IEC-265 (Part 1 & Part 2) - High Voltage switches
ANSI-C37.32 - Schedule of preferred Ratings, Manufacturing Specifications and
Application Guide for high voltage Air Switches, Bus supports
and switch accessories
ANSI-C37.34 - Test Code for high voltage air switches
NEMA-SG6 - Power switching equipment
PLCC and line traps
IS-8792 - Line traps for AC power system.
IS-8793 - Methods of tests for line traps.
IS-8997 - Coupling devices for PLC systems.
IS-8998 - Methods of test for coupling devices for PLC systems.
IEC-353 - Line traps for A.C. power systems.
IEC-481 - Coupling Devices for power line carrier systems.
IEC-495 - Single sideboard power line carrier terminals
IEC-683 - Planning of (single Side-Band) power line carrier systems.
CIGRE - Teleprotection report by Committee 34 & 35.
CIGRE - Guide on power line carrier 1979.
CCIR - International Radio Consultative Committee
CCITT - International Telegraph & Telephone Consultative Committee
EIA - Electric Industries Association
Protection and control equipment
IEC-51 : (P1 to P9) - Recommendations for Direct Acting indicating
analogue electrical measuring instruments and their accessories.
IEC-255 (Part 1 to part 23) - Electrical relays.
IEC-297
(P1 to P4) - Dimensions of mechanical structures of the 482.6mm (19 inches)
series.
IEC-359 - Expression of the performance of electrical & electronic
measuring equipment.
IEC-387 - Symbols for Alternating-Current Electricity meters.
IEC-447 - Man machine interface (MMI) - Actuating principles.
IEC-521 - Class 0.5, 1 and 2 alternating current watt hour meters
IEC-547 - Modular plug-in Unit and standard 19-inch rack mounting unit
based on NIM Standard (for electronic nuclear instruments)
ANSI-81 - Screw threads
ANSI-B18 - Bolts and Nuts
ANSI-C37.1 - Relays, Station Controls etc.
ANSI-C37.2 - Manual and automatic station control, supervisory and associated
telemetering equipment
ANSI-C37.2 - Relays and relay systems associated with electric power apparatus
ANSI-C39.1 - Requirements for electrical analog indicating instruments
MOTORS
IS-325 - Three phase induction motors.
IS-4691 - Degree of protection provided by enclosure for rotating electrical
machinery.
IEC-34 (P1 to P19:) - Rotating electrical machines
IEC-Document 2 - Three phase induction motors
(Central Office) NEMA-MGI - Motors and Generators
Electronic equipment and components
MIL-21B, MIL-833 & MIL-2750
IEC-68 (P1 to P5) : Environmental testing
IEC-326 (P1 to P2) : Printed boards
Material and workmanship standards
IS-1363 (P1 to P3) - Hexagon head bolts, screws and nuts of product IS-grade C.
1364 (P1 to P5) - Hexagon head bolts, screws and nuts of products grades A and B.
IS-3138 - Hexagonal Bolts and Nuts (M42 to M150)
ISO-898 - Fasteners: Bolts, screws and studs
ASTM - Specification and tests for materials
Clamps & connectors
IS-5561 - Electric power connectors.
NEMA-CC1 - Electric Power connectors for sub station
NEMA-CC 3 - Connectors for Use between aluminium or aluminum-Copper
Overhead Conductors
Bus hardware and insulators
IS: 2121 - Fittings for Aluminum and steel cored Al conductors for overhead
power lines.
IS-731 - Porcelain insulators for overhead power lines with a nominal
voltage greater than 1000 V.
IS-2486 (P1 to P4) - Insulator fittings for overhead power lines with a nominal voltage
greater than 1000 V
IEC-120 - Dimensions of Ball and Socket Couplings of string
IEC-137 - Insulated bushings for alternating voltages above 1000 V.
IEC-168 - Tests on indoor and outdoor post insulators of ceramic material or
glass for Systems with Nominal Voltages Greater than 1000 V.
IEC-233 - Tests on Hollow Insulators for use in electrical equipment.
IEC-273 - Characteristics of indoor and outdoor post insulators for systems
with nominal voltages greater than 1000V.
IEC-305 - Insulators for overhead lines with nominal voltage above 1000V-
ceramic or glass insulator units for a.c. systems Characteristics
of String Insulator Units of the cap and pin type
IEC-372 (1984) - Locking devices for ball and socket couplings of string insulator
units : dimensions and tests.
IEC-383 (P1 and P2) - Insulators for overhead lines with a nominal voltage above 1000V.
IEC-433 - Characteristics of string insulator units of the long rod type.
IEC-471 - Dimensions of Clevis and tongue couplings of string insulator
units.
ANSI-C29 - Wet process porcelain insulators
ANSI-C29.1 - Test methods for electrical power insulators
ANSI-C92.2 - For insulators, wet-process porcelain and toughened glass
suspension type
ANSI-C29.8 - For wet-process porcelain insulators apparatus, post-Type
ANSI-G.8 - Iron and steel hardware
CISPR-7B - Recommendations of the CISPR, tolerances of form and of Position, Part 1
ASTM A-153 - Zinc Coating (Hot-Dip) on iron and steel hardware
Strain and rigid bus-conductor
IS-2678 - Dimensions & tolerances for Wrought Aluminum and Aluminum
Alloys drawn round tube.
IS-5082 - Wrought Aluminum and Aluminum Alloy Bars. Rods, Tubes and
Sections for Electrical purposes.
ASTM-B 230-82 - Aluminum 1350 H19 Wire for electrical purposes
ASTM-B 231-81 - Concentric - lay - stranded, aluminum 1350 Conductors
ASTM-B 221 - Aluminum - Alloy extruded bar, road, wire, shape
ASTM-B 236-83 - Aluminum bars for electrical purpose (Bus-bars)
ASTM-B 317-83 - Aluminum-Alloy extruded bar, rod, pipe and structural shapes for
electrical purposes (Bus Conductors)
Batteries and batteries charger
Battery
IS:1651 - Stationary Cells and Batteries, Lead-Acid Type (with Tubular
Positive Plates)
IS:1652 - Stationary Cells and Batteries, Lead-Acid Type (with Plante
Positive Plates)
IS:1146 - Rubber and Plastic Containers for Lead-Acid Storage Batteries
IS:6071 - Synthetic Separators for Lead-Acid Batteries
IS:266 - Specification for Sulphuric Acid
IS:1069 - Specification for Water for Storage Batteries
IS:3116 - Specification for Sealing Compound for Lead-Acid Batteries
IS:1248 - Indicating Instruments
Battery Charger
IS:3895 - Mono-crystalline Semiconductor Rectifier Cells and stacks
IS:4540 - Mono-crystalline Semiconductor Rectifier Assemblies and
Equipment.
IS:6619 - Safety Code for Semiconductor Rectifier Equipment
IS:2026 - Power Transformers
IS:2959 - AC Contactors for Voltages not Exceeding 1000 Volts
IS:1248 - Indicating Instruments
IS:2208 - HRC Fuses
IS:13947 (Part-3) - Air break switches, air break disconnectors & fuse combination
units for voltage not exceeding 1000V AC or 1200V DC
IS:2147 - Degree of protection provided by enclosures for low voltage
switchgear and control gear.
IS:6005 - Code of practice for phosphating of Iron and Steel
IS:3231 - Electrical relays for power system protection
IS:3842 - Electrical relay for AC Systems
IS:5 - Colours for ready mix paint
IEEE-484 - Recommended Design for installation design and installation
of large lead storage batteries for generating stations
and substations
IEEE-485 - Sizing large lead storage batteries for generating stations and
Substations
Wires and cables
ASTMD-2863 - Measuring the minimum oxygen concentration to support candle
like combustion of plastics (oxygen index)
IS-694 - PVC insulated cables for working voltages upto and including
1100 Volts.
IS-1255 - Code of practice for installation and maintenance of power
cables, upto and including 33 kV rating
IS-1554 (P1 and P2) - PVC insulated (heavy duty) electric cables (part 1) for working
voltage upto and including 1100 V.
- Part (2) for working voltage from 3.3 kV upto and including
11kV.
IS:1753 - Aluminium conductor for insulated cables
IS:2982 - Copper Conductor in insulated cables.
IS-3961 (P1 to P5) - Recommended current ratings for cables.
IS-3975 - Mild steel wires, formed wires and tapes for armouring of cables.
IS-5831 - PVC insulating and sheath of electric cables.
IS-6380 - Elastometric insulating and sheath of electric cables.
IS-7098 - Cross linked polyethylene insulated PVC sheathed cables for
working voltage upto and including 1100 volts.
IS-7098 - Cross-linked polyethyle insulated PVC sheathed cables
for working voltage from 3.3kV upto and including 33 kV.
IS-8130 - Conductors for insulated electrical cables and flexible cords.
IS-1753 - Aluminum Conductors for insulated cables.
IS-10418 - Specification for drums for electric cables.
IEC-96 (part 0 to p4) - Radio Frequency cables.
IEC-183 - Guide to the Selection of High Voltage Cables.
IEC-189 (P1 to P7) - Low frequency cables and wires with PVC insulation and
PVC sheath.
IEC-227 (P1 to P7) - Polyvinyl Chloride insulated cables of rated voltages up to and.
including 450/750V
IEC-228 - Conductors of insulated cables
IEC-230 - Impulse tests on cables and their accessories.
IEC-287 (P1 to P3) - Calculation of the continuous current rating of cables
(100% load factor).
IEC-304 - Standard colours for insulation for low-frequency cables and
wires.
IEC-331 - Fire resisting characteristics of Electric cables.
IEC-332 (P1 to P3) - Tests on electric cables under fire conditions.
IEC-502 - Extruded solid dielectric insulated power cables for rated
voltages from 1 kV upto to 30 kV
IEC-754 (P1 and P2) - Tests on gases evolved during combustion of electric cables.
AIR conditioning and ventilation
IS-659 - Safety code for air conditioning
IS-660 - Safety code for Mechanical Refrigeration
ARI:520 - Standard for Positive Displacement Refrigeration Compressor
and Condensing Units
IS:4503 - Shell and tube type heat exchanger
ASHRAE-24 - Method of testing for rating of liquid coolers
ANSI-B-31.5 - Refrigeration Piping
IS:2062 - Steel for general structural purposes
IS:655 - Specification for Metal Air Dust
IS:277 - Specification for Galvanised Steel Sheets
IS-737 - Specification for Wrought Aluminium and Aluminium Sheet &
Strip
IS-1079 - Hot rolled cast steel sheet & strip
IS-3588 - Specification for Electrical Axial Flow Fans
IS-2312 - Propeller Type AC Ventilation Fans
BS-848 - Methods of Performance Test for Fans
BS-6540 Part-I - Air Filters used in Air Conditioning and General Ventilation
BS-3928 - Sodium Flame Test for Air Filters (Other than for Air Supply to
I.C. Engines and Compressors)
US-PED-2098 - Method of cold DOP & hot DOP test
MIL-STD-282 - DOP smoke penetration method
ASHRAE-52 - Air cleaning device used in general ventilation for removing
particle matter
IS:3069 - Glossary of Terms, Symbols and Units Relating to Thermal
Insulation Materials.
IS:4671 - Expanded Polystyrene for Thermal Insulation Purposes
IS:8183 - Bonded Mineral Wool
IS:3346 - Evaluation of Thermal Conductivity properties by means of
guarded hot plate method
ASTM-C-591-69 - Standard specification for rigid preformed cellular urethane
thermal insulation
BS:848 - Method of Performance Test for Centrifugal Fans
IS:325 - Induction motors, three-phase
IS:4722 - Rotating electrical machines
IS:1231 - Three phase foot mounted Induction motors, dimensions of
IS:2233 - Designations of types of construction and mounting arrangements
of rotating electrical machines
IS:2254 - Vertical shaft motors for pumps, dimensions of
IS:7816 - Guide for testing insulation resistance of rotating machines
IS:4029 - Guide for testing three phase induction motors
IS:4729 - Rotating electrical machines, vibration of, Measurement and
evaluation of
IS:4691 - Degree of protection provided by enclosures for rotating
electrical machinery
IS:7572 - Guide for testing single-phase a.c. motors
IS:2148 - Flame proof enclosure for electrical apparatus
BS:4999 - Noise levels
(Part-51)
Galvanizing
IS-209 - Zinc Ingot
IS-2629 - Recommended Practice for Hot-Dip galvanizing on iron and steel.
IS-2633 - Methods for testing uniformity of coating of zinc coated articles.
ASTM-A-123 - Specification for zinc (Hot Galvanizing) Coatings, on products
Fabricated from rolled, pressed and forged steel shapes, plates,
bars and strips.
ASTM-A-121-77 - Zinc-coated (Galvanized) steel barbed wire
Painting
IS-6005 - Code of practice for phosphating of iron and steel.
ANSI-Z551 - Gray finishes for industrial apparatus and equipment
SSPEC - Steel structure painting council
Fire protection system
Fire protection manual issued by tariff advisory committee (TAC) of India
HORIZONTAL CENTRIFUGAL PUMPS
IS:1520 - Horizontal centrifugal pumps for clear, cold and fresh water
IS:9137 - Code for acceptance test for centrifugal & axial pumps
IS:5120 - Technical requirement - Rotodynamic special purpose pumps
API-610 - Centrifugal pumps for general services
- Hydraulic Institutes Standards
BS:599 - Methods of testing pumps
PTC-8.2 - Power Test Codes - Centrifugal pumps
DIESEL ENGINES
IS:10000 - Methods of tests for internal combustion engines
IS:10002 - Specification for performance requirements for constant speed
compression ignition engines for general purposes (above 20 kW)
BS:5514 - The performance of reciprocating compression ignition (Diesel)
engines, utilizing liquid fuel only, for general purposes
ISO:3046 - Reciprocating internal combustion engines performance
IS:554 - Dimensions for pipe threads where pressure tight joints are
required on threads
ASME Power Test Code - Internal combustion engine PTC-17
- Codes of Diesel Engine Manufacturer’s Association, USA
PIPING VALVES & SPECIALITIES
IS:636 - Non percolating flexible fire fighting delivery hose
IS:638 - Sheet rubber jointing and rubber inserting jointing
IS:778 - Gun metal gate, globe and check valves for general purpose
IS:780 - Sluice valves for water works purposes (50 to 300 mm)
IS:901 - Couplings, double male and double female instantaneous pattern
for fire fighting
IS:902 - Suction hose couplings for fire fighting purposes
IS:903 - Fire hose delivery couplings branch pipe nozzles and nozzle
spanner
IS:1538 - Cast iron fittings for pressure pipes for water, gas and sewage
IS:1903 - Ball valve (horizontal plunger type) including floats for water supply
purposes
IS:2062 - SP for weldable structural steel
IS:2379 - Colour Code for the identification of pipelines
IS:2643 - Dimensions of pipe threads for fastening purposes
IS:2685 - Code of Practice for selection, installation and maintenance of
sluice valves
IS:2906 - Sluice valves for water-works purposes (350 to 1200 mm size)
IS:3582 - Basket strainers for fire fighting purposes (cylindrical type)
IS:3589 - Electrically welded steel pipes for water, gas and sewage (150 to
2000 mm nominal diameter)
IS:4038 - Foot valves for water works purposes
IS:4927 - Unlined flax canvas hose for fire fighting
IS:5290 - Landing valves (internal hydrant)
IS:5312 - Swing check type reflex (non-return) valves (Part-I)
IS:5306 - Code of practice for fire extinguishing installations and equipment
on premises
Part-I - Hydrant systems, hose reels and foam inlets
Part-II - Sprinkler systems
BS:5150 - Specification for cast iron gate valves
MOTORS & ANNUNCIATION PANELS
IS:325 - Three phase induction motors
IS:900 - Code of practice for installation and maintenance of induction motors
IS:996 - Single phase small AC and universal electric motors
IS:1231 - Dimensions of three phase foot mounted induction motors
IS:2148 - Flame proof enclosure of electrical apparatus
IS:2223 - Dimensions of flange mounted AC induction motors
IS:2253 - Designations for types of construction and mounting arrangements of
rotating electrical machines
IS:2254 - Dimensions of vertical shaft motors for pumps
IS:3202 - Code of practice for climate proofing of electrical equipment
IS:4029 - Guide for testing three phase induction motors
IS:4691 - Degree of protection provided by enclosure for rotating electrical
machinery
IS:4722 - Rotating electrical machines
IS:4729 - Measurement and evaluation of vibration of rotating electrical
machines
IS:5572 - Classification of hazardous areas for electrical (Part-I) installations
(Areas having gases and vapours)
IS:6362 - Designation of methods of cooling for rotating electrical machines
IS:6381 - Construction and testing of electrical apparatus with type of
protection ‘e’
IS:7816 - Guide for testing insulation for rotating machine
IS:4064 - Air break switches
IEC DOCUMENT 2 - Three Phase Induction Motor
(Control Office) 432
VDE 0530 Part I/66 - Three Phase Induction Motor
IS:9224 - HRC Fuses
(Part-II)
IS:6875 - Push Button and Control Switches
IS:694 - PVC Insulated cables
IS:1248 - Indicating instruments
IS:375 - Auxiliary wiring & bus bar markings
IS:2147 - Degree of protection
IS:5 - Colour Relay and timers
IS:2959 - Contactors
PG Test Procedures
NFPA-13 - Standard for the installation of sprinkler system
NFPA-15 - Standard for water spray fixed system for the fire protection
NFPA-12A - Standard for Halong 1301 Fire Extinguishing System
NFPA-72E - Standard on Automatic Fire Detectors
Fire Protection Manual by TAC (Latest Edition)
NFPA-12 - Standard on Carbon dioxide extinguisher systems
IS:3034 - Fire of industrial building:
Electrical generating and distributing stations code of practice
IS:2878 - CO2 (Carbon dioxide) Type Extinguisher
IS:2171 - DC (Dry Chemical Powder) type
IS:940 - Pressurised Water Type
D.G. SET
IS:10002 - Specification for performance requirements for constant
speed compression ignition (diesel engine) for general purposes
IS:10000 - Method of tests for internal combustion engines
IS:4722 - Rotating electrical machines-specification
IS:12063 - Degree of protection provided by enclosures
IS:12065 - Permissible limit of noise levels for rotating electrical machines.
- Indian Explosive Act 1932
Steel structures
IS-228 (1992) - Method of Chemical Analysis of pig iron, cast iron and plain carbon
and low alloy steels.
IS-802 (P1 to 3:) - Code of practice for use of structural steel in overhead transmission
line towers.
IS-806 - Code of practice for use of steel tubes in general building
construction
IS-808 - Dimensions for hot rolled steel beam, column channel and angle
sections.
IS-814 - Covered electrodes for manual arc welding of carbon of carbon
manganese steel.
IS-816 - Code of Practice for use of metal arc welding for general
construction in Mild steel
IS-817 - Code of practice for training and testing of metal arc welders.
Part 1 : Manual Metal arc welding.
IS-875 (P1 to P4) - Code of practice for design loads (other than earthquake) for
buildings and structures.
IS-1161 - Steel tubes for structural purposes.
IS-1182 - Recommended practice for radiographic examination of fusion
welded butt joints in steel plates.
IS-1363 (P1 to P3) - Hexagonal head bolts, screws & nuts of products grade C.
IS-1364 - Hexagon head bolts, screws and nuts of product grades A and B.
IS-1367 (P1 to P18) - Technical supply condition for threaded steel fasteners.
IS-1599 - Methods for bend test.
IS-1608 - Method for tensile testing of steel products.
IS-1893 - Criteria for earthquake resistant design of structures.
IS-1978 - Line Pipe.
IS-2062 - Steel for general structural purposes.
IS-2595 - Code of practice for Radiographic testing.
IS-3063 - Single coil rectangular section spring washers for bolts, nuts and
screws
IS-3664 - Code of practice for ultrasonic pulse echo testing by contact and
immersion methods.
IS-7205 - Safety code for erection of structural steel work.
IS-9595 - Recommendations for metal arc welding of carbon and carbon
manganese steels.
ANSI-B18.2.1 - Inch series square and Hexagonal bolts and screws
ANSI-B18.2.2 - Square and hexagonal nuts
ANSI-G8.14 - Round head bolts
ASTM-A6 - Specification for General Requirements for rolled steel plates,
shapes, sheet piling and bars of structural use
ASTM-A36 - Specifications of structural steel
ASTM-A47 - Specification for malleable iron castings
ASTM-A143 - Practice for safeguarding against embilement of Hot Galvanized
structural steel products and procedure for detaching embroilment
ASTM-A242 - Specification for high strength low alloy structural steel
ASTM-A283 - Specification for low and intermediate tensile strength carbon steel
plates of structural quality
ASTM-A394 - Specification for Galvanized steel transmission tower bolts and nuts
ASTM-441 - Specification for High strength low alloy structural manganese
vanadium steel.
ASTM-A572 - Specification for High strength low alloy columbium-Vanadium steel
of structural quality
AWS D1-0 - Code for welding in building construction welding inspection
AWS D1-1 - Structural welding code
AISC - American institute of steel construction
NEMA-CG1 - Manufactured graphite electrodes
Piping and pressure vessels
IS-1239 (Part 1 and 2) - Mild steel tubes, tubulars and other wrought steel fittings
IS-3589 - Seamless electrically welded steel pipes for water, gas and sewage.
IS-6392 - Steel pipe flanges
ASME - Boiler and pressure vessel code
ASTM-A120 - Specification for pipe steel, black and hot dipped, zinccoated
(Galvanized) welded and seamless steel pipe for ordinary use
ASTM-A53 - Specification for pipe, steel, black, and hot-dipped, zinc coated
welded and seamless
ASTM-A106 - Seamless carbon steel pipe for high temperature service
ASTM-A284 - Low and intermediate tensile strength carbon-silicon steel plates for
machine parts and general construction.
ASTM-A234 - Pipe fittings of wrought carbon steel and alloy steel for moderate and
elevated temperatures
ASTM-S181 - Specification for forgings, carbon steel for general purpose piping
ASTM-A105 - Forgings, carbon steel for piping components
ASTM-A307 - Carbon steel externally threaded standard fasteners
ASTM-A193 - Alloy steel and stainless steel bolting materials for high temperature
service
ASTM-A345 - Flat rolled electrical steel for magnetic applications
ASTM-A197 - Cupola malleable iron
ANSI-B2.1 - Pipe threads (Except dry seal)
ANSI-B16.1 - Cast iron pipe flanges and glanged fitting. Class 25, 125,250 and
800
ANSI-B16.1 - Malleable iron threaded fittings, class 150 and 300
ANSI-B16.5 - Pipe flanges and flanged fittings, steel nickel alloy and other special
alloys
ANSI-B16.9 - Factory-made wrought steel butt welding fittings
ANSI-B16.11 - Forged steel fittings, socket-welding and threaded
ANSI-B16.14 - Ferrous pipe plug, bushings and locknuts with piplethreads
ANSI-B16.25 - Butt welding ends
ANSI-B18.1.1 - Fire hose couplings screw thread.
ANSI-B18.2.1 - Inch series square and hexagonal bolts and screws
ANSI-B18.2.2 - Square and hexagonal nuts
NSI-B18.21.1 - Lock washers
ANSI-B18.21.2 - Plain washers
ANSI-B31.1 - Power piping
ANSI-B36.10 - Welded and seamless wrought steel pipe
ANSI-B36.9 - Stainless steel pipe
Other civil works standards
IS-269 - 33 grade ordinary portland cement.
IS2721 - Galvanized steel chain link fence fabric
IS-278 - Galvanized steel barbed wire for fencing.
IS-383 - Coarse and fine aggregates from natural sources for concrete.
IS-432 (P1 and P2) - Mild steel and medium tensile steel bars and hard-dawn steel wire for
concrete reinforcement.
IS-456 - Code of practice for plain and reinforced concrete.
IS-516 - Method of test for strength of concrete.
IS-800 - Code of practice for general construction in steel.
IS-806 - Steel tubes for structural purposes.
IS-1172 - Basic requirements for water supply, drainage and sanitation.
IS-1199 - Methods of sampling and analysis of concrete.
IS-1566 - Hard-dawn steel wire fabric for concrete reinforcement.
IS-1742 - Code of Practice for Building drainage.
IS-1785 - Plain hard-drawn steel wire for prestressed concrete.
IS-1786 - High strength deformed Steel Bars and wires for concrete
reinforcement.
IS-1811 - Methods of sampling Foundry sands.
IS-1893 - Criteria for earthquake resistant design of structures.
IS-2062 - Steel for general structural purposes.
IS-2064 - Selection, installation and maintenance of sanitary appliances-code
of practices.
IS-2065 - Code of practice for water supply in buildings.
IS-2090 - High tension steel bars used in prestressed concrete.
IS-2140 - Standard Galvanized steel wire for fencing.
IS-2470 (P1 & P2) - Code of practice for installation of septic tanks.
IS-2514 - Concrete vibrating tables.
IS-2645 - Integral cement waterproofing compounds.
IS-3025 (Part 1 to Part 48) - Methods of sampling and test (Physical and chemical) for water and
waste water.
IS-4091 - Code of practice for design and construction of foundations for
transmission line towers and poles.
IS-4111
(Part 1 to P5) - Code of practice for ancillary structures in sewerage system.
IS-4990 - Plywood for concrete shuttering work.
IS-5600 - Sewage and drainage pumps.
ACSR MOOSE CONDUCTOR
IS:6745 - Methods for Determination of BS:443-1969
Mass of zinc coating on zinc
coated Iron and Steel Articles
IS:8263 - Methods for Radio Interference
IEC:437 - 1973Test on High Voltage Insulators NEMA:107-1964 CISPR
IS:209 - Zinc Ingot BS:3436-1961
IS:398 - Aluminum Conductors for IEC:209-1966
Part – V - Overhead Transmission Purposes
BS:215(Part-II) - Aluminium Conductors galvanized IEC:209-1966 steel reinforced
extra high
BS:215(Part-II) - voltage (400 kV and above)
IS:1778 - Reels and Drums forBS:1559-1949 Bare Conductors
IS:1521 - Method for Tensile Testing ISO/R89-1959 of steel wire
IS:2629 - Recommended practice for Hot dip Galvanising on Iron and Steel.
IS:2633 - Method for Testing Uniformity of coating of zinc Coated Articles.
IS:4826 - Hot dip galvanised coatings on round steel wires ASTMA-472-729
GALVANISED STEEL EARTHWIRE
IS:1521 - Method for Tensile Testing ISO/R:89-1959 of Steel Wire
IS:1778 - Reels and Drums for Bare Conductors
IS:2629 - Recommended practice forHot Dip Galvanising on Ironand Steel.
IS:2633 - Methods for testing Uniformityof Coating of Zinc Coated Articles.
IS:4826 - Hot dip Galvanised Coatings ASTM:A 475-72a on Round Steel
Wires BS:443-1969
IS:6745 - Method for Determination BS:443-1969of mass of Zinc Coating on
Zinc coated Iron and Steel Articles.
IS:209 - Zinc ingot BS:3463-1961
IS:398 - (Pt. I to Aluminum Conductors for BS:215 (Part-II)
P5:1992) overhead transmission purposes.
Lighting Fixtures and Accessories
(i) IS:1913 - General and safety requirements for electric lighting fittings.
(ii) IS:3528 - Water proof electric lighting fittings.
(iii) IS:4012 - Dust proof electric lighting fittings.
(iv) IS:4013 - Dust tight proof electric lighting fittings.
(v) IS:10322 - Industrial lighting fittings with metal reflectors.
(vi) IS:10322 - Industrial lighting fittings with plastic reflectors.
(vii) IS:2206 - Well glass lighting fittings for use under ground in mines (non-
flameproof type).
(viii) IS:10322 - Specification for flood light.
(ix) IS:10322 - Specification for decorative lighting outfits.
(x) IS:10322 - Lumanaries for street lighting
(xi) IS:2418 - Tubular flourescent lamps
(xii) IS:9900 - High pressure mercury vapour lamps.
(xiii) IS:1258 - Specification for Bayonet lamp flourescent lamp.
(xiv) IS:3323 - Bi-pin lamp holder tubular flourescent lamps.
(xv) IS:1534 - Ballasts for use in flourescent lighting fittings.
(Part-I)
(xvi) IS:1569 - Capacitors for use in flourescent lighting fittings.
(xvii) IS:2215 - Starters for flourescent lamps.
(xviii) IS:3324 - Holders for starters for tubular flourescent lamps
(xix) IS:418 - GLS lamps
(xx) IS:3553 - Water tight electric fittings
(xxi) IS:2713 - Tubular steel poles
(xxii) IS:280 - MS wire for general engg. Purposes
Conduits, Accessories and Junction Boxes
(1) IS:9537 - Rigid steel conduits for electrical wiring
(2) IS:3480 - Flexible steel conduits for electrical wiring
(3) IS:2667 - Fittings for rigid steel conduits for electrical wiring
(4) IS:3837 - Accessories for rigid steel conduits for electrical wiring
(5) IS:4649 - Adaptors for flexible steel conduits.
(6) IS:5133 - Steel and Cast Iron Boxes
(7) IS:2629 - Hot dip galvanising of Iron & Steel.
Lighting Panels
(1) IS:13947 - LV Switchgear and Control gear(Part 1 to 5)
(2) IS:8828 - Circuit breakers for over current protection for house hold and
similar installations.
(3) IS:5 - Ready mix paints
(4) IS:2551 - Danger notice plates
(5) IS:2705 - Current transformers
(6) IS:9224 - HRC Cartridge fuse links for voltage above 650V(Part-2)
(7) IS:5082 - Wrought aluminium and Al. alloys, bars, rods, tubes and sections
for electrical purposes.
(8) IS:8623 - Factory built Assemblies of Switchgear and Control Gear for
voltages upto and including 1000V AC and 1200V DC.
(9) IS:1248 - Direct Acting electrical indicating instruments
Electrical Installation
(1) IS:1293 - 3 pin plug
(2) IS:371 - Two to three ceiling roses
(3) IS:3854 - Switches for domestic and similar purposes
(4) IS:5216 - Guide for safety procedures and practices in electrical work.
(5) IS:732 - Code of practice for electrical wiring installation (system voltage not
exceeding 650 Volts.)
(6) IS:3043 - Code of practice for earthing.
(7) IS:3646 - Code of practice of interior illumination part II & III.
(8) IS:1944 - Code of practice for lighting of public through fares.
(9) IS:5571 - Guide for selection of electrical equipment for hazardous areas.
(10) IS:800 - Code of practice for use of structural steel in general building
construction.
(11) IS:2633 - Methods of Testing uniformity of coating on zinc coated articles.
(12) IS:6005 - Code of practice for phosphating iron and steel.
(13) INDIAN ELECTRICITY ACT
(14) INDIAN ELECTRICITY RULES
LT SWITCHGEAR
IS:8623 (Part-I) - Specification for low voltage switchgear and control gear assemblies
IS:13947 (Part-I) - Specification for low voltage switchgear and control gear, Part 1
General Rules
IS:13947 (part-2) - Specification for low voltage switchgear and control gear, Part 2
circuit breakers.
IS:13947 (part-3) - Specification for low voltage switchgear and control gear. Part 3
Switches, Disconnectors, Switch-disconnectors and fuse combination units
IS:13947 (part-4) - Specification for low voltage switchgear and control gear. Part 4
Contactors and motors starters.
IS:13947 (part-5) - Specification for low voltage switchgear and control gear. Part 5
Control-circuit devices and switching elements
IS:13947 (part-6) - Specification for low voltage switchgear and control gear. Part 6
Multiple function switching devices.
IS:13947 (part-7) - Specification for low voltage switchgear and control gear. Part 7
Ancillary equipments
IS:12063 - Degree of protection provided by enclosures
IS:2705 - Current Transformers
IS:3156 - Voltage Transformers
IS:3231 - Electrical relays for power system protection
IS:1248 - Electrical indicating instruments
IS:722 - AC Electricity meters
IS:5578 - Guide for Marking of insulated conductors of apparatus terminals
IS:13703 (part 1) - Low voltage fuses for voltage not exceeding 1000V AC or 1500V DC
Part 1 General Requirements
IS:13703 (part 2) - Low voltage fuses for voltage not exceeding 1000V AC or 1500V
DC Part 2 Fuses for use of authorized persons
IS:6005 - Code of practice of phosphating iron and steel
IS:5082 - Wrought Aluminum and Aluminum alloys for electrical purposes
IS:2633 - Hot dip galvanizing
SECTION-F
Diagnostic tools: At least the following diagnostic tools shall be provided by the Bidder. However additional tools, if required/recommended shall be mentioned in the offer.
S.No. Item 1. Dissolved Gas Analysis of Transformer oil 2. Frequency response analysis of transformer/reactors 3. Tan δ and capacitance measurement 4. Circuit breaker operational analyzer 5. Dynamic contact resistance measurement of breakers 6. Third harmonic resistive current measurements of surge arresters 7. Recovery voltage measurements of transformers/reactors 8. Vibration measurement of the reactors 9. Steady state and Dynamic testing of protective relays 10. Signature Analysis 11. Partial Discharge measurement for transformers/Gas Insulated Switchgear 12. Static resistance meter for circuit breakers, Isolators, bus bar joint, earth
switches etc. 13. Ground tester for measurement of resistivity of soil and ground resistance 14. Battery impedance test equipment 15. Insulator tester 16. SF6 gas leakage detector and dew point 17. Power quality analyzer 18. Fibre optic cable testing devices
APPENDIX-I
APPENDIX-II