technical specification 216 kv surge arrester in … · moisture ingress test (refer 10.8.13 of...

Annexure 12

TECHNICAL SPECIFICATION

216 KV SURGE ARRESTER IN POLYMER HOUSING FOR

CHEMBUR 2ND FEED CONNECTIVITY

DOC NO: TD-SP-216kV Surge Arrestor-355-R0

Prepared By Reviewed By Approved By Rev Date

Manali Sarvankar /

Prakash Permalla Ashish Waknis Shekhar Huprikar

R0 29.04.2019 Executive / Dy. In Charge

(Engineering)

In Charge

(Engineering)

Head

(Engineering)

216 KV SURGE ARRESTER IN POLYMER HOUSING DOC NO: TD-SP-216kV Surge Arrestor-355-R0

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216 KV SURGE ARRESTER IN POLYMER HOUSING

1. SCOPE OF SUPPLY ................................................................................................................................... 3

2. CODES & STANDARDS ............................................................................................................................. 3

3. DESIGN REQUIREMENT .......................................................................................................................... 4

4. CONSTRUCTIONAL FEATURE ................................................................................................................ 4

5. DESIGN PARAMETERS ............................................................................................................................ 5

6. SURGE COUNTER ..................................................................................................................................... 6

7. INSULATOR ................................................................................................................................................ 6

8. NAME PLATE DETAILS ............................................................................................................................ 6

9. TESTING ..................................................................................................................................................... 6

10. DRAWINGS & DOCUMENTS .................................................................................................................... 8

10.1 DOCUMENTS TO BE SUBMITTED ALONG WITH BID ......................................................................... 8

10.2 DOCUMENTS TO BE SUBMITTED AFTER AWARD OF CONTRACT .................................................. 8

10.3 DOCUMENTS TO BE SUBMITTED PRIOR DISPATCH ......................................................................... 9

11. PACKING ..................................................................................................................................................... 9

12. SHIPPING, HANDLING & STORAGE ....................................................................................................... 9

13. DOCUMENT SUBMISSION .................................................................................................................... 10

14. DESIGN PARAMETERS .......................................................................................................................... 10

15. SITE CONDITION ...................................................................................................................................... 11

16. LIST OF RECOMMENDED SPARES ....................................................................................................... 12

17. LIST OF TOOLS & TACKLES .................................................................................................................... 12

18. MAINTENANCE TOOLS AND TACKLES ................................................................................................ 13

19. DEVIATIONS .............................................................................................................................................. 13

20. GUARANTEED TECHNICAL PARTICULARS .........................................................................................15

21. BILL OF MATERIAL ................................................................................................................................. 16

21.1 BOM FOR SUPPLY .................................................................................................................................. 16

21.2 BOM FOR SERVICE ................................................................................................................................. 16


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216 kV SURGE ARRESTER IN POLYMER HOUSING

1. SCOPE OF SUPPLY

1.1 GENERAL

1.1.1 This specification covers the technical requirements, design, manufacturing, assembly,

testing at manufacturer's works, packing, transportation with transit insurance, loading,

unloading at site including installation, & commissioning of 216kV Lightning Arrester in

polymer housing complete with all accessories for efficient and trouble-free operation.

1.1.2 The list of past supplies along with performance certificate from users of the system

shall be submitted for approval of purchaser.

1.1.3 All the accessories, mandatory spares is in the scope of manufacturer/Supplier.

1.1.4 Suitable structure for mounting of the LA shall be provided.

1.1.5 Guarantee for Five years of 216 kV LA complete with all accessories for making the

system complete and for warranty a trouble free and safe operation.

1.1.6 The Contractor shall supply the materials/equipment as per approved drawings and bill

of materials and no extra cost shall be paid for any variation on this account.

1.1.7 It is not the intention of these specifications to specify in complete, the details of

practices of manufacturers, who shall furnish the equipment, which shall meet in all

respects the specified requirements in regard to performance durability and satisfactory

operation.

1.1.8 However, certain design features, materials and operational requirements specified, are

intended to establish minimum standards of the work.

2. CODES & STANDARDS

Sr. No. Standard No. Description

1 Indian Electricity Rules 2 IS : 3070 – Part 3 Specification for Lightning Arresters for alternating current system 3 IS : 2071 - Part I Method of high voltage testing 4 IS : 2629 - 1985 Recommended Practice for Hot-Dip Galvanizing of Iron and Steel 5 IS : 5621 - 1980 Hollow insulators for use in electrical equipment 6 IS : 6639 - 1972 Specification for Hexagon Bolts for Steel Structures 7 IS : 2633 Method for testing uniformity of coating on zinc coated articles 8 IEC 60099-4-Specification for Surge Arresters without gap for AC system


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9 IEC 60099-5 Surge arresters - Part 5: Selection and application recommendations.

3. DESIGN REQUIREMENT

Duty Requirement

3.1 The surge arresters shall be of heavy duty station class and gapless type without any

series or shunt gaps.

3.2 The surge arresters shall be capable of discharging over voltage occurring during

switching of unloaded transformers and reactors.

3.3 Surge Arresters shall be capable of discharging severe switching surges on a 245 kV

Line/ Cables.

3.4 The arrester shall be capable of discharging energy equivalent to class 3 of IEC for a 245

kV System on the two successive operations.

3.5 The surge arresters shall be suitable for withstanding short circuit forces caused by

short circuit current of 50 KA on the 245 KV bus.

3.6 It should also be able to withstand wind load calculated at 195 kg/sq.m.

3.7 The reference current of the arresters shall be high enough to eliminate the influence of

grading and stray capacitances on the measured reference voltage.

3.8 The Bidder shall furnish the values and supporting calculations along with the bid.

3.9 The surge arresters shall be provided to protect the following equipments whose

insulation levels are indicated in the table given below:-

Sr. no. Equipment to be protected Insulation level Lightning impulse 1.2/50 micro sec 1 Switchyard Equipments +/-1050kVp

3.10 The arrester shall be fully stabilized thermally to give a life expectancy of whole life

under site conditions and shall take care of the effect of direct solar radiation.

3.11 The duty cycle of CB installed in 245 kV system of the Employer shall be 0-0.3sec-CO-

3min-CO. The surge arrester shall be suitable for such circuit breaker duties in the

system.

4. CONSTRUCTIONAL FEATURE

4.1 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.

4.2 The surge arresters shall be fitted with pressure relief along with the arc transfer device


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of class A suitable for preventing shattering of Polymer 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.

4.3 Seals shall be provided in such a way that these are always effectively maintained even

when discharging rated lightning current. Outer insulation shall be of polymer. Polymer

housing shall be so co-ordinate that external flashover will not occur due to application

of any impulse or switching surge voltage up to maximum design value for arrester.

4.4 The end fittings shall be made of non-magnetic and corrosion proof material.

4.5 The name plate shall conform to the requirements of IEC incorporating the year of

manufacture.

4.6 The arrester shall be suitable for mounting on lattice type support structures as per

system requirements.

4.7 The heat treatment cycle details along with necessary quality checks used for individual

blocks along with insulation layer formed across each block are to be furnished.

Metalized coating thickness for reduced resistance between adjacent discs shall be

furnished along with the procedures for checking the same. Details of thermal stability

test for uniform current distribution on individual discs shall also be furnished.

5. DESIGN PARAMETERS

5.1 Arresters shall be complete with insulating base having provision of bolting to flat

surface of structure.

5.2 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. The

cyclometer counters shall be visible through an inspection window. The counter

terminals shall be robust and of adequate size and shall so located that incoming and

outgoing connections are made with minimum possible bends.

5.3 Suitable milli-ammeters on each pole of the arrester with appropriate connections shall

be supplied to measure the leakage currents.

5.4 Suitable means to differentiate between the internal grading current and the external

leakage current shall be indicated. The details of these shall be brought out in the

additional information schedule. The bidder shall also indicate in the bid, the price of

optional equipment, if any, required for this purpose.(If available)

5.5 Discharge counters and milli-ammeters shall be suitable for mounting on support

structure of the arrester.


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5.6 Grading / Corona rings shall be provided on each complete arrester unit as required.

6. SURGE COUNTER

6.1 Surge counters shall be in weather proof enclosures suitable for mounting on structure

of lightning arrester.

6.2 Surge counter shall be IP 55 protection.

6.3 Surge counter shall be Non-resettable type.

6.4 Surge counter shall be of 0 to 5mA.

7. INSULATOR

7.1 Polymer insulator shall be provided.

7.2 Minimum creepage distance shall be 7700mm (35mm/kV)

8. NAME PLATE DETAILS

Following minimum information must be marked:

a) Name of the manufacturer

b) Type and serial No.

c) Model No.

d) Rated voltage

e) Max. continuous Operating Voltage

f) Nominal discharge current

g) Pr. Relief Class

h) Pressure relief rated current in KA rms

i) Identification mark on each separately housed unit to enable it to be replaced in correct

position after the multiunit arrester has been dismantled.

9. TESTING

Sr No. Test to be carried out

Manufacturer shall carry out comprehensive inspection and testing during manufacture of the equipment.

A Type test to be carried out

1

The product must be of type tested quality. Type test reports shall be submitted for the type, size & rating of equipment offered along with bid. If the manufacturer’s lab is accredited by govt./ authorized body then it shall be acceptable for type testing

2

In accordance with the requirements the surge arresters shall conform to type tests and shall be subjected to routine and acceptance tests as per IS 3070/ IEC-60099 .Type test reports shall be submitted as per IEC-60099 in the relevant schedule.


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3 Radio interference voltage test

4 Seismic withstand test

5 Contamination test

6 Dynamic over voltage withstand test

7 Insulation withstand tests on the arrester housing – (Refer 10.8.2.of IEC- 60099-4)

8 Long-duration current impulse withstand test – (Refer 10.8.4. of IEC- 60099-4)

9 Operating duty tests – (Refer 10.8.5. of IEC- 60099-4)

10 Tests of arrester disconnectors / fault indicators – (Refer 10.8.6. of IEC- 60099-4)

11 In addition, the following tests are to be carried out:

11.1 Moisture ingress test (Refer 10.8.13 of IEC- 60099-4) This test demonstrates the ability of the arrester to resist ingress of moisture after being subjected to specified mechanical stresses.

11.2

Weather ageing test (Refer 10.8.14 of IEC- 60099-4). This test demonstrates the ability of the arrester to withstand specified climatic conditions. Bidder shall submit type test procedure along with the bid. Each ZnO block shall be tested to the guaranteed specific energy capability in addition to the routine / acceptance tests as per IEC-60099/IEC-TC37-WG4.

B Routine test to be carried out

1 Visual Inspection

2 Dimensional Verification

3 Reference Voltage test

4 Residual voltage Test

5 PD Measurement

6 Test on fitting & accessories

C Acceptance Test

1 Visual Inspection

2 Dimensional Verification

3 Reference Voltage test

4 Residual voltage Test

5 PD Measurement.

6 Galvanization test on Ferrous parts.

7

Tests on Surge counters. Visual Inspection o Dimensional Verification o Operational check.


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10. DRAWINGS & DOCUMENTS 10.1 DOCUMENTS TO BE SUBMITTED ALONG WITH BID

a) Tentative GA / cross sectional drawing of product showing all the views / sections.

b) Detailed reference list of customers already using the offered product during the last 5

years with particular emphasis on units of similar design and rating.

c) Completely filled GTP

d) Deviations from this specification. Only deviations approved in writing before award of

contract shall be accepted.

e) Details of manufacturer's quality assurance standards and program and ISO 9000 series

or equivalent national certification.

f) Type test reports shall be submitted for the type, size & rating of product / equipment

offered along with bid. In case the type test report for identical product is not available

then type test report of nearby size/ rating shall be submitted for review. They shall be

considered valid for 5 years from date of test performed on product /equipment.

g) Complete product catalogue and Manual along with the bid.

h) Recommended spare parts and consumable items for five years of operation with prices

and spare parts catalogue with price list for future requirements.

i) Bill of material with make, model & quantity of items.

10.2 DOCUMENTS TO BE SUBMITTED AFTER AWARD OF CONTRACT

a) The seller has to submit : for buyer’s Approval (A) / Reference (R) -Program for

production and testing (A (Schedule of activity)

b) Guaranteed Technical Particulars (A)

c) Calculations to substantiate choice of electrical, structural, mechanical component

size / ratings (A)

d) Detailed dimension drawing for all components (A)

e) Drawings of major components (A)

f) Rating and diagram plate (A)

g) Detailed loading drawing to enable the buyer to design and construct foundations (as

applicable) (R)

h) Transport / Shipping dimensions with weights (R)

i) Detailed Bill of Materials for all fittings and accessories with their make, model & tag

no. etc. (A)


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j) Detailed installation and commissioning instructions (R)

k) Quality plan (A)

l) Standard size paper of drawings shall be A0, A1, A2, A3, A4

m) Recommendations of routine tests, its frequencies & mandatory parameters to be

carried out during maintenance shall be provided to ascertain healthiness of 216 kV LA.

10.3 DOCUMENTS TO BE SUBMITTED PRIOR DISPATCH

a) Inspection and test reports, carried out in manufacturer’s works (R)

b) Test certificates of all bought out items

c) Operation and maintenance Instruction as well as trouble shooting charts/ manuals

11. PACKING

a) Packing shall be protected against corrosion, dampness, heavy rains, breakage and

vibration.

b) Packing for accessories shall be Robust wooden non returnable packing case with all

the above protection & identification Label.

c) In each packing case, following details are required :

Individual serial number

Purchaser's name

PO number (along with SAP item code, if any) & date

Equipment Tag no. (if any)

Destination

Manufacturer / Supplier's name

Address of Manufacturer / Supplier / it’s agent

Description and Quantity

Country of origin

Month & year of Manufacturing

Case measurements

Gross and net weights in kilograms

All necessary slinging and stacking instructions

12. SHIPPING, HANDLING & STORAGE


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a) The seller shall give complete shipping information concerning weight, size etc.

of each package.

b) The seller shall ascertain at an early date before the commencement of

manufacture, any transport limitations such as weights, dimensions, road

culverts, overhead lines, free access etc. from the manufacturing plant to the

project site. Bidder shall furnish the confirmation that the proposed packages

can be safely transported, as normal or oversize packages, upto the site. Any

modifications required in the infrastructure and cost thereof in this connection

shall be brought to the notice of the Purchaser.

c) The seller shall be responsible for any transit damage due to improper packing

d) Manufacturer’s instructions shall be followed. Detail handling & storage

instruction sheet/manual needs to be furnished before commencement of

supply.

e) During transportation from the factory to site the Lightning Arrester shall be

installed with impact recorder. Maximum allowable limit of impact shall be

stated by the manufacturer.

13. DOCUMENT SUBMISSION

Submission of drawings, calculations, catalogues, manuals, test reports shall be as follows:

Item Description Along with

Offer

For Approval after award of contract

Final after approval

Drawings 1 copy (soft) (Typical drgs)

1 copy(Hard) + 1 Soft Copy 6 copies + 1soft copy in CD

Calculations 1 copy (soft) (Typical)

1 copy(Hard) + 1 Soft Copy 6 copies + 1soft copy in CD

Catalogues 1 copy (soft) 6 copies + 1soft copy in CD

Instruction manual

1 copy (soft) 6 copies + 1soft copy in CD

Test Report 1copy (soft) 6 copies + 1soft copy in CD

14. DESIGN PARAMETERS

Sr. No Attributes Parameters

1 Rated system voltage 245 kV

2 System neutral earthing Solidly Grounded


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3 Installation Outdoor

4 Rated arrester voltage 216 kV

5 Nominal discharge current 10kA of 8/20 micro second wave

6 Rated frequency 50 Hz

7 Minimum discharge capability 7.5 KJ / KV (referred to rated arrester voltage)

8 Continuous operating voltage 156 kV at 50 deg. C

9.1 Min. switching surge residual 400 kVp voltage (1 kA)

9.2 Max. switching surge residual 420 kVp voltage (1 kA)

10 Max. residual voltage for current impulse of 8/20 µsec wave

10.1 5 kA 480 kVp

10.2 10kA 510 kVp

14 Long duration discharge class 3

15 High current short duration test value (4/10 micro sec. wave) 65 k Amp

16 Current for pressure relief test 63 kA (r.m.s)

17 Low current long duration test value (2000 micro sec.) 1000 A

18 Min. total creepage distance 7700mm (35mm/kV)

19 Prospective symmetrical fault 63 kA r.m.s current

20 Pressure relief class Class A of table VII of IS3070 OR Equivalent to IEC

21 RIV at 156 kV r.m.s. Less than 1000 micro volts

22 Partial discharge at 1.05 COV Not more than 50 p.c

23 Seismic acceleration 0.3 g

24 Reference Ambient Temp 50 deg. C

15. SITE CONDITION

Sr No Particulars Details

1 Site Location Mumbai

2 Altitude <1000m

3 Atmospheric pressure 1.01246 bar

4 Seismic Zone IS:1893 Zone III


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5 Pollution level Very Heavy (IEC 60815-1986)

6 Ambient Conditions

a) Max. average dry bulb temp 50°C

b) Maximum Relative Humidity 95%

7 Wind Data

A Wind design pressure for structure As per IS:875

B Wind zone As per IS:875

8 c)Basic Wind Speed 47 m/sec

16. LIST OF RECOMMENDED SPARES

Sr.No. Description Quantity Nature of spare 1 2 3 4

In Column `4' indicate nature of spare by a letter

as applicable:

C - Consumable

E - Emergency

S - Susceptible to damage during erection, testing and commissioning.

Name of Firm ……………………

Signature of Bidder ……………………

Name of Bidder ……………………

Designation ……………………

Date ……………………

Seal of Company …………………….

17. LIST OF TOOLS & TACKLES

a) List of instruments, testing equipment, tools and tackles for erection and maintenance

b) Instruments, testing equipment, tools and tackles for erection (to be taken back by

bidder after completion of job)

c) Instruments, testing equipment, tools and tackles for maintenance (to be taken back

by bidder after completion of job)


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d) Special instruments, testing equipment, tools and tackles for erection (to

be retained by the purchaser).

e) Special instruments, testing equipment, tools and tackles for maintenance (To be

retained by the Purchaser)

18. MAINTENANCE TOOLS AND TACKLES

Bidder shall furnish below item wise list of proposed special maintenance tools and tackles for which prices shall be indicated in the price schedule:

Sr.No. System/sub-system Description Quantity

Note : Additional sheets of similar size and format may be annexed as per bidder's requirement.

Signature of Bidder:

Name:

Designation:

Company seal:

Date:

19. DEVIATIONS Deviation Schedule (Technical)

If the proposal has got any deviation from the technical specification, scope of

supply, etc., Bidder shall tabulate those deviations and sign below. Attach more

sheets if necessary. It will automatically be confirmed that except these

deviations, as tabulated hereunder, the complete offer is in agreement with the

specification requirement. Deviations for Technical and Commercial Conditions

shall be given separately.

Specification Part

Page No. Clause & Reference

Deviation taken Effect on lumpsum proposal price |(+) or (-) indicate

currency

Note:

Any deviations taken by the Bidder to the stipulations of the Bid document shall be brought as per this format only and enclosed along with offer.

Any deviations not brought out in this form and written elsewhere in the Bid documents shall not be recognized and the same is treated as null and void.


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20. GUARANTEED TECHNICAL PARTICULARS

Sr. No.

Description Data to be supplied by Manufacturer

1 Name of Manufacturer

2 Type of Designation

3 Model

4 Applicable Standard

5 No. of Units per Arresters

6 Rated Voltage

7 Normal Discharge Current (8/20 usec)

8 Maximum Continuous Operating Voltage (kV r.m.s)

9 Lightning Impulse Residual Voltage

(8/20 µsec)

i) 5000 A

ii) 10000 A

iii) 20000 A

10 Steep Current Impulse Residual Voltage at 10 kA of 1 µsec front time

11 Switching Impulse Residual Voltage 50/100 µsec at 500 amps

12 Current Impulse withstand capability

i) Long Duration Discharge Class

ii) Minimum energy Discharge capability

13 Protective Ratio = BIL of the protected equipment / Residual voltage

14 High current Impulse withstand value (4/10 µsec)

15 Pressure Relief Class

i) High Current

ii) Low Current

16 Reference current

17 Currents at MCOV

i) Resistive Current (Ir.)


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ii) Capacitive Current (IC)

18 Temporary Overvoltage Capability

i) 0.1 sec

ii) 1.0 sec

iii) 10 sec

iv) 100 sec

19 Total Creepage Distance

20 Overall Dimensions

i) Height

ii) Diameter

21 Cantilever Strength

22 Mounting Flange Dimension

23 Minimum Clearance

i) Between Arresters

ii) Arresters and adjoining earthed objects

24 Net Weight of Arrester

21. BILL OF MATERIAL

21.1 BOM FOR SUPPLY

Sr. no Item Description UoM Qty Spare Total Qty

1 216kV Lightning Arrestors Nos 6 1 7

21.2 BOM FOR SERVICE

Sr. no Item Description UoM Qty Total Qty

1 Erection, Installation, Testing and Commissioning of the 216kV Lightning Arrestor

No 6 6

technical specification 216 kv surge arrester in … · moisture ingress test (refer 10.8.13 of...

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