132 KV SS

HARYANA VIDYUT PRASARAN NIGAM LIMITED (INDIA) ICB No.
WB/2008/G-11
TECHNICAL SPECIFICATION
OF PACKAGE G-11(B) 1. 2. 3. 4. 5. 132kV Substation Badli (Upgradation from 33kV level) 132kV Substation Machhrauli 132 kV Substation Gurnawati 132kV Substation Bhattu Sotter One No. 132 kV Bay at 132 kV Substation Beri to accommodate 132 kV S/C Kaboolpur- Beri Line 6. One No. 132kV Bay at 132kV Substation Aherwan for accommodating one circuit of 132 kV Ratia-Aherwan D/C Line.
VOLUME II (PART- II)
TECHNICAL
Chief Engineer/MM, Haryana Vidyut Prasaran Nigam Limited Shakti Bhawan, Sector-6, Panchkula-134109 Ph: 0172-2583724 / 2583744 Fax: 0172-2583724/2565746
CONTENTS TECHNICAL SPECIFICATIONS BID DOCUMENT NO.: G-11 (PKG-B) VOLUME-II FOR 132 kV SUB-STATION MATERIAL
GENERAL GENERAL TECHNICAL REQUIREMENTS TECHNICAL SPECIFICATIONS OF POWER TRANSFORMER 20/25 MVA, 132/33 KV T/F 16/20 MVA, 132/11KV T/F TECHNICAL SPECIFICATIONS OF SWITCH-GEAR 145 KV SF-6 Circuit Breakers 145 & 36 KV Isolators & L&E Switches 120,30 & 9KV Gapless Surge Arrestor 33 KV VCB 630 Amp 11KV VCB 1250Amp TECHNICAL SPECIFICATIONS OF PROTECTIVE GEAR 145kV & 36kV CTs & NCTs & 12kV NCTs 145kV Capacitive Voltage Transformers (Cvts) And 36kv Potential Transformers (PTs) Chapter-3 (A) 132kV control and relay panel boards for substations without substation automation system Chapter-3 (B) 132 kV & 33 kV control and relay panel boards for substations with substation automation system Chapter-4 Sub-Station Automation System Chapter-5 Inter-utility Metering System SECTION-6 TECHNICAL SPECIFICATION OF ELEC. AND MECH. AUX. Chapter-1 Bus post insulators Chapter-2 220V 200AH VRLA Battery Chapter-3 220 V 200AH Battery Charger for VRLA Batteries Chapter-4 220 V 200AH DCDB Chapter-5 415 V 300A LT switch-board Chapter-6 Fire fighting equipments Chapter-7 Specification of cable Chapter-8 200 KVA, 11/0.4KV Distribution transformer Chapter-9 200 KVA, 33/0.4KV Distribution transformer Chapter-10 LT Power Cables Chapter-11 11kV XLPE Power Cable Chapter-12 33KV Capacitor With allied equipments Chapter-13 11KV Capacitor With allied equipments Chapter-14 MK SECTION-7 SWITCHYARD ERECTION AND INSTALLATION SECTION-8 STEEL STRUCTURE SECTION-9 CIVIL WORKS SECTION-10 LIST OF DRAWINGS SECTION-11 GENERAL TECHNICAL PARAMETERS SECTION-1 SECTION-2 SECTION-3 Chapter-1 Chapter-2 SECTION-4 Chapter-1 Chapter-2 Chapter-3 Chapter-4 Chapter-5 SECTION-5 Chapter-1 Chapter-2 1 To 39 1 To 77 1 To 22 1 To 22 1 To 20 1 To 13 1 To 6 1 To 6 1 To 12 1 To 12 1 To 12 1To 21 1To 23 1 To 37 1 To 17 1 To 4 1 To 6 1 To 4 1 To 4 1 To 6 1 To 4 1 To 3 1 To 9 1 To 9 1 To 3 1 To 2 1 To 8 1 To 6 1 To 8 1 To 30 1 To 3 1 To 40 1 To 2
SECTION -1 (GENERAL) PACKAGE G-11 (B) 1.1 INTRODUCTION: The scope of this specification covers construction of 132kV S/Stns. & 132kV Line bays on supply-cum-erection (turnkey) basis as per Annexure-I on single source responsibility basis.
1.2
SCOPE: The detailed scope of work shall be as under: 1.2.1 1) Scope of work for 132 kV S/Stn. Machhrauli is as under:Providing 1x20/25 MVA 132/33 kV T/F, its bay along with allied switchgear and protective equipments, 4 No. 132 kV bays for accommodating LILO of 132 kV Jhajhar-Rewari S/C line and 132kV D/C Badhana-Machhrauli line at 132 kV Machhrauli and 1 No. 132 kV bus coupler bay with allied switchgear and protective equipments (Total 9 No. 132 kV bays including 3 No. spare bays) alongwith 33kV bays as per detailed in Drg. No. HGD-1/3218. Design, Engineering, manufacture, testing, supply on CIP basis, transportation to site, insurance, storage, testing and commissioning of following items:a) 1 x20/25 MVA, 132/33kV power transformer along with mandatory spares. b) 132 kV SF6 circuit breakers, 33kV VCBs, isolators, L&E Switch, transformer CTs, line CTs, NCT, surge arrestors, bus post insulators, CVT & P.T. along with their terminal connectors and mandatory spares. c) Complete 132kV &33 kV C&R panels. d) Complete Sub-Station automation including Hardware & Software. e) Air Conditioning system. f) 220V, 200 AH VRLA DC battery with battery charger & DCDB along with associated accessories. g) 415 Volt LT AC Board 300 Amp. along with associated accessories. h) Associated electrical and mechanical auxiliaries. i) j) Complete fire - fighting equipment. Providing 1 No. 2x5.43 MVAR 33kV rating Cap. Bank along with structure & allied equipment such as L&E, LA & NCTs/Series reactors etc as per General Arrangement Drg. attached with specification as Annexure-I. k) 1.1kV grade Power & unarmoured control copper Cable along with complete accessories for switchgear and protection equipment. l) Sub-station structures for S/Stn. towers & Beams and equipment structures. m) Insulator strings, hardware clamps and connectors, junction box, copper lug, glands & PVC ferrules for control cabling, wooden cleats, aluminum clamps, bolts, nuts, washers etc. for fixing control cables in trenches, galvanized iron trays & clamps, ACSR Zebra, GS earth wire, spares. Cables supporting angles/channels, buried cable trenches & outdoor channels with trenches with trench covers. n) Complete switchyard lighting. o) Complete Earth mat lying. The earth mat will be designed/quoted for soil resistivity of 50m. In case soil resistivity is more than 50m then the earth mat will be designed for actual soil resistivity. The payment of extra material to be used for earth mat shall be made on pro rata basis. p) C-wedge connector & equipment interconnections shall be suitable for ACSR Zebra Conductor. q) 1X200 KVA 33/0.4 kV station T/Fs for auxiliary supplies with complete self protected (CSP) features. r) Any other equipment/material required to complete the specified scope.
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CIVIL WORKS 132 KV S/Stn. Machhrauli The work shall be included but not limited to the following:a) Foundation for S/Stn. main gantry, steel structures and equipments as per drawings attached. For breakers, the Design/drawing of foundations shall be submitted by successful bidder for approval before execution. Foundation for 1 No. 20/25 MVA 132/33kV T/F along with jacking pad and pylon support etc. as per attached drawings. Additional foundations, if required as per approved equipment shall be constructed by the successful bidder without any extra cost to HVPNL. The successful bidder, therefore, would seek approval before execution. Foundation of 1 No. 200 KVA 33/0.4 kV auxiliary transformer. Foundation design/drawing shall be evolved and submitted by the bidder for approval before execution. Foundation for lighting poles, Junction box, panels, control cubicles & A.C.Kiosks of equipments shall be provided by the successful bidder without extra cost to HPVNL. (wherever required). Out door cable trenches along with covers, cable racks, drainage system including drainage pipes, manholes, rain water harvesting system, sum pit cum pump chamber and installation of pump, etc. including cable trench crossings the road. The layout drawing shall be evolved by the successful bidder and got approved from HVPNL before execution. Foundation for 1 No. 2x5.430 MVAR 33 kV Capacitor Banks complete. Design/drawings shall be evolved and submitted for approval before execution by successful bidders. Laying of concrete roads leading to switch yard and switch house building from main PWD (B&R) road/local govt. road as applicable including earth filling for road and berms if required and PCC in front & rear and of the switch house building for parking as per drawings attached and GELO/CLO. Fencing & Boundary Wall for the S/Stn. along with gates as per drawings attached. Site surfacing including cutting, leveling and dressing, lean conc./PCC wherever required in the S/Stn area as per CLO. Construction of Switch House building including indoor cable trenches covers, all services, laying of drainage pipes, collecting tank & soakage pit, rain harvesting system and all other services as per drawings/specifications to complete the building in all respect and making it functional. Filling of earth to required depth including compaction etc. in switchyard area including approach roads, wherever required to achieve required formation level as desired by HVPNL. Construction of drainage cum rain harvesting system (rechargeable bore) as per HVPNL drawing(s). The layout plan including material for collection of water from switch house building and S/Stn. area shall be evolved by the successful bidder and got approved from HVPNL before execution. Scope of work for 132 kV S/Stn. Badli is as under:Providing 2x20/25 MVA 132/33 kV T/F, its bay along with allied switchgear and protective equipments, 2No. 132 kV line bay for accommodating 132 kV D/C Badhana-Badli Line and 1 No. 132 kV bus coupler bay with allied switchgear and protective equipments (Total 6 No. 132 kV bays including 1 No. spare bay) along with 33kV bays as per detailed in Drg. No. HGD-1/3212. Design, Engineering, manufacture, testing, supply on FOR destination site basis, transportation, insurance, storage, testing and commissioning of following items:a) b) 2 x20/25 MVA 132/33kV power transformer along with mandatory spares. 132 kV SF6 circuit breakers, 33kV VCBs, isolators, L&E Switch, transformer CTs, line CTs, NCT, surge arrestors, bus post insulators, CVT & P.T. along with their terminal connectors and mandatory spares. Complete 132kV & 33 kV C&R panels. Complete Sub-Station automation including Hardware & Software.
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b)
c) d)
e)
f) g)
h) i) j)
k) l)
2)
c) d)
e) f) g)
Air Conditioning system. 1x200 KVA, 33/0.4 kV Station Auxiliary Transformer along with associated accessories.
220V, 200 AH VRLA DC Battery with battery charger & DCDB along with associated accessories. h) 415 Volt LT AC Board 300 Amp. along with associated accessories. i) Associated electrical and mechanical auxiliaries. j) Complete switchyard lighting. k) Complete fire - fighting equipment. l) Providing 2 No. 2x5.43 MVAR 33kV rating Cap. Bank along with structure & allied equipment such as L&E, LA & NCTs/Series reactors etc. as per General Arrangement Drg. attached with specification as Annexure-I. m) 1.1 kV grade Power & unarmoured control copper Cable along with complete accessories. n) Sub-station structures for S/Stn. towers & Beams and equipment structures. o) Insulator strings, hardware clamps and connectors, junction box, copper lug, glands & PVC ferrules for control cabling, wooden cleats, aluminum clamps, bolts, nuts, washers etc. for fixing control cables in trenches, galvanized iron trays & clamps, ACSR Zebra, GS earth wire, spares. Cables supporting angles/channels, buried cable trenches & outdoor channels with trenches with trench covers. p) Complete Earth mat lying. The earth mat will be designed/quoted for soil resistivity of 50m. In case soil resistivity is more than 50m then the earth mat will be designed for actual soil resistivity. The payment of extra material to be used for earth mat shall be made on pro rata basis. q) C-wedge connector & equipment interconnections shall be suitable for ACSR Zebra Conductor. r) Any other equipment/material required to complete the specified scope. CIVIL WORKS 132 KV S/Stn. Badli The work shall be included but not limited to the following:a) Foundation for S/Stn. main gantry, steel structures and equipments as per drawings attached. For breakers, the Design/drawing of foundations shall be submitted by successful bidder for approval before execution. b) Foundation for 2 No. 20/25 MVA 132/33kV T/F along with jacking pad and pylon support etc. as per attached drawings. Additional foundations, if required as per approved equipment shall be constructed by the successful bidder without any extra cost to HVPNL. The successful bidder, therefore, would seek approval before execution. c) Foundation for lighting poles, Junction box, panels, control cubicles & A.C.Kiosks of equipments shall be provided by the successful bidder without extra cost to HPVNL (wherever required). d) Foundation of 1 No. 200 KVA 33/0.4 kV auxiliary transformer. Foundation design/drawing shall be evolved and submitted by the bidder for approval before execution. e) Out door cable trenches along with covers, cable racks, drainage system including drainage pipes, manholes, rain water harvesting system, sum pit cum pump chamber and installation of pump, etc. including cable trench crossings the road. The layout drawing shall be evolved by the successful bidder and got approved from HVPNL before execution. f) Foundation for 2 No. 2x5.430 MVAR 33 kV Capacitor Banks complete. Design/drawings shall be evolved and submitted for approval before execution by successful bidders. g) Laying of concrete roads leading to switch yard and switch house building from main PWD (B&R) road/ local govt. road as applicable including earth filling for road and berms if required and PCC in front & rear and of the switch house building for parking as per drawings attached and GELO/CLO. h) Fencing & Boundary Wall for the S/Stn. along with gates as per drawings attached. i) Site surfacing including cutting, leveling and dressing, lean conc./PCC wherever required in the S/Stn area as per CLO.
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Construction of Switch House building including indoor cable trenches covers, all services, laying of drainage pipes, collecting tank & soakage pit, rain harvesting system and all other services as per drawings/specifications to complete the building in all respect and making it functional. k) Filling of earth to required depth including compaction etc. in switchyard area including approach roads, wherever required to achieve required formation level as desired by HVPNL. l) Construction of drainage cum rain harvesting system (rechargeable bore) as per HVPNL drawing(s). The layout plan including material for collection of water from switch house building and S/Stn. area shall be evolved by the successful bidder and got approved from HVPNL before execution. 3) Scope of work for 132 kV S/Stn. Gharnawati is as under:Providing 1x20/25 MVA 132/33 kV T/F & 1x16/20MVA, 132/11Kv T/F, its bay along with allied switchgear and protective equipments, 4No. 132 kV line bays for accommodating 132 kV D/C Line from 400kV S/Stn. Kabulpur and LILO of augmented S/C Hisar Road Rohtak-Kalanaur line at 132Kv S/Stn. Gharnawati & 1 No. 132 kV bus coupler bay with allied switchgear and protective equipments (Total 9 No. 132 kV bays including 2 No. spare bays) alongwith 33kV bays as per detailed in Drg. No. HGD-1/3232. Design, Engineering, manufacture, testing, supply on FOR destination site basis, transportation, insurance, storage, testing and commissioning of following items:a) 1x20/25 MVA 132/33kV & 1x16/20MVA, 132/11Kv T/F power transformers along with mandatory spares. b) 132 kV SF6 circuit breakers, 33kV VCBs, isolators, L&E Switch, transformer CTs, line CTs, NCT, surge arrestors, bus post insulators, CVT & P.T. along with their terminal connectors and mandatory spares. c) Complete 132kV & 33 kV C&R panels. d) Complete Sub-Station automation including Hardware & Software. e) Air Conditioning system. f) 1x200 KVA, 11/0.4 kV Station Auxiliary Transformer along with associated accessories. g) 220V, 200 AH VRLA DC Battery with battery charger & DCDB along with associated accessories. h) 415 Volt LT AC Board 300 Amp. along with associated accessories. i) Associated electrical and mechanical auxiliaries. j) Complete switchyard lighting. k) Providing 1 No. 2x5.43 MVAR 33kV rating Cap. Bank along with structure & allied equipment such as L&E, LA & NCTs/Series reactors etc. as per General Arrangement Drg. attached with specification as Annexure-I & Providing 1x2.268MVAR + 1x4.536 MVAR 11kV rating Cap. Bank with 2 no. RVTs and 2 no. L&E Switch (capacitor panel available in 11 kV Indoor metal clad switch gear) controlled by one VCB. l) 1.1 kV grade Power & Unarmoured Control copper Cable along with complete accessories. m) Sub-station structures for S/Stn. towers & Beams and equipment structures. n) Insulator strings, hardware clamps and connectors, junction box, copper lug, glands & PVC ferrules for control cabling, wooden cleats, aluminum clamps, bolts, nuts, washers etc. for fixing control cables in trenches, galvanized iron trays & clamps, ACSR Zebra, GS earth wire, spares. Cables supporting angles/channels, buried cable trenches & outdoor channels with trenches with trench covers. o) Complete Earth mat lying. The earth mat will be designed/quoted for soil resistivity of 50m. In case soil resistivity is more than 50m then the earth mat will be designed for actual soil resistivity. The payment of extra material to be used for earth mat shall be made on pro rata basis. p) C-wedge connector & equipment interconnections shall be suitable for Single/Twin ACSR Zebra Conductor. q) 11kv 12 Panel board indoor metal clad switchgear (VCB Type) along with mandatory spares. r) Any other equipment/material required to complete the specified scope.
k)
j)
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CIVIL WORKS 132 KV S/Stn. Gharnawati The work shall be included but not limited to the following:a) Foundation for S/Stn. main gantry, steel structures and equipments as per drawings attached. For breakers, the Design/drawing of foundations shall be submitted by successful bidder for approval before execution. b) Foundation for 1 No. 20/25 MVA 132/33kV & 1No. 16/20MVA 132/11KV T/Fs along with jacking pad and pylon support etc. as per attached drawings. Additional foundations, if required as per approved equipment shall be constructed by the successful bidder without any extra cost to HVPNL. The successful bidder, therefore, would seek approval before execution. c) Foundation for lighting poles, Junction box, panels, control cubicles & A.C.Kiosks of equipments shall be provided by the successful bidder without extra cost to HPVNL (wherever required). d) Foundation of 1 No. 200 KVA 11/0.4 kV auxiliary transformer. Foundation design/drawing shall be evolved and submitted by the bidder for approval before execution. e) Out door cable trenches along with covers, cable racks, drainage system including drainage pipes, manholes, rain water harvesting system, sum pit cum pump chamber and installation of pump, etc. including cable trench crossings the road. The layout drawing shall be evolved by the successful bidder and got approved from HVPNL before execution. f) Foundation for 1No. 2x5.430 MVAR 33 kV Capacitor Banks & 1x2.268MVAR + 1x4.536 MVAR 11kV rating Cap. Bank with 2 no. RVTs and 2 no. L&E Switch complete. Design/drawings shall be evolved and submitted for approval before execution by successful bidders. g) Laying of concrete roads leading to switch yard and switch house building from main PWD (B&R) road/ local govt. road as applicable including earth filling for road and berms if required and PCC in front & rear and of the switch house building for parking as per drawings attached and GELO/CLO. h) Fencing & Boundary Wall for the S/Stn. along with gates as per drawings attached. i) Site surfacing including cutting, leveling and dressing, lean conc./PCC wherever required in the S/Stn area as per CLO. j) Construction of Switch House building including indoor cable trenches covers, all services, laying of drainage pipes, collecting tank & soakage pit, rain harvesting system and all other services as per drawings/specifications to complete the building in all respect and making it functional. k) Filling of earth to required depth including compaction etc. in switchyard area including approach roads, wherever required to achieve required formation level as desired by HVPNL. l) Construction of drainage cum rain harvesting system (rechargeable bore) as per HVPNL drawing(s). The layout plan including material for collection of water from switch house building and S/Stn. area shall be evolved by the successful bidder and got approved from HVPNL before execution. 4) Scope of work for 132 kV S/Stn. Bhattu Khurd (Sotter) is as under:Providing 2x20/25 MVA 132/33 kV T/F, its bay along with allied switchgear and protective equipments, 1 No. 132 kV line bay for accommodating 132 kV S/C Hukmawali line on D/C tower and 1 No. 132 kV bus coupler bay with allied switchgear and protective equipments (Total 6 No. 132 kV bays including 2 No. spare bays) along with 33kV bays as per detailed in Drg. No. HGD-1/3230. Design, Engineering, manufacture, testing, supply on FOR destination site basis, transportation, insurance, storage, testing and commissioning of following items:a) 2 x20/25 MVA 132/33kV power transformer along with mandatory spares. b) 132 kV SF6 circuit breakers, 33kV VCBs, isolators, L&E Switch, transformer CTs, line CTs, NCT, surge arrestors, bus post insulators, CVT & P.T. along with their terminal connectors and mandatory spares. c) Complete 132kV & 33 kV C&R panels. d) Complete Sub-Station automation including Hardware & Software.
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e) Air Conditioning system. f) 1x200 KVA, 33/0.4 kV Station Auxiliary Transformer along with associated accessories. g) 220V, 200 AH VRLA DC Battery with battery charger & DCDB along with associated accessories. h) 415 Volt LT AC Board 300 Amp. along with associated accessories. i) Associated electrical and mechanical auxiliaries. j) Complete switchyard lighting. k) Complete fire - fighting equipment. l) Providing 2 No. 2x5.43 MVAR 33kV rating Cap. Bank along with structure & allied equipment such as L&E, LA & NCTs/Series reactors etc. as per General Arrangement Drg. attached with specification as Annexure-I. m) 1.1 kV grade Power & unarmoured Control copper Cable along with complete accessories. n) Sub-station structures for S/Stn. towers & Beams and equipment structures. o) Insulator strings, hardware clamps and connectors, junction box, copper lug, glands & PVC ferrules for control cabling, wooden cleats, aluminum clamps, bolts, nuts, washers etc. for fixing control cables in trenches, galvanized iron trays & clamps, ACSR Zebra, GS earth wire, spares. Cables supporting angles/channels, buried cable trenches & outdoor channels with trenches with trench covers. p) Complete Earth mat lying. The earth mat will be designed/quoted for soil resistivity of 50m. In case soil resistivity is more than 50m then the earth mat will be designed for actual soil resistivity. The payment of extra material to be used for earth mat shall be made on pro rata basis. q) C-wedge connector & equipment interconnections shall be suitable for ACSR Zebra Conductor. r) Any other equipment/material required to complete the specified scope. CIVIL WORKS 132 KV S/Stn. Bhattu Khurd (Sotter) The work shall be included but not limited to the following:a) Foundation for S/Stn. main gantry, steel structures and equipments as per drawings attached. For breakers, the Design/drawing of foundations shall be submitted by successful bidder for approval before execution. b) Foundation for 2 No. 20/25 MVA 132/33kV T/F along with jacking pad and pylon support etc. as per attached drawings. Additional foundations, if required as per approved equipment shall be constructed by the successful bidder without any extra cost to HVPNL. The successful bidder, therefore, would seek approval before execution. c) Foundation for lighting poles, Junction box, panels, control cubicles & A.C.Kiosks of equipments shall be provided by the successful bidder without extra cost to HPVNL (wherever required). d) Foundation of 1 No. 200 KVA 33/0.4 kV auxiliary transformer. Foundation design/drawing shall be evolved and submitted by the bidder for approval before execution. e) Out door cable trenches along with covers, cable racks, drainage system including drainage pipes, manholes, rain water harvesting system, sum pit cum pump chamber and installation of pump, etc. including cable trench crossings the road. The layout drawing shall be evolved by the successful bidder and got approved from HVPNL before execution. f) Foundation for 2 No. 2x5.430 MVAR 33 kV Capacitor Banks complete. Design/drawings shall be evolved and submitted for approval before execution by successful bidders. g) Laying of concrete roads leading to switch yard and switch house building from main PWD (B&R) road/ local govt. road as applicable including earth filling for road and berms if required and PCC in front & rear and of the switch house building for parking as per drawings attached and GELO/CLO. h) Fencing & Boundary Wall for the S/Stn. along with gates as per drawings attached. i) Site surfacing including cutting, leveling and dressing, lean conc./PCC wherever required in the S/Stn area as per CLO.
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j)
Construction of Switch House building including indoor cable trenches covers, all services, laying of drainage pipes, collecting tank & soakage pit, rain harvesting system and all other services as per drawings/specifications to complete the building in all respect and making it functional. k) Filling of earth to required depth including compaction etc. in switchyard area including approach roads, wherever required to achieve required formation level as desired by HVPNL. l) Construction of drainage cum rain harvesting system (rechargeable bore) as per HVPNL drawing(s). The layout plan including material for collection of water from switch house building and S/Stn. area shall be evolved by the successful bidder and got approved from HVPNL before execution. 1.2.2 132kV S/Stn. Beri The detailed scope of work includes providing 1 No. 132kV line bay at existing 132kV S/Stn. Beri for accommodating 132 kV Kabulpur-Beri S/C line on D/C tower along with allied switchgear and protective equipments as per attached GELO Drg. No. HGD-1/3124 (Revision R-3). The scope covers Design, Engineering, manufacture, testing, supply on FOR destination site basis, transportation, insurance, storage, testing and commissioning of following items as per drawing: 132kV SF-6 Circuit Breakers, Isolators, all type of Current Transformers, CVT, SurgeArrestors, Bus Post Insulators, L&E switches, C&R Panel etc. along with their terminal connectors and mandatory spares. Associated mechanical & electrical auxiliaries. 1.1 kV grade power & unarmoured control copper cables along with complete accessories for switchgear and protection equipments. Substation structures for sub-station towers & beams and equipment structures. Insulator strings, hardware clamps and connectors, marshalling Kiosks, copper lugs, glands & PVC ferrules for control cabling, wooden cleats, aluminum clamps, bolts, nuts, washers etc. for fixing control cables in trenches, galvanised iron trays & clamps, ACSR conductor, GS earth wire, spares. Cables supporting angles/channels & outdoor channels with trenches with trench covers. C-wedge connector & equipment interconnections shall be suitable for Single Zebra Conductor. Earthing material for connecting the equipments with main Earth mat & risers. Complete lighting for bay. Any other equipment/material required to complete the specified scope. CIVIL WORKS The work shall be included but not limited to the following: Foundation for S/Stn main gantry, steel structures and equipments are as per drawings attached. However, for breaker, the design/ drawing of foundation shall be submitted by successful bidder for approval before execution. Foundation for lighting poles, Bay marshalling box, panels & control cubicles of equipments (wherever required). Out door cable trenches along with covers, cable racks, drainage system including drainage pipes, manholes etc. Site surfacing including leveling and dressing wherever required in the S/Stn area. Cutting/Filling of earth to required depth including compaction etc. in S/Stn./ switchyard area wherever required to achieve required formation level as decided by employer. Dismantlement of existing fencing, roads etc. and re-construction as per BOQ/Site requirements and HVPNL Drgs. 132kV S/Stn. Aherwan The detailed scope of work includes providing 1 No. 132kV line bay at existing 132kV S/Stn. Aherwan for accommodating 132 kV 2nd Ckt. line on D/C tower to 132 kV S/Stn.Ratia on existing spare bay along with allied switchgear and protective equipments as per attached GELO Drg. No. HGD-1/2092 (Revision R-9).
a)
b) c) d) e)
f) g) h) i)
a)
b) c) d) e) f) 1.2.3
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a)
b) c) d) e)
f) g) h) i)
The scope covers Design, Engineering, manufacture, testing, supply on FOR destination site basis, transportation, insurance, storage, testing and commissioning of following items as per drawing: 132kV SF-6 Circuit Breakers, Isolators, all type of Current Transformers, CVT, SurgeArrestors, Bus Post Insulators, L&E switches, C&R Panel etc. along with their terminal connectors and mandatory spares. Associated mechanical & electrical auxiliaries. 1.1 kV grade power & unarmoured control copper cables along with complete accessories for switchgear and protection equipments. Substation structures for sub-station towers & beams and equipment structures. Insulator strings, hardware clamps and connectors, marshalling Kiosks, copper lugs, glands & PVC ferrules for control cabling, wooden cleats, aluminum clamps, bolts, nuts, washers etc. for fixing control cables in trenches, galvanised iron trays & clamps, ACSR conductor, GS earth wire, spares. Cables supporting angles/channels & outdoor channels with trenches with trench covers. C-wedge connector & equipment interconnections shall be suitable for Single Zebra Conductor. Earthing material for connecting the equipments with main Earth mat & risers. Complete lighting for bay. Any other equipment/material required to complete the specified scope. CIVIL WORKS The work shall be included but not limited to the following: Foundation for S/Stn main gantry, steel structures and equipments are as per drawings attached. However, for breaker, the design/ drawing of foundation shall be submitted by successful bidder for approval before execution. Foundation for lighting poles, Bay marshalling box, panels & control cubicles of equipments (wherever required). Out door cable trenches along with covers, cable racks, drainage system including drainage pipes, manholes etc. Site surfacing including leveling and dressing wherever required in the S/Stn area. Cutting/Filling of earth to required depth including compaction etc. in S/Stn./ switchyard area wherever required to achieve required formation level as decided by employer. Dismantlement of existing fencing, roads etc. and re-construction as per BOQ/Site requirements and HVPNL Drgs. SCHEDULE OF QUANTITIES The detailed description of various items/equipment and civil works are indicated at Annexure - AI to CI (for 132/33kV S/Stns. Machhrauli, Badli, Gharnawati & Bhattu Khurd (Sotter)) and A2 to C2 (for 132/33kV line bays). The bill of quantity of major equipment is also indicated and wherever the quantities are not indicated the bidder is required to compute the quantity. Bidder is required to indicate unit rate and total price of the items under a particular head in bid proposal sheets. Bidder should include all such items in the bid proposal sheets, which may not be specifically mentioned but are essential for the execution of the contract. GENERAL ELECTRICAL LAYOUT The GELO for 132kV S/Stns. Machhrauli, Badli, Gharnawati & & Bhattu Khurd (Sotter) and 132kV Bays at Beri & Aherwan is enclosed as indicated at Annexure-IV. LOCATIONS OF THE SUBSTATION The location of the substations along with the nearest Railhead is indicated at Annexure-II. METEOROLOGICAL DATA. The meteorological data of the substation is indicated at Annexure-III. However, for design purpose, ambient temperature should be considered as 50 C. SOIL DATA The earth resistivity for various 132kV S/Stns. shall be ascertained by the bidder himself.
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b) c) d) e) f) 1.2.4
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1.7
DRAWING 1. The bidder shall maintain inter equipment distances, bay length, bay width etc. in accordance with the enclosed general/electrical layouts of the respective substations while doing so the bidder will ensure that the statutory electrical clearances required for substation are maintained. (Annexure-IV). The drawing enclosed give the basic scheme, layout of substation, substation buildings, associated service etc. In case of any discrepancy between the drawing and text of specification the bidder is advised to get these clarified before submission of bid. No claim what-so-ever on this score shall be entertained after award of contract.
2.
The bidder shall adopt HVPNL design of galvanised steel structure for tower, beam and equipment supporting structures for 132/33kV S/Stns. 1.8 SPARES 1.8.1 MANDATORY SPARES The spare parts and maintenance accessories shall be included in the bid proposal by the bidder. The prices of these spares shall be given by the bidder in the relevant schedule of BOPS and shall be considered for evaluation of bid. It shall not be binding on the Purchaser to procure all these mandatory spares. The bidder is clarified that no mandatory spares shall be used during the commissioning of the equipment. Any spares required for commissioning purpose shall be a part of the equipment only. Further all the mandatory spares will be consigned to AEE dedicated store, Hisar/Panipat. 1.8.2 OPTIONAL SPARES The Bidder shall identify and recommend the list of optional spare parts required together with their quantity to meet the specified performance for a period of three years. The item schedule and prices of these shall be given by the Bidder in relevant schedule of BOPS and shall not be considered for evaluation of the bid. The Bidder must also indicate the basis for recommendation of optional spares. The Bidder shall also recommend their source of availability and technical particulars. The Bidder may also suggest addition or deletion of spare items over this list. It will be the option of HVPNL to buy the spares quoted by the bidder in his bid at the time of finalisation of contract. 1.8.3 The Bidder shall advise the Purchaser of the required lead time for ordering of spares and the minimum re-order quantities. 1.9 In addition to meeting the qualification requirement stipulated in Volume-IA the bidder of its own or his manufacturer subvendor/fabricator shall also meet the qualifying requirement set forth for all the equipments in the relevant sections of the technical specification, failing which the bid is liable to be rejected. SPECIAL TOOLS AND TACKLES The bidder may include in his proposal the deployment of all such special tools and tackles required for erection testing, commissioning and maintenance of equipment. The Bidder would be free to take these back at the end of work or sell to HVPNL at a negotiated price. At the completion of job, the Bidder will hand over a separate set of tools and tackles required for routine maintenance of S/Stn equipment erected by him as a part of contract. The details of tools and tackles (which will be reviewed by HVPNL at the time of award of contract) will be furnished in attachment 4A Volume-IB. TRAINING OF OWNER'S PERSONNEL The Bidder shall organise and conduct complete and thorough training programmers (to be conducted in English language) for two engineers & two technicians for a period of two weeks providing necessary training material, at no extra cost to the Owner. However, the traveling and living expenses of Owner's engineers/technicians, if any shall be borne by Owner (HVPNL). The training shall be carried out at the place of manufacturer of circuit breakers & C&R panels or as the case may require and as agreed by Owner so as to
-9-
3.
1.10
1.11
ensure complete adequacy of the programme and imparting of detailed knowledge of system/equipment design, engineering, operation and maintenance aspects. Notes: 1. The bidder or his authorised representative should visit the site of works and its surroundings to obtain himself at his responsibility and expenses, all information regarding general site characteristics, accessibility, infrastructure details and factual position in respect of scope of work vis--vis GELO drg. attached with the bid document. Any alteration/addition envisage in the document must be got clarified before submission of the bid. No extra payment shall be made on account of any change in the layout drgs. required for providing DSLP as per Rezvik method. In addition to switchyard lighting (as per Section-7) of Vol-II the successful bidder is required to provide fluorescent tube fitting (2x4 feet) along the periphery of fencing at a interval of 30 meters. Any other items not specifically mentioned in the specification but which are required for erection, testing, commissioning and satisfactory operation of S/Stn. are to be included in the scope of the specification unless specifically excluded
2. 3.
4.
- 10 -
ANNEXURE-I 132kV SUB-STATIONS Sr. No. 1. Name of S/Stn. 132 kV S/Stn. Machhrauli Scope of Work Providing 1x20/25 MVA 132/33 kV T/F, its bay along with allied switchgear and protective equipments, 4 No. 132 kV bays for accommodating LILO of 132 kV JhajharRewari S/C line and 132kV D/C BadhanaMachhrauli line at 132 kV Machhrauli and 1 No. 132 kV bus coupler bay with allied switchgear and protective equipments (Total 9 No. 132 kV bays including 3 No. spare bays) alongwith 33kV bays as per detailed in Drg. No. HGD- 1/3218. Providing 2x20/25 MVA 132/33 kV T/F, its bay along with allied switchgear and protective equipments, 2No. 132 kV line bay for accommodating 132 kV D/C BadhanaBadli Line and 1 No. 132 kV bus coupler bay with allied switchgear and protective equipments (Total 6 No. 132 kV bays including 1 No. spare bay) alongwith 33kV bays as per detailed in Drg. No. HGD1/3212. Providing 1x20/25 MVA 132/33 kV T/F & 1x16/20MVA, 132/11kV T/F, its bay along with allied switchgear and protective equipments, 4No. 132kV line bays for accommodating 132kV D/C Line from 400kV S/Stn. Kabulpur and LILO of augmented S/C Hisar Road Rohtak-Kalanaur line at 132kV S/Stn. Gharnawati & 1 No. 132kV bus coupler bay with allied switchgear and protective equipments (Total 9 No. 132kV bays including 2 No. spare bays) alongwith 33kV bays as per detailed in Drg. No. HGD1/3232. Scheme Double Bus arrangement bar Remarks
2.
132 kV S/Stn. Badli
Double Bus arrangement
bar
3.
132 kV S/Stn. Gharnawati
bar
132 kV S/Stn. Bhattu Khurd (Sotter)
Providing 2x20/25 MVA 132/33 kV T/F, its Double Bus bay along with allied switchgear and arrangement protective equipments, 1 No. 132 kV line bay for accommodating 132 kV S/C Hukmawali line on D/C tower and 1 No. 132 kV bus coupler bay with allied switchgear and protective equipments (Total 6 No. 132 kV bays including 2 No. spare bays) along with 33kV bays as per detailed in Drg. No. HGD1/3230.
bar
- 11 -
Sr. No. 5.
Name of S/Stn. 132kV S/Stn. Beri
Scope of Work Providing 1 No. 132kV line bay at existing 132kV S/Stn. Beri for accommodating 132 kV Kabulpur-Beri S/C line on D/C tower along with allied switchgear and protective equipments as per attached GELO Drg. No. HGD-1/3124 (Revision R-3) Providing 1 No. 132kV line bay at existing 132kV S/Stn. Aherwan for accommodating 132 kV 2nd Ckt. line on D/C tower to 132 kV S/Stn.Ratia on existing spare bay along with allied switchgear and protective equipments as per attached GELO Drg. No. HGD-1/2092 (Revision R-9).
Scheme Double Bus arrangement bar
Remarks
6.
132kV S/Stn. Aherwan
bar
For detailed BOQ for Sr.No. 1, 2, 3 &4 refer Annexure A I, BI & C I and for Sr. No. 5 & 6 Annexure A-2, B-2 & C-2.
- 12 -
ANNEXURE-II LOCATION OF SUB-STATIONS Sr. No. 1. 2. 3. 4. 5. 6. Name of Substation 132 kV S/Stn. Machhrauli 132 kV S/Stn. Badli 132 kV S/Stn. Gharnawati 132kV S/Stn. Bhattu Khurd (Sotter) 132kV S/Stn. Beri 132kV S/Stn. Aherwan Nearest Rail Head Rohtak Rohtak Rohtak Hisar Rohtak Hisar
- 13 -
ANNEXURE-III METEOROLOGICAL DATA 1.1 Equipment to be supplied against this specification shall be suitable for satisfactory continuous operation under the following tropical conditions: i) ii) iii) iv) v) Location Max. Ambient air temp. (deg. C) Min ambient air temp. (deg. C) In the state of Haryana 50 -2.5 35 45
Daily average air temp. (deg. C) Average no. of Thunder storm days per Annum Maximum Relative Humidity (%) Minimum Relative Humidity (%) Average annual rain fall (mm) Max. wind pressure (kg/sq m) Max. altitude above mean sea level (meters) Isoceraunic level (days/year) Seismic level (horizontal acceleration) Average no. of rainy days per Annum
vi) vii) viii) ix) x) xi) xii)
100 26 900 195 1000 45 0.3 g
xiii)
120
NOTE:
Moderately hot and humid tropical climate conductive to rust and fungus growth. The climate conditions are also prone to wide variations in ambient condition. Smoke is also present in the atmosphere. Heavy lightening also occurs during June to October.
- 14 -
ANNEXURE-IV
Sr. No. 1. 2. 3. 4. 5. 6.
NAME OF SUB STATION
SINGLE LINE LAYOUT DRG. DIAGRAM NO. NO. HGD-1/3128 HGD-1/3212 HGD-1/3232 HGD-1/3230 HGD-1/3124 (Revision R-3) HGD-1/2092 (R-9)
132 kV S/Stn. Machhrauli 132 kV S/Stn. Badli 132 kV S/Stn. Gharnawati 132 kV S/Stn. Bhattu Khurd (Sotter) 132kV S/Stn. Beri 132 kV S/Stn. Aherwan
- 15 -
ANNEXURE-A-I BILL OF QUANTITIES

Sr. No. DESCRIPTION UNIT 132 kV 132 kV 132 kV S/Stn. S/Stn. S/Stn. Badli Gharnawati Machhrauli 132kV S/Stn. Bhattu Khurd (Sotter) 2 1 4 1 8 9 8 3 6 3 3 2 Total
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. a)
20/25 MVA, 132/33 kV Power T/F 16/20MVA, 132/11KV Power T/F 220V 200 AH Battery (VRLA) 132 kV SF-6 Breaker 132 kV Isolator with E/SWITCH 132 kV Isolator without E/SWITCH 132 kV Surge Arrestor 132 kV Post Insulator 132 kV CTs For Line (600-300150/1-1-1A) 132 kV T/F CT (150-10075/0.577-1-1A) 132 kV CT for Bus coupler (600-300-150/1-1-1A) 132 kV CVT for line 132kV C&R Panels Ckt breaker control panel without auto reclose & T/F Protection Panel (Both for HV & LV side) Ckt. Breaker control panel without auto reclose & Line Protection Panel Ckt breaker control panel without auto reclose & Bus Coupler Protection Panel Time synchronization equipment 132 kV NCT (150-100-75/1A) 33 kV VCB for lines and T/Fs 33 kV Capacitor VCB 33 kV LAs for lines & I/C T/F 33 kV Ckt breaker control panel without auto reclose for T/F I/C with one No. SEM for each panel 33 kV Ckt breaker control panel without auto reclose & Line Protection Panel
No.
1 -
2 1 5 2 10 12 10 6 6 3 6 2
1 1 1 7 4 14 18 14 12 6 3 12 2
6 1 4 22 11 44 54 44 33 21 12 33 7
No. No. No. No. No. No. No. No. No. No. Set
1 6 4 12 15 12 12 3 3 12 1
b)
Set
11
c)
Set
14. 15. 16. 17. 18. 19.
No. No. No. No. No. Set
1 1 4 1 12 1
1 2 4 2 12 2
1 2 3 1 9 1
1 2 5 2 15 2
4 7 16 6 48 6
20.
Set
10
- 16 -
Sr. No.
DESCRIPTION
UNIT 132 kV S/Stn. 132 kV S/Stn. 132 kV S/Stn. Machhrauli Badli Gharnawati
21.
22. 23. 24. 25. 26. 27. 28. 29.
30. 31. 32(a) 32(b) 33. 34. 35.
36.
37. 38. 39. 40. 41.a)
33 kV Ckt breaker control panel Set without auto reclose & Cap. Protection Panel No. 33 kV Isolator No. 33 kV L&E Switch for Line No. 33 kV PT No. 33 kV Line CT 300-150/5A 33 kV CT For Capacitor Unit No. 300-150/5A 33 kV I/C T/F CT(600-400No. 300/0.577-5-5-1) No. 33 kV NCT(600-400-300/5A) 2x5.43 MVAR 33 kV Capacitor Set Bank along with Str. & allied equipment 220 V 200 AH Battery charger & Set D.C.D.B. 415 V LT AC Distribution Board No. 300 A 33/0.4 kV Station T/F 200 KVA No. 11/0.4 kV Station T/F 200 KVA 11 kV NCT (1200-900/5A) No. 11 kV LA No. 11 kV 12 Panel Board (1250A) Set with one SEM on each T/F I/C Panel 1X2.268 MVAR+1x4.536 MVAR Set 11 kV Capacitor Bank with 2 No. 11 kV RVT & 2 No. 11 kV L&E Switch along with structure (controlled by one VCB) 11 kV Power Cable XLPE Meter (single core) 630sq mm 11 kV Power Cable XLPE 300 Meter sq mm 11 kV Power Cable XLPE 185 Meter sq mm 11 kV Power Cable XLPE 50 sq Meter mm 1.1 kV Copper Control Cable Lot (unarmoured for 132 kV bays)
132kV S/Stn. Bhattu Khurd (Sotter) 2
Total
6 3 3 9 3 3 1 1
8 2 6 6 6 6 2 2
4 2 3 6 3 3 1 1
9 3 6 9 6 6 2 2
27 10 18 30 18 18 6 6
1 1 1 -
1 1 1 -
1 1 1 1 3 1
1 1 1 -
4 4 3 1 1 3 1
Lot
Lot
900 40 40 30
Lot
Lot
900 40 40 30
Lot
- 17 -
Sr. No.
DESCRIPTION
UNIT 132 kV S/Stn. 132 kV S/Stn. 132 kV S/Stn. Machhrauli Badli Gharnawati
41.b)
42.
43.
44.
45. a) b) c) d) e) f) 46.
1.1 kV Copper Control Cable (unarmoured for 33kV & 11kV bays) 650/1100 Volts 3.5 core 240 mm2 aluminium power cable from Aux. T/F to ACDB 650/1100 Volt 3.5 core 70 mm2 aluminium cable for oil filteration set. 650/1100 Volt 4 core 16 mm2 copper power cable for MLDB and other cables required as per contract. Fire Fighting equipments as per section-6 as under: 22.5Kg Capacity FE CO2 type, Trolley Mounted 25Kg Capacity FE DCP type, Trolley Mounted DCP 10Kg Capacity , Wall Mounted FE CO2 6.5Kg Capacity, Wall Mounted DCP 5Kg Capacity , Wall Mounted Water CO2 9 Litre, Wall Mounted Complete lighting of control room building, Switch yard area, road and street as per section-7 of the specification. In addition supply and installation of fluorescenet tube fitting (2x4 feet) along with the fencing at a distance of 30meter
Lot
Lot
Lot
Lot
132kV S/Stn. Bhattu Khurd (Sotter) Lot
Total
Lot
Lot
Lot
Lot
Lot
Lot
Lot
Lot
Lot
Lot
Lot
Lot
Lot
Lot
Lot
Lot
Lot
Lot
Lot
No. No. No. No. No. No. Lot
2 2 7 1 1 1 Lot
4 4 7 1 1 1 Lot
4 4 7 1 1 1 Lot
4 4 7 1 1 1 Lot
14 14 28 4 4 4 Lot
47.
Earthing Mat Material. The earth mat will be designed/quoted for soil resistivity of 50m. In case soil resistivity is more than 50m then the earth mat will be designed for actual soil resistivity. The payment of extra material to be used for earth mat shall be made on pro rata basis. The approximate area of earth mat to be laid is given in the corresponding columns of the substations. However, item will remain a Lot item.
Lot
Earthmat area 18383m2 (approx).
Earthmat area 7690m2 (approx).
Earthmat area 9149m2 (approx.)
Earthmat area 15000m2 (approx.)
Lot
- 18 -
Sr. No.
48.
a) b) 49.
132kV Total S/Stn. Bhattu Khurd (Sotter) Complete Substation automation system for 132/33 kV substations including hardware (for present bays) and software (for present as well as future bays) along with associated equipments and Kiosks including foundation of kiosks for the following bays (bay as defined in the technical specification, sec-sub-station automation system) as per technical specification 132 kV (presently A bays & B for Nos. A=6, B=6 A=5, B=1 A=7, B=5 A=4, B=5 future) 33 kV (presently A bays & B for Nos. A=5, B=8 A=6, B=3 A=4, B=5 A=7, B=7 future) High wall type split AC unit of Nos. 1 1 1 1 4 2 Ton capacity DESCRIPTION UNIT 132 kV S/Stn. 132 kV S/Stn. 132 kV S/Stn. Machhrauli Badli Gharnawati
- 19 -
ANNEXURE B-I Sr. No. DESCRIPTION UNIT 132 kV 132 kV S/Stn. S/Stn. Machhrauli Badli 132 kV S/Stn. Gharnawati 51 132kV Total S/Stn. Bhattu Khurd (Sotter) 27 156
1.
2.
3.
4.
132 kV bolted type single suspension string assembly with 9 numbers ANTI FOG type disc insulators (E&M strength 9000 kg) per string with all hardware accessories including ball & socket connections and suspension clamp set suitable for single Zebra ACSR. Alternatively the bidder may quote silicon polymer composite insulator string in place of Disc Insulators (type of insulator whether disc or polymer insulator to be identified at the time of bidding and quoted accordingly which will not be altered at later stage by the bidder). 132 kV bolted type single tension string assembly with 10 numbers ANTI FOG type disc insulators (E&M strength 9000 kg) per string with all hardware accessories including ball & socket connections and tension clamp set suitable for single zebra ACSR. Alternatively the bidder may quote silicon polymer composite insulator string in place of Disc Insulators (type of insulator whether disc or polymer insulator to be identified at the time of bidding and quoted accordingly which will not be altered at later stage by the bidder). 33 kV bolted type Single tension string assembly with 3 numbers ANTI FOG type disc insulators (E&M strength 9000 kg) per string with all hardware accessories including ball & socket connections and tension clamp sets suitable for Single Zebra ACSR. Alternatively the bidder may quote silicon polymer composite insulator string in place of Disc Insulators (type of insulator whether disc or polymer insulator to be identified at the time of bidding and quoted accordingly which will not be altered at later stage by the bidder). 33 kV bolted type Single suspension string assembly with 3 numbers ANTI FOG type disc insulators (E&M strength 9000 kg) per string with all hardware accessories including ball & socket connections and tension clamp sets suitable for Single Zebra ACSR. Alternatively the bidder may quote silicon polymer composite insulator string in place of Disc Insulators (type of insulator whether disc or polymer insulator to be identified at the time of bidding and quoted accordingly which will not be altered at later stage by the bidder).
No.
45
33
No.
72
54
78
48
252
No.
12
24
12
24
72
No.
12
12
36
- 20 -
Sr. No.
DESCRIPTION
UNIT
132 kV S/Stn. Machhrauli
132 kV S/Stn. Badli
132 kV S/Stn. Gharnawati
Bolted type 11kV Single tension string No. 6 assembly with 3 numbers ANTI FOG type disc insulators (E&M strength 9000 kg) per string with all hardware accessories including ball & socket connections and tension clamp sets suitable for twin Zebra Conductor. Alternatively the bidder may quote silicon polymer composite insulator string in place of Disc Insulators (type of insulator whether disc or polymer insulator to be identified at the time of bidding and quoted accordingly which will not be altered at later stage by the bidder). C-Wedge connectors matching with Lot Lot Lot Lot Lot Lot 6. conductor size. Copper lugs glands, PVC ferrules & Junction L/S L/S L/S L/S L/S L/S 7. Box for control cabling. Wooden cleats, Aluminium clamps, bolts, L/S L/S L/S L/S L/S L/S 8. nuts, washers etc for fixing control cables in trenches Galvanised iron perforated tray with side L/S L/S L/S L/S L/S L/S 9. coupler plate bolts, nuts, washers and clamps etc. of size 150x25x2 mm, 100x25x2 mm and 75x25x2 mm 2925 10. ACSR Zebra Conductor Mt 2975 3350 2700 11950 Lot Lot Lot Lot 11. 7/3.15 & 7/2.5 GS Earthwire Lot Lot Lot Lot 12. Spacers for Twin Zebra conductor No. Lot Lot Lot Lot Lot Lot 13. U-bolt 20mm dia 14. Mandatory spares for hardware/ mechanical/ L/S L/S L/S L/S L/S L/S Electrical auxiliaries to be supplied. 10 % of the finally approved quantities Note: The quantities given in Annexure B-I is approx. and for evaluation purpose, however, the payment shall be made as per actual on the basis of unit price. 5.
132kV Total S/Stn. Bhattu Khurd (Sotter) 6
- 21 -
ANNEXURE C-I Schedules of items for associated steel structure works to be quoted for each substation as applicable.The bidder is required to estimate the quantities and furnish the unit rate for each item/ works and the total price for each item in the bid proposal sheets. The list may not be exhaustive, and the bidder may modify/append the same as required. Sr. No. DESCRIPTION UNIT 132 kV 132 kV 132 kV S/Stn. S/Stn. Gharnawati S/Stn. Machhrauli Badli 132kV Total S/Stn. Bhattu Khurd (Sotter)
A. a) b) c) d) e) f) g) h) i) j) B. 1. 2. 3. 4. 5. 6. 7. 8. 9.
Item for associated structure work Lattice type steel structure for 132 kV S/Stns. Machhrauli, Badli, Gharnawati & Bhattu Khurd (Sotter). Supply of material, preparation of fabrication drawing, galvanizing and delivery of lattice type steel structure for tower and beams for 132/33 KV switchyard fabricated from steel conforming to IS:2062 including nuts-bolts gusset plates foundation bolts and other accessories as per drawings supplied by the owner. Main S/Stn. tower and beam Tower type BT-1 Tower type BT-3 Tower type BT-4 Tower type BT-6 Beam type BB-1 Beam type BB-2 Tower type DT-2 Tower type DT-3 Beam type DB-2 Beam type DB-2X Equipment Structure 132 kV CT drg. No. HHW/ST-67 132 kV CVT drg. No. HHW/ST-67
132 kV Surge Arrestor drg. No. HSW/ST63R 132 kV Bus Post Insulator drg. No. HTD/ST144 132 kV Isolator/L&E drg. No. HTD/ST90R 132 kV NCT drg. No. HTD/ST-145 33 kV LA for lines & I/C T/F drg. No. HTD/ST-89R 33 kV CT drg. HTD/ST-88 33 kV Isolator/L&E drg. No. HTD/ST-110
No. No. No. No. No. No. No. No. No. No.
No. No. No. No. No. No. No. No. No.
7 7 4 8 15 8 5 5 6 18 12 15 12 16 1 12 15 9
6 5 3 6 11 6 7 7 7 15 6 12 10 12 2 12 18 10
8 7 4 8 16 8 5 6 5 1 21 12 18 14 18 2 9 12 6
6 5 3 6 10 6 7 7 8 12 3 9 8 9 2 15 21 12
27 24 14 28 52 28 24 25 26 1 66 33 54 44 55 7 48 66 37
- 22 -
Sr. No.
DESCRIPTION
UNIT
132 kV 132 kV 132 kV S/Stn. S/Stn. Gharnawati S/Stn. Machhrauli Badli
10. 11. 12. 13. 14.
33 kV NCT drg. HTD/ST-88 33 kV PT drg. HTD/ST-88 2x5.43 MVAR 33 kV capacitor bank with str.& allied equipment
No. No. Set.
1 3 1 -
2 6 2 -
1 3 1 1 1
132kV Total S/Stn. BhattuKhurd (Sotter) 2 6 6 2 18 6 1 1
11 kV NCT Drg. HTD/ST-149 1X2.268 MVAR+1x4.536 MVAR 11 kV Capacitor Bank with 2 No. 11 kV RVT & 2 No. 11 kV L&E Switch along with structure (controlled by one VCB)
No. Set
Note: The quantity given above are as approximate in case of variation of quantities at the time of detailed engineering, actual quantities shall be payable as per quoted price.
- 23 -
ANNEXURE-A-2 BILL OF QUANTITIES OF 132 KV LINE BAY (WITHOUT AUTOMATION) Sr. No DESCRIPTION UNIT 132kV S/Stn. Beri 1 1 2 3 3 3 2 1 1 4 Lot Lot 132kV S/Stn. Aherwan 1 1 2 3 3 3 2 1 1 4 Lot Lot Total
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
132 kV SF-6 Breaker 132 kV Isolator with E/Switch 132 kV Isolator without E/Switch 132 kV Surge Arrestor 132 kV CTs for Line (600-300-150/1-1-1A) 132 kV CVT For Line 132KV Post Insulator 132 kV Line C&R Panel (for S/Stn. without SAS) 250TB Marshalling Kiosks Complete lighting for bay with 250W HPSV lamp with weather proof fitting 1.1kV Copper Control Cable unarmoured for 132kV bay Earthing material for connecting the equipments with main Earth mat & risers.
No. No. No. No. No. No. No. No. No. No. Lot Lot
2 2 4 6 6 6 4 2 2 8 Lot Lot
- 24 -
ANNEXURE B-2
Sr. No. 1.
DESCRIPTION
UNIT
132 kV S/Stn. Beri 6
2.
3. 4. 5.
6.
7. 8. 9.
132 kV Bolted type single tension string assembly with 10 numbers Anti FOG type disc insulators (E&M strength 9000 kg) per string with all hardware accessories including ball & socket connection and tension clamp set suitable for single Zebra ACSR. Alternatively the bidder may quote silicon polymer composite insulator string in place of Disc Insulators (type of insulator whether disc or polymer insulator to be identified at the time of bidding and quoted accordingly which will not be altered at later stage by the bidder). 132 kV bolted type single suspension string assembly with 9 numbers Anti FOG type disc insulators (E&M strength 9000 kg) per string with all hardware accessories including ball & socket connections and suspension clamp set suitable for single Zebra ACSR. Alternatively the bidder may quote silicon polymer composite insulator string in place of Disc Insulators (type of insulator whether disc or polymer insulator to be identified at the time of bidding and quoted accordingly which will not be altered at later stage by the bidder). C-Wedge connectors matching with conductor size. Copper lugs glands and PVC ferrules for control cabling. Wooden cleats, Aluminium clamps, bolts, nuts, washers etc for fixing control cables in trenches Galvanised iron perforated tray with side coupler plate bolts, nuts, washers and clamps etc. of size 150x25x2 mm, 100x25x2 mm and 75x25x2 mm ACSR Conductor 0.4sq U-bolt 20mm dia Mandatory spares for hardware/ mechanical/ Electrical auxiliaries to be supplied. 10 % of the finally approved quantities
No.
132kV S/Stn. Aherwan 6
Total
12
No.
12
Lot Lot L/S
Lot Lot L/S
Lot Lot L/S
Lot Lot L/S
L/S
L/S
L/S
L/S
Mtr. Lot Lot
275 Lot Lot
250 Lot Lot
525 Lot Lot
Note: The quantities given in Annexure B-2 are approx. and for evaluation purpose, however, the payment shall be made as per actual on the basis of unit price.
- 25 -
ANNEXURE-C-2 Schedules of items for associated steel structure works to be quoted for each substation as applicable. The bidder is required to estimate the quantities and furnish the unit rate for each item/ works and the total price for each item in the bid proposal sheets. The list may not be exhaustive, and the bidder may modify/ append the same as required. Sr. DESCRIPTION 132kV S/Stn. 132kV UNIT Total No S/Stn. Beri Aherwan A. Main S/StnStn. tower and beam Lattice type steel structure for 132kV S/Stn. Beri & Aherwan. Supply of material, preparation of fabrication drawing, galvanizing and delivery of lattice type steel structure for tower and beams fabricated from steel conforming to IS: 2062 including nuts-bolts gusset plates foundation bolts and other accessories as per drawings supplied by the owner. 1 1 Beam type BB-1 No. 2 a) Equipment supporting structure B. 3 3 6 132 kV CT Drg. No. HHW/ST-67 No. a) 3 3 6 132 kV CVT Drg. No. HHW/ST-67 No. b) 132 kV Surge Arrestor Drg. No. HSW/ST- No. 3 3 6 c) 63R 2 2 4 132 kV Isolator Drg. No. HTD/ST-90R No. d) No. 1 1 2 132kV L&E Switch Drg. No. HTD/ST-90R e) No. 2 2 4 132kV Post Insulator Drg. No. HTD/ST-144 f) Note: The quantity given above are as approximate in case of variation of quantities at the time of detailed engineering, actual quantities shall be payable as per quoted price.
- 26 -
G-11/Package-B
Schedule D-1
132KV SUB-STATION AT BADLI, MACHHRAULI, GURNAWATI, BERI, BHATTU KHURD (SOTTER) AND AHERWAN. (Schedule of rates and Prices for Civil works) (Price Break Down for Goods & Services to be performed in INDIA)
Name of Bidder & Address Price Schedule S. ITEM DESCRIPTION N. 1 2 1.0 EARTH WORK 1.1 Earth filling with good earth as per satisfaction of concerned Executive Engineer/Civil Works Division & laying in layers (as per specification clause 3.5.2), dressing, including carriage, irrespective of lead, loading and unloading, watering and compaction in layers with roller including compensation of earth within sub-station area including yard, roads, approach road etc. complete in all respect. a. BADLI b. MACHHRAULI c. GURNAWATI d. BERI e. BHATTU KHURD (SOTTER) f. AHERWAN 1.2 Earth work in cutting & spreading of cut earth within sub-station in layers (as per specification clause 3.5.3), dressing, including carriage, irrespective of lead, loading and unloading, watering and compaction in layers with roller within substation area including yard, roads, approach road etc. or disposal of surplus earth complete in all respect. a. BADLI b. MACHHRAULI c. GURNAWATI d. BERI e. BHATTU KHURD (SOTTER) f. AHERWAN UNIT 3 QTY. 4 UNIT TOTAL PRICE PRICE 5 6
Cum Cum Cum Cum Cum Cum
15,000 20,000 14,000 30,000 -
20,000 12,000 20 20
- 27 -
S. ITEM DESCRIPTION N. 1 2 2.0 FOUNDATIONS Supply of labour, material and construction of RCC footings & pedestals etc. complete, including the cost of excavation, cement concreting, reinforcement steel, form work, grouting, underpinning backfilling etc. for steel gantry structures/equipments as per approved HVPNL drawings and technical specifications. 2.1 GANTRY TOWERS a. BADLI 132/33kV side i). BT-1 ii). BT-3 iii). BT-4 iv). BT-6 v). DT-2 vi). DT-3 b. MACHHRAULI 132/33kV side i). BT-1 ii). BT-3 iii). BT-4 iv). BT-6 v). DT-2 vi). DT-3 c. GURNAWATI 132/33kV side i). BT-1 ii). BT-3 iii). BT-4 iv). BT-6 v). DT-2 vi). DT-3 d. BHATTU KHURD (SOTTER) 132/33kV side i). BT-1 ii). BT-3 iii). BT-4 iv). BT-6 v). DT-2 vi). DT-3
UNIT 3
QTY. 4
UNIT TOTAL PRICE PRICE 5 6
No. No. No. No. No. No.
06 05 03 06 07 07
07 07 04 08 05 05
08 07 04 08 05 06
06 05 03 06 07 07
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S. ITEM DESCRIPTION N. 1 2 2.2 EQUIPMENT STRUCTURE FOUNDATION a. BADLI 132kV side i) LA ii) Isolator & L&E Switch iii) CVT iv) CT v) NCT vi) Post Insulator 33kV side i) LA ii) NCT iii) CT iv) Isolator and L&E v) PT b. MACHHRAULI 132kV side i) LA ii) Isolator & L&E Switch iii) CVT iv) CT v) NCT vi). Post Insulator 33kV side i) LA ii) NCT iii) CT iv) Isolator and L&E v) PT c. GURNAWATI 132kV side i) LA ii) Isolator & L&E Switch iii) CVT iv) CT v) NCT vi) Post Insulator 33kV side i) LA ii) Isolator and L&E iii) PT iv) CT v) NCT 11kV side i) NCT
UNIT 3
QTY. 4
No. No. No. No. No. No. No. No. No. No. No.
12 12 06 15 02 10 12 02 18 10 06
15 16 12 18 01 12 12 01 15 09 03
No. No. No. No. No. No. No. No. No. No. No. No.
18 18 12 21 02 14 09 06 03 12 01 01
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S. ITEM DESCRIPTION N. 1 2 d. BERI 132kV side i) LA ii) Isolator & L&E Switch iii) CVT iv) CT v) Post Insulator e. BHATTU KHURD (SOTTER) 132kV side i) LA ii) Isolator & L&E Switch iii) CVT iv) CT v) NCT vi) Post Insulator 33kV side i) LA ii) Isolator and L&E iii) PT iv) CT v) NCT f. AHERWAN 132kV side i) LA ii) Isolator & L&E Switch iii) CVT iv) CT v) Post Insulator 33kV side i) LA ii) Isolator and L&E iii) PT iv) CT v) NCT 3.0 CAPACITOR BANK FOUNDATIONS 3.1 Design, Engineering & supply of labour, material & construction of foundations for 2x5.43 MVAR, 33kV-rating capacitor bank with all associated equipment foundations complete in all respect including any other items not specifically mentioned herein but required for completion of job as per technical specifications. a. BADLI b. MACHHRAULI c. GURNAWATI
UNIT 3
QTY. 4
No. No. No. No. No.
03 03 03 03 02
09 09 03 12 02 08 15 12 06 21 02
No. No. No. No. No. No. No. No. No. No.
03 03 03 03 02 -
Set Set Set
02 01 01
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d. BHATTU KHURD (SOTTER) S. ITEM DESCRIPTION N. 1 2 3.2 Design, Engineering, and supply of labour, material and construction of foundations for 1x2.268 MVAR+1X4.536 MVAR, 11kV-rating capacitor bank with all associated equipments complete in all respect including any other items not mentioned herein but required for completion of job as per technical specifications. a. BADLI b. MACHHRAULI c. GURNAWATI d. BERI e. BHATTU KHURD (SOTTER) f. AHERWAN 4.0 BREAKER FOUNDATION Design, engineering, supply of labour, material, equipment for construction of foundation of breakers including all associated works PCC, RCC, structural steel, steel reinforcement and any other items not specifically mentioned herein but required for completion of work as per technical specification. a. BADLI i. 132kV, SF-6 Breaker ii. 33kV, VCB b. MACHHRAULI i. 132kV, SF-6 Breaker ii. 33kV, VCB c. GURNAWATI i. 132kV, SF-6 Breaker ii. 33kV, VCB d. BERI i. 132kV, SF-6 Breaker ii. 33kV, VCB e. BHATTU KHURD (SOTTER) i. 132kV, SF-6 Breaker ii. 33kV VCB f. AHERWAN i. 132kV, SF-6 Breaker ii. 33kV, VCB
Set UNIT 3
02 QTY. 4
Set Set Set Set Set Set
01 -
No. No. No. No. No. No. No. No. No. No. No. No.
05 06 06 05 07 04 01 -04 07 01 --
- 31 -
S. ITEM DESCRIPTION N. 1 2 5.0 CABLE TRENCH Supply of labour, material such as cement, reinforcement steel, steel angles, flats, PCC and brick pillars below cable trenches for construction of Out Door Cable Trenches (ODCT) of required depth/type with pre-cast RCC covers including associated works like Cable Trench Culverts crossings for roads as per approved electrical (trench) layout plan, HVPNL drawing(s) and technical specifications complete in all respect. a. BADLI b. MACHHRAULI c. GURNAWATI d. BERI e. BHATTU KHURD (SOTTER) f. AHERWAN 6.0 TRANSFORMER FOUNDATION 6.1 Design, Engineering, Supply of labour & material for construction of following station transformers including all associated works, PCC, RCC, Reinforcement steel, misc. structural steel and other items not specifically mentioned herein but required for completion of work as per approved equipment drawing and technical specifications. a. BADLI i. 33/0.4kV, 200kVA transformer. b. MACHHRAULI i. 33/0.4kV, 200kVA transformer. c. GURNAWATI i. 11/0.4kV, 200kVA transformer. d. BHATTU KHURD (SOTTER) i. 33/0.4kV, 200kVA transformer.
UNIT 3
QTY. 4
Lot Lot Lot Lot Lot Lot
LS LS LS LS LS LS
No. No. No. No.
01 01 01 01
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S. ITEM DESCRIPTION N. 1 2 6.2 Supply of labour, material and construction of under mentioned transformer foundations including all associated works, RCC, PCC, Reinforcement steel, misc. structural steel and other items not mentioned herein but required for the completion of work as per technical specifications and HVPNL drawing. In case additional foundation is required due to approved equipment drawing, the same shall be constructed by the successful bidder without any extra cost to HVPNL, such drawing(s) shall, however, be got approved from HVPNL . a. BADLI i) 20/25MVA, 132/33T/F foundation including radiator foundations etc. complete. b. MACHHRAULI i) 20/25MVA, 132/33T/F including radiator foundations etc. complete. c. GURNAWATI i) 20/25MVA, 132/33kV T/F foundation including radiator foundations etc. complete. ii). 16/20MVA, 132/11kV T/F foundation including radiator foundations etc. complete d. BHATTU KHURD (SOTTER) i) 20/25MVA, 132/33kV T/F foundation including radiator foundations etc. complete. 7.0 SITE SURFACING 7.1 Providing, supplying and laying two layers of uncrushed/crushed/broken stone pebbles gravel fill. The first layer after compaction shall make minimum 50mm thickness course/layer of 40mm (20mm for Beri & Aherwan) nominal size including dressing, rolling & compacting complete as per GELO, specifications & instructions of concerned Executive Engineer/Civil Works Division. a. BADLI b. MACHHRAULI c. GURNAWATI d. BERI e. BHATTU KHURD (SOTTER) f. AHERWAN
UNIT 3
QTY. 4
No.
02
No.
01
No. No.
01 01
No.
02
Sqm Sqm Sqm Sqm Sqm Sqm
450 1160 900 480 750 580
- 33 -
S. ITEM DESCRIPTION N. 1 2 7.2 Providing, supplying and laying 100mm thick PCC (1:4:8) using 20mm nominal coarse aggregates and spreading 100mm thick layer of 40mm single size uncrushed/crushed/ broken stone pebbles over the PCC including construction of toe wall (exposed wall plastered with cement mortar 1:5) to hold 40mm single size uncrushed/crushed/broken stone pebbles wherever required in the bays covered under the present scope as detailed in the GELO & instructions of concerned Executive Engineer/Civil Works Division. a. BADLI b. MACHHRAULI c. GURNAWATI d. BERI e. BHATTU KHURD (SOTTER) f. AHERWAN 8.0 ROADS & PCC PAVEMENT 8.1 Construction of cement concrete roads and walkways/shoulders from NH/SH/etc. road to switchyard/switch house building as per GELO/CLO and sectional detail drawing no. HCD/SK-181 and technical specification. a. BADLI i. 6.0M from PWD road and 5M within the main entrance gate. ii. 3.66M wide as per GELO/CLO. iii. PCC in front and rear of parking area of SH Building as per tech. specification and drawing HCD/SK-172. b. MACHHRAULI i. 6.0M from PWD road and 5M within the main entrance gate. ii. 3.66M wide as per GELO/CLO. iii. PCC in front & rear of parking area of SH Building as per tech. spec. & drg HCD/SK172. c. GURNAWATI i. 6.0M from PWD road and 5M within the main entrance gate. ii. 3.66M wide as per GELO/CLO. iii. PCC in front and rear of parking area of SH Building as per tech. specification and drawing HCD/SK-172.
UNIT 3
QTY. 4
Sqm Sqm Sqm Sqm Sqm Sqm
4000 4050 3800 3500 -
Mtr. Mtr. Sq.m
15 190 150
Mtr. Mtr. Sq.m
35 155 150
Mtr. Mtr. Sq.m
30 240 150
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S. ITEM DESCRIPTION N. 1 2 d. BHATTU KHURD (SOTTER) i. 6.0M wide road from PWD road including 5M within the main entrance gate. ii. 3.66M wide road as per GELO/CLO. iii. 3.048M wide road as per GELO/CLO. iv. PCC in front and rear of parking area of SH Building as per tech. specification and drawing HCD/SK-172. 8.2 Construction of 3.66M wide bitumen approach road with walkways/shoulders including earth filling (about 2 feet average) from village Gurnawati to Substation. The road shall be constructed as per sectional details provided in drawing no. HVPNL-001R and technical specifications. i. GURNAWATI 9.0 ROAD CULVERTS Design, Engineering and construction of (one/two number) pipe culverts at suitable locations under the approach road (from main PWD road to the sub-station entry point) including, cost of labour, material complete in all respects as per I.R.C. Standards. a. BADLI b. MACHHRAULI c. GURNAWATI d. BERI e. BHATTU KHURD (SOTTER) f. AHERWAN 10.0 U/C CHAIN LINK FENCING & GATES Providing and fixing chain link fencing including gates complete as per electrical layout and tech. specification and as per drawing attached. BADLI MACHHRAULI GURNAWATI BHATTU KHURD (SOTTER) AHERWAN
UNIT 3 Mtr. Mtr. Mtr. Sqm
QTY. 4 20 100 60 150
Mtr.
700
01 01 03 01 -
a. b. c. d. e.
Mtr. Mtr. Mtr. Mtr. Mtr.
180 35 40 100 -
- 35 -
S. ITEM DESCRIPTION N. 1 2 11.0 BOUNDARY WALL 11.1 Supply of labour and material for construction of front, C & U/C boundary walls including main gate foundations (brickwork below DPC level) as per GELO/CLO, technical specifications and HVPNL drawing HCD/TS1176 including excavation backfilling, lean and DPC complete in all respect. a. BADLI b. MACHHRAULI c. GURNAWATI d. BHATTU KHURD (SOTTER) 11.2 Design, Engineering, Supply of labour and material for construction of RCC retaining wall upto DPC level as per GELO/CLO and technical specification including excavation backfilling, lean complete in all respect. The height shall be decided as per natural ground level and the FGL fixed by HVPNL. a. BADLI i. Retaining wall upto 3.0m ii. Retaining wall (3.0 to 3.5m) b. MACHHRAULI i. Retaining wall upto (3.0m) ii. Retaining wall upto 3.5m 11.3 Supply of labour and material for construction of front, C-wall & U/C boundary walls including main gate (brickwork above DPC level) as per GELO/CLO, angles with barbed wire, grill etc. at top of B/wall as per HVPNL drawing and technical specification complete in all respect. a. BADLI i. 6 ft. high U/C wall. ii. 4 ft. high front wall. iii. 4 ft. high side wall. b. MACHHRAULI i. 6 ft. high U/C wall. ii. 4 ft. high front wall. iii. 4 ft. high side wall. c. GURNAWATI i. 6 ft. high U/C wall. ii. 4 ft. high front wall. iii. 4 ft. high side wall. d. BHATTU KHURD (SOTTER) i. 6 ft. high U/C wall. ii. 4 ft. high front wall. iii. 4 ft. high side wall
UNIT 3
QTY. 4
Cum Cum Cum Cum
35 660 755 630
Mtr. Mtr. Mtr. Mtr.
35 30 75 60
Mtr. Mtr. Mtr. Mtr. Mtr. Mtr. Mtr. Mtr. Mtr. Mtr. Mtr. Mtr.
65 30 690 40 20 645 40 20 430 130 50

- 36 -
S. ITEM DESCRIPTION N. 1 2 12.0 DIMOLISHING including foundations of followings structures at BADLI. The material whatsoever shall be the property of the successful bidder. The dismantled material shall not be allowed for reuse at any of the sub-stations; however, HVPNL may allow use of bricks for brick ballast purpose. 12.1 Dismantlement of Boundary wall of Sewer line and 12.2 Dismantlement reconstruction at suitable place. The layout shall be got approved from HVPNL. 13.0 CONTROL ROOM BUILDING Supply of labour, material & construction of control room building for 132kV automated S/Stns. Complete in all respect as per technical specifications & approved drawings attached including exterior acrylic cement paint, interior acrylic emulsion paint, all internal services like water supply including supply & providing of 5000ltr. Capacity double layer Sintex/Diplast PVC tank, Sewerage system, electrification including wiring, modular switches, 4 long CFL tubes, ceiling/exhaust fans & 2T split Acs, Finishing, Plinth protection, Indoor trenches, Soakage pit near the switch house building, connection of sewerage system to Soakage pit/Sewerage system of local authorities (as applicable), connection to main water supply system of local authority, bore (as applicable) etc. & any other item not mentioned herein but required for completion of works. a. BADLI b. MACHHRAULI c. GURNAWATI d. BHATTU KHURD (SOTTER) e. AHERWAN
UNIT 3
QTY. 4
Mtr. Lot
200 L/S
Sqft. Sqft. Sqft. Sqft. Sqft.
3759.65 3759.65 4695.01 3759.65 -
- 37 -
S. ITEM DESCRIPTION N. 1 2 14.0 DRAINAGECUM-RAIN HARVESTING SYSTEM 14.1 Supply of labour, material for construction of 2 nos. recharge structures with bore wells as per HVPNL drawings & specifications complete in all respect. The location of recharge structures shall preferably be located on corner(s) of the substation and shall be got decided from the concerned Executive Engineer/Civil Works Division on the basis of surroundings of the substation(s) be decided by the concerned Executive Engineer/Civil Works Division. In case ground water table is above 8m from NSL, rain harvesting system shall not be constructed. a. BADLI b. MACHHRAULI c. GURNAWATI d. BHATTU KHURD (SOTTER) 14.2 The successful bidder shall evolve design & prepare drainage layout drawing for disposal of rain water from buildings roof top & switch yard (substation) area into respective bore wells in such a way that there shall be no pounding of water on the roof and switch yard (sub-station). The layout so developed shall be got approved from the employer. The location of sump-pit-cum-pump chamber shall preferably be located on corner(s) of the substation and shall be got decided from the concerned Executive Engineer/Civil Works Division on the basis of surroundings of the substation(s). The successful bidder will also supply labour and material for construction sump-pit-cum-pump chamber as per HVPNL drawings and provide two no. clog pump(s) of suitable capacity (for each sump pit) for disposal of excess water to outfall point. Any other item not mentioned herein but is/are required for completion of works shall be done by the successful bidder without any extra cost to the employer. a. BADLI b. MACHHRAULI c. GURNAWATI d. BHATTU KHURD (SOTTER)
UNIT 3
QTY. 4
Lot Lot Lot Lot
L/S L/S L/S L/S
Lot Lot Lot Lot
L/S L/S L/S L/S

- 38 -
S. ITEM DESCRIPTION N. 1 2 15.0 RCC M-20 inclusive of labour, material, shuttering, Steel reinforcement etc. complete in all respects to compensate excess quantity required to execute difference in execution and tender drawings only due to increased depth of foundations. a. BADLI b. MACHHRAULI c. GURNAWATI d. BERI d. BHATTU KHURD (SOTTER) e. AHERWAN IMPORTANT NOTES: 1.
UNIT 3
QTY. 4
20 50 50 02 50 02
2. 3.
4.
The quantities mentioned above are approximate. In case of variations actual quantities shall be payable. For earth filling, site surfacing, boundary wall, U/C fencing and road etc. the payment will be made as per actual measurement at site. Before use, the water test results will have to be submitted by the successful bidder to Civil Design Dte. for approval through concerned Executive Engineer/Civil Works Division. The detailed architectural & structural drawings relating to sub-stations shall be supplied in due course. The payment for S/H building shall be made as per actual on Sq.ft basis.
- 39 -
MODEL TECHNICAL SPECIFICATION

SEC-2 GTR (GENERAL TECHNICAL REQUIREMENT)
SECTION-2 GTR (GENERAL TECHNICAL REQUIREMENTS) CLAUSE NO. 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0 16.0 17.0 18.0 19.0 20.0 21.0 PARTICULARS Foreword General Requirement Standards Services to be performed by the Equipment being furnished Engineering Data and Drawings Material/Workmanship Design Improvements/Coordination Quality Assurance Programme Type Testing, Inspection & Inspection Certificate Tests Packaging & Protection Finishing of Metal Surfaces Handling, Storing & Installation Tools and Tackles Auxiliary Supply Support Structure Clamps and Connectors including Terminal Connectors Control Cabinets, Junction Boxes, Terminal Boxes & Marshalling Boxes for Outdoor Equipment Auxiliary Switches Terminal Blocks and Wiring Lamps and Sockets 30 31 32 29 20 21 21 24 25 26 26 27 8 12 16 17 18 PAGE NO. 1 1 1 2
CLAUSE NO. PARTICULARS 22.0 23.0 24.0 Bushings, Hollow Column Insulators, Support Insulators Motors Technical Requirement of Equipments (RIV) Test Annexure-B List of Specifications
PAGE NO. 33 34 36 44 47
Annexure-A Corona and Radio Interference Voltage
SEC-2 GTR (GENERAL TECHNICAL REQUIREMENTS) 1.0 1.1 FOREWORD 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 is not exclusive. However in case of conflict between the requirements specified in this section and requirements specified under other sections, the requirements specified under respective sections shall prevail. GENERAL REQUIREMENT The bidders shall submit the technical requirements, data and information as per the technical data sheets provided in the Volume II of bid documents. The bidders shall furnish catalogues, engineering data, technical information, design documents, drawings etc. It is recognised that the bidders may have standardised on the use of certain components, materials, processes or procedures different from those specified herein. Alternate proposals offering similar equipment based on the manufacturers standard practice will also be considered provided such proposals meet the specified designs, standard and performance requirements and are acceptable to the HVPNL. Except for lighting fixtures, 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. For lighting fixtures , makes shall be as defined in Section- Lighting System. 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 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.
STANDARDS
2.0 2.1
2.2 2.3
2.4
2.5
3.0
3.1
The works covered by the specification shall be designed, engineered, manufactured, built, tested and commissioned in accordance with the Acts, Rules, Laws and Regulations of India.
Page-1-
3.2
The equipment to be furnished under this specification shall conform to latest issue with all amendments (as on the date of bid opening) of standard specified under Annexure -B of this section, unless specifically mentioned in the specification. The Bidder shall note that standards mentioned in the specification are not mutually exclusive or complete in themselves, but intended to compliment each other. The Bidder shall also note that list of standards presented in this specification is not complete. Whenever necessary the list of standards shall be considered in conjunction with specific IS/IEC. When the specific requirements stipulated in the specifications exceed or differ than those required by the applicable standards, the stipulation of the specification shall take precedence. Other internationally accepted standards which ensure equivalent or better performance than that specified in the standards specified under Annexure B /individual sections for various equipments shall also, be accepted, however the salient points of difference shall be clearly brought out in additional information schedule of Vol III along with English language version of such standard. The equipment conforming to standards other than specified under Annexure-B/ individual sections for various equipments shall be subject to HVPNLs approval. The bidder shall clearly indicate in his bid the specific standards in accordance with which the works will be carried out. SERVICES TO BE PERFORMED BY THE EQUIPMENT BEING FURNISHED The lighting impulse voltage shall be 650kVp. All equipments shall also perform satisfactorily under various other electrical, electromechanical and meteorological conditions of the site of installation. 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. The bidder shall design terminal connectors of the equipment taking into account various forces that are required to withstand. The equipment shall also comply to the following: a) b) c) All outdoor EHV equipments except marshalling kiosks shall be suitable for hot line washing. To facilitate erection of equipment, all items to be assembled at site shall be match marked. 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.
Page-2-
3.3 3.4
3.5
3.6
3.7 4.0 4.1 4.2
4.3
4.4 4.5
4.6 4.7 4.7.1
Operating times of circuit breakers, protective relays and PLCC equipment have been specified in respective sections. EHV equipments and system shall be designed to meet the following major technical parameters as brought out hereunder. System Parameter 132 kV System 132kV 50Hz 3 33 kV System 33kV 50Hz 3 11kV System 11kV 50Hz 3
S.NO Description of parameters 1. 3. 4. 5. i) System operating voltage Rated frequency No. of phase Rated Insulation levels Full wave impulse withstand voltage(1.2/50 micro sec.) Switching impulse withstandvoltage (250/2500micro sec.) dry and wet One minute power frequency dry and wet withstand voltage (rms) Corona extinction voltage Max. radio interference voltage for frequency between 0.5 MHz and 2 MHz 156kV rms for 220kV system & 92 kV rms for 132kV system
650kVp
170kVp
75kVp
ii)
Iii)
275kV
80kV
28kV
6. 7.
105kV 500 microvolt
Page-3-
8. 9. i)
Minimum creepage distance Min. clearances Phase to phase
25 mm/kV (3625mm) (for 1300 mm Rod conductor configuration) and (for conductor configuration) 1300mm 4000 mm 31.5 kA
25 mm/kV 25mm/kV (900mm) (300mm) 320 mm
ii) iii) 10.
Phase to earth Sectional clearances Rated short circuit current for 1 sec. duration System neutral earthing
320 mm 3000 mm 25 kA 18.4kA
11.
Effectively earthed
Effectively earthed
Effectively earthed
4.7.2
Major Technical Parameters The major technical parameters of the equipments are given below. For other parameters and features respective technical sections should be referred. (A) 20/25MVA 132/33 KV Power Transformer Maximum Continuous Capacity (MVA) ONAN 20 Rated Voltage Percentage Impedance Vector Group Insulation level HV 132KV YYO HV 650KV 275KV LV 170KV 70KV 10% at 25MVA Base ONAF 25 LV 33KV
Lightning Impulse withstand voltage Power Frequency withstand voltage
Page-4-
(B) 16/20MVA 132/11 KV Power Transformer Maximum Continuous Capacity (MVA) ONAN 16 Rated Voltage Percentage Impedance Vector Group Insulation level Lightning Impulse withstand voltage Power Frequency withstand voltage HV 550KV 230KVrms HV 132KV YYO LV 75KV 28KV rms ONAF 20 LV 11KV
10% at 20MVA Base
(A) For 145 kV Circuit Breaker and Isolator Rated voltage kV (rms) Rated frequency (Hz) No. of Poles Design ambinet temperature (C) Rated insulation levels : 1) Full wave impulse withstand voltage (1.2/50 micro sec.) between line terminals and ground between terminals with circuit breaker open between terminals with isolator open 650 kVp 145 50 3 50 36 50 3 50
650 kVp
750 kVp
2) One minute power frequency dry and wet withstand voltage between line terminals and ground 275 kV (rms)
Page-5-
between terminals with circuit breaker open
275 kV (rms) 315 kV (rms) 500 (at 92 kV rms)
between terminals with Isolator open Max. radio interference voltage (microvolts) for frequency between 0.5 MHz and 2 MHz in all positions of the equipments. Minimum creepage distance:Phase to ground (mm) Between CB Terminals (mm) System neutral earthing Seismic acceleration Rating of Auxiliary Contacts Breaking capacity of Auxiliary Contacts Phase to phase spacing (mm)
3625 3625 Effectively earthed - 0.3g horizontal - 10 A at 220 V DC 2 A DC with circuit time constant of not less than 20 ms. 2700
Auxiliary Switch shall also Comply with other clauses of this chapter. (B) FOR 145 kV and 36KV CT/CVT/SA Rated voltage kV (rms) Rated frequency (Hz) No. of poles Design ambient temperature (C) Rated insulation levels : 145 50 1 50 50 36 50 1
Page-6-
1) Full wave impulse withstand voltage (1.2/50 micro sec.) between line terminals and ground for CT and CVT for arrester housing 650 kVp 170 kVp 650 kVp 170 kVp
2) One minute power frequency dry and wet withstand voltage between line terminals and ground for CT and CVT for arrester housing 275kV rms 1000 for CT/CVT 500 500 for SA (at 92 kV rms) 275 kV rms 70kV rms
Max. radio interference voltage (microvolts) for frequency between 0.5 MHz and 2 MHz in all positions of the equipment. Minimum creepage Phase to ground (mm) System neutral earthing Seismic acceleration Partial discharge for :Surge arrester at 1.05 COV for CT/CVT distance:-
3625
900
- Effectively earthed - 0.3g horizontal - Not exceeding 50 pc. - Not exceeding 10 pc.
Page-7-
(C) Technical Parameters of Bushings/Hollow Column insulators/support insulators : For 132 kV System (a) Rated Voltage (kV) (b) Impulse withstand voltage(Dry& Wet) (kVp) (c) Switching surge Withstandvoltage (dry and wet) (kVp) (d) Power frequency withstand voltage (dry and wet) (kV rms) (e) Total creepage distance (mm) (f) 145 650 For 33 kV System 36 170 For 11kV System 12 -
275
70
3625
900
Pollution Class-III Heavy (as per IEC 71) and as specified in Section-2 for all class of equipment.
5.0 5.1
ENGINEERING DATA AND DRAWINGS The engineering data shall be furnished by the Bidder in accordance with the Schedule for each set of equipment as specified in the Bid Document. The list of drawings/documents which are to be submitted to the HVPNL as detailed below/ in individual sections. The Bidder shall necessarily submit all the drawings/ documents unless anything is waived. The Bidder shall submit 4 (four) sets of drawings/ design documents /data/ test reports as may be required for the approval of the HVPNL.
5.2
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5.3 5.3.1
Drawings All drawings submitted by the Bidder including those submitted at the time of bid 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. Each drawing submitted by the Bidder shall be clearly marked with the name of the HVPNL, the unit designation, the specifications title, the specification number and the name of the Project. If standard catalogue pages are submitted, the applicable items shall be indicated therein. All titles, noting, markings and writings on the drawing shall be in English. All the dimensions should be in metric units. Further work by the Bidder shall be in strict accordance with these drawings and no deviation shall be permitted without the written approval of the HVPNL, if so required. The review of these data by the HVPNL 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 HVPNL 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 HVPNL shall not be considered by the Bidder, as limiting any of his responsibilities and liabilities for mistakes and deviations from the requirements, specified under these specifications and documents. All manufacturing and fabrication work in connection with the equipment prior to the approval of the drawings shall be at the Bidders risk. The Bidder 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 HVPNL. Approval of Bidders drawing or work by the HVPNL shall not relieve the Bidder of any of his responsibilities and liabilities under the Contract. All engineering data submitted by the Bidder after final process including review and approval by the HVPNL 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 HVPNL in Writing.
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5.3.2
5.3.3
5.4
5.5
5.6
5.7
Approval Procedure The successful bidder shall submit 4 sets of drawings as detailed in relevant specifications complete in all respects for approval to HVPNL as per schedule given in bar-chart. The following schedule shall be followed generally for approval and for providing final documentation. i) Approval/comments/ by HVPNL on initial Submission Resubmission (where ever required) Within 4 weeks of receipt of drawings by HVPNL.
ii)
Within 3 (three) weeks from date of comments including both ways postal time). Within 3 weeks of receipt of resubmission.
iii)
Approval or comments
iv)
Furnishing of final sets of Before commissioning of S/Stn. drawings(10 copies for each item per Sub-station) Furnishing of instruction/ operation manual (10 copies for each item per sub-station) Before commissioning of S/Stn.
v)
vi) Furnishing of CD-ROM of final Drawings (2 Nos. for each item per Sub-Station)
Before commissioning of S/Stn.
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Before commissioning of S/Stn. (vii) Furnishing of CD-ROM of Instruction & operation manual (2 Nos. for each item per SubStation) Before commissioning of S/Stn. (viii) Furnishing of CD-ROM of Automation Software (2 Nos. for each Sub-Station) Before commissioning of S/Stn. (ix) Furnishing of CD-ROM of Application software for numerical relays (2 nos. for each sub-station) NOTE :
(1)
The Bidder may please note that all resubmissions must incorporate all comments given in the earlier submission by the HVPNL or adequate justification for not incorporating the same must be submitted failing which the submission of documents is likely to be returned. The drawings which are required to be referred frequently during execution should be submitted on cloth lined paper. The list of such drawings shall be intimated to the Bidder at the time of approval of drawings. All major drawings should be submitted in Auto Cad. 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. 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 Bidder to the HVPNL.
(2)
(3) (4)
(5)
(6) The Bidder shall furnish to the HVPNL catalogues of spare parts.
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5.8
List of drawings other than equipment drawings (detailed in relevant specifications) to be submitted for approval shall be as under:1) Earthmat design and layout 2) Switchyard structural layout and section (for reference and record of HVPNL). 3) DSLP Calculation and drawings (for reference and record of HVPNL). 4) Earth Resistivity measurement report (for reference & record of HVPNL). 5) Wiring diagram & cable schedule of each bay. 6) Trench Layout drawing.
6.0 6.1 6.1.1
MATERIAL/ WORKMANSHIP General Requirement 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 the best quality of their kind, conforming to best engineering practice and suitable for the purpose for which they are intended. Incase where the equipment, materials or components are indicated in the specification as similar to any special standard, the HVPNL shall decide upon the question of similarity. When required by the specification or when required by the HVPNL the Bidder 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 Bidder. 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 HVPNL.
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6.1.2
6.1.3
6.1.4
6.1.5
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. All materials and equipment shall be installed in strict accordance with the manufacturers 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, levelling, 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 manufacturers tolerances, instructions and the Specification. All factory assembled rotating machinery shall be checked for alignment and adjustments made as necessary to re-establish the manufacturers 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. The Bidder 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 Bidder shall apply all operational lubricants to the equipment installed by him. All oil, grease and other used in the Works/ Equipment shall be purchased in India unless the Bidder has any special requirement for the specific application of a type of oil or grease not available in India. A cast iron or welded steel base plate shall be provided for all rotating equipment which are to be installed on a concrete base unless otherwise agreed to by the HVPNL. Each base plate shall support the unit and its drive assembly, shall be of design with pads for anchoring the units, shall have a raised up all around and shall have threaded in air connections, if so required.
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6.1.6
6.1.7
6.1.8
6.1.9 6.2
Corona and radio interference voltage test for equipments shall be in line with the procedure given at Annexure-A. 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 favourable to the growth of fungi and mildew. The indoor equipments located in non air conditioned areas shall also be of same type.
6.2.1 6.2.1.1 6.2.1.2
Space Heaters The heaters shall be suitable for continuous operation at 240 V as supply voltage. On-off switch and fuse shall be provided. 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. Suitable anti condensation heaters with the provision of thermostat shall be provided. 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.
6.2.1.3 6.2.2
6.2.3
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.
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6.2.4
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) b) d) Installed out door: IP- 55 Installed indoor in air conditioned area: IP-31 c) Installed indoor in non air conditioned area where possibility of entry of water is limited: IP-41.
Installed in covered area: IP-52
e) For LT Switchgear (AC & DC distribution Boards) : IP-52 The degree of protection shall be in accordance with IS:13947 (Part-I) / IEC-947 (Part-I) / IS 12063 / IEC 529. Type test report for degree of protection test, on each type of the box shall be submitted for approval. 6.3 6.3.1 RATING PLATES, NAME PLATES AND LABELS 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 HVPNL PO No., manufacturers 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 HVPNL. The rating plate of each equipment shall be according to IEC requirement. 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. FIRST FILL OF CONSUMABLES, OIL AND LUBRICANTS 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 Bidder unless specifically excluded under the exclusions in these specifications and documents.
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6.3.2
6.4
7.0 7.1
DESIGN IMPROVEMENTS / COORDINATION The bidder shall note that the equipment offered by him in the bid only shall be accepted for supply. However, the HVPNL or the Bidder may propose changes in the specification of the equipment or quality thereof and if the HVPNL & Bidder agree upon any such changes, the specification shall be modified accordingly. 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 Bidder proceeds with the change. Following such agreement, the provision thereof, shall be deemed to have been amended accordingly. The Bidder shall be responsible for the selection and design of appropriate equipments to provide the best co-ordinated performance of the entire system. The basic design requirements are detailed out in this Specification. The design of various components, subassemblies and assemblies shall be so done that it facilitates easy field assembly and maintenance. The Bidder has to coordinate designs and terminations with the agencies (if any) who are Consultants/Bidder for the HVPNL. The names of agencies shall be intimated to the successful bidders. The Bidder will be called upon to attend design co-ordination meetings with the Engineer, other Bidders and the Consultants of the HVPNL (if any) during the period of Contract. The Bidder shall attend such meetings at his own cost at Panchkula or at mutually agreed venue as and when required and fully cooperate with such persons and agencies involved during those discussions. QUALITY ASSURANCE PROGRAMME To ensure that the equipment and services under the scope of this Contract whether manufactured or performed within the Bidders Works or at his Sub-Bidders premises or at the HVPNLs site or at any other place of Work are in accordance with the specifications, the Bidder shall adopt suitable quality assurance programme to control such activities at all points necessary. Such programme shall be broadly outlined by the Bidder and finalised after discussions before the award of contract. The detailed programme shall be submitted by the Bidder after the award of contract and finally accepted by HVPNL after discussion. However, in case detailed valid programme approved by HVPNL for the equipment already exist, same would be followed till its validity. A quality assurance programme of the Bidder shall generally cover the following:
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7.2
7.3
7.4
7.5
8.0 8.1
(a)
His organisation structure for the management and implementation of the proposed quality assurance programme : Qualification data for bidders key personnel; The procedure for purchases of materials, parts components and selection of sub-Bidders services including vendor analysis, source inspection, incoming raw material inspection, verification of material purchases etc. System for shop manufacturing and site erection controls including process controls and fabrication and assembly control; Control of non-conforming items and system for corrective actions; Inspection and test procedure both for manufacture and field activities. Control of calibration and testing of measuring instruments and field activities; System for indication and appraisal of inspection status; System for quality audits; System for authorising release of manufactured product to the Purcahser. System for maintenance of records; 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.
(b) Documentation control system; (c) (d)
(e) (f) (g) (h) (i) (j) (k) (l) (n)
(m) System for handling storage and delivery; and
The HVPNL or his duly authorised representative reserves the right to carry out quality audit and quality surveillance of the system and procedure of the Bidder/his vendors quality management and control activities. 8.2 Quality Assurance Documents The Bidder would be required to submit all the Quality Assurance Documents as stipulated in the Quality Plan at the time of HVPNLs inspection of equipment/material
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9.0 9.1
TYPE TESTING, INSPECTION, TESTING & INSPECTION CERTIFICATE All equipment being supplied shall conform to type tests including additional type tests as per technical specification and shall be subject to routine tests in accordance with requirements stipulated under respective sections. HVPNL reserves the right to witness any or all the type tests. The Bidder shall intimate the HVPNL the detailed program about the tests at least three (3) weeks in advance in case of domestic supplies & six (6) weeks in advance in case of foreign supplies. The reports for all type tests and additional type tests as per technical specification shall be furnished by the Bidder along with equipment /material drawings. The type tests conducted earlier should have either been conducted in accredited laboratory (accredited based on ISO / IEC Guide 25 / 17025 or EN 45001 by the national accredition body of the country where laboratory is located) or witnessed by the representative(s) of HVPNL or Utility. The test reports submitted shall be of the tests conducted within last 7 (Seven) years prior to the date of bid opening. In case the test reports are of the test conducted earlier than 7 (Seven) years prior to the date of bid opening, the Bidder shall repeat these test(s) at no extra cost to the HVPNL. 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 additional type tests not carried out, same shall be carried out without any additional cost implication to the HVPNL.
9.2
9.3
The HVPNL intends to repeat the type tests and additional type tests on transformers for which test charges shall be payable as per provision of contract. The price of conducting type tests and additional type tests shall be included in Bid price 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. For outdoor receptacles, trefoil clamps, diesel engine, alternator, motors, cable glands and junction boxes, type testing and type test reports as per relevant standard shall be submitted for HVPNLs approval.
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9.4
The HVPNL, his duly authorised representative and/or outside inspection agency acting on behalf of the HVPNL shall have at all reasonable times free access to the Bidders/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 Bidder shall obtain for the Engineer and for his duly authorised representative permission to inspect as if the works were manufactured or assembled on the Bidders own premises or works. Inspection may be made at any stage of manufacture, despatch or at site at the option of the HVPNL and the equipment if found unsatisfactory due to bad workmanship or quality, material is liable to be rejected. The Bidder shall give the HVPNL /Inspector thirty (30) days written notice of any material being ready for joint testing including Bidder and HVPNL. Such tests shall be to the Bidders account except for the expenses of the Inspector. The HVPNL /inspector, unless witnessing of the tests is virtually waived, will attend such tests within thirty (30) days of the date of which the equipment is notified as being ready for test/inspection. The HVPNL or Inspector shall, within fifteen (15) days from the date of inspection as defined herein give notice in writing to the Bidder, 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 Bidder 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 HVPNL /Inspector giving reasons therein, that no modifications are necessary to comply with the Contract. When the factory tests have been completed at the Bidders or Sub-Bidders works, the HVPNL/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 HVPNL /Inspector, the certificate shall be issued within fifteen (15) days of receipt of the Bidders Test certificate by the HVPNL/Inspector. The completion of these tests or the issue of the certificate shall not bind the HVPNL to accept the equipment should, it, on further tests after erection, be found not to comply with the Contract. The equipment shall be dispatched to site only after approval of test reports and issuance of Despatch Instruction by the HVPNL .
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9.5
9.6
9.7
9.8
9.9
In all cases where the Contract provides for tests whether at the premises or at the works of the Bidder or of any Sub-Bidder, the Bidder 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 HVPNL /Inspector or his authorised representative to carry out effectively such tests of the equipment in accordance with the Contract and shall give facilities to the HVPNL /Inspector or to his authorised representative to accomplish testing. The inspection by HVPNL and issue of Inspection Certificate thereon shall in no way limit the liabilities and responsibilities of the Bidder in respect of the agreed quality assurance programme forming a part of the Contract. The HVPNL will have the right of having at his own expenses any other test(s) of reasonable nature carried out at Bidders 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. The HVPNL 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 HVPNL. TESTS 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 HVPNL and the Bidder for correctness and completeness of installation and acceptability for charging, leading to initial pre-commissioning tests at Site. The list of pre-commissioning tests to be performed shall be included in the Bidders quality assurance programme.
9.10
9.11
10. 10.1
10.2 Commissioning Tests 10.2.1 The testing equipments required for testing and commissioning shall be arranged by the Bidder. 10.2.2 The specific tests requirement on equipment shall be included in quality assurance program. 10.2.3 The Bidder 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 HVPNL on production of requisite documents.
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11.0 11.1
PACKAGING & PROTECTION 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 HVPNL, the Bidder shall also submit packing details/associated drawing for any equipment/material under his scope of supply, to facilitate the HVPNL 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 Bidder 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 Bidder. HVPNL takes no responsibility of the availability of the wagons. All coated surfaces shall be protected against abrasion, impact, discolouration 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 pipings and conduit equipment connections shall be properly sealed with suitable devices to protect them from damage. FINISHING OF METAL SURFACES 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
12.0 12.1
12.2
HOT DIP GALVANISING
12.2.1 The minimum weight of the zinc coating shall be 610 gm/sq. m and minimum thickness of coating shall be 85 microns for all items thicker than 6mm. For items lower than 6mm thickness requirement of coating thickness shall be as per relevant Standard/Specification. For surface which shall be embedded in concrete, the zinc coating shall be 610 gm/sq. m minimum. 12.2.2 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 presence of any of these defects noticed on visual or microscopic inspection shall render the material liable to rejection.
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12.2.3
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. The galvanized steel shall be subjected to six one minute dips in copper sulphate solution as per IS-2633. 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
12.2.4 12.2.5
12.2.6
Galvanised material must be transported properly to ensure that galvanised surfaces are not damaged during transit. Application of zinc rich paint at site shall not be allowed. PAINTING 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. 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. 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.
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12.3 12.3.1
12.3.2
12.3.3
12.3.4
The exterior colour of the paint shall be as per shade no: 631 (for outdoor) & 631 (for indoor) of IS-5 and inside shall be glossy white for all equipment, marshalling boxes, junction boxes, control cabinets, panels etc. unless specifically mentioned under respective sections of the equipments. 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. 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 Bids for HVPNLs review & approval. The colour scheme as given below shall be followed for Fire Protection and Air Conditioning systems S.No. PIPE LINE Fire Protection System 1 Hydrant and Emulsifier system pipeline 2 Emulsifier system detection line - water 3 Emulsifier system detection line -Air 4 Pylon support pipes Air Conditioning System 5 Refrigerant gas pipeline - at compressor suction 6 Refrigerant gas pipeline - at compressor discharge 7 Refrigerant liquid pipeline 8 9 Chilled water pipeline Condenser water pipeline Base colour Band colour Sea Green Sky Blue
12.3.5
12.3.6
FIRE RED FIRE RED FIRE RED FIRE RED Canary Yellow Canary Yellow Dark Admiralty Green Sea Green Sea Green
Red Dark Blue
The direction of flow shall be marked by
(arrow) in black colour.
Base Colour Direction of flow Band Colour

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13.0 13.1
HANDLING, STORING AND INSTALLATION In accordance with the specific installation instructions as shown on manufacturers drawings or as directed by the HVPNL or his representative, the Bidder 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. Bidder may engage manufacturers Engineers to supervise the unloading, transportation to site, storing, testing and commissioning of the various equipment being procured by them separately. Bidder shall unload, transport, store, erect, test and commission the equipment as per instructions of the manufacturers supervisory Engineer(s) and shall extend full cooperation to them. In case of any doubt/misunderstanding as to the correct interpretation of manufacturers drawings or instructions, necessary clarifications shall be obtained from the HVPNL. Bidder shall be held responsible for any damage to the equipment consequent to not following manufacturers drawings/instructions correctly. Where assemblies are supplied in more than one section, Bidder shall make all necessary mechanical and electrical connections between sections including the connection between buses. Bidder 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 Bidder at his own expense. Bidder shall be responsible for examining all the shipment and notify the HVPNL immediately of any damage, shortage, discrepancy etc. for the purpose of HVPNLs information only. The Bidder shall submit to the HVPNL every week a report detailing all the receipts during the weeks. However, the Bidder 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 Bidder.
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13.2
13.3
13.4
13.5
13.6
The Bidder shall be fully responsible for the equipment/material until the same is handed over to the HVPNL in an operating condition after commissioning. Bidder shall be responsible for the maintenance of the equipment/material while in storage as well as after erection until taken over by HVPNL, as well as protection of the same against theft, element of nature, corrosion, damages etc. Where material / equipment is unloaded by HVPNL before the Bidder arrives at site or even when he is at site, HVPNL by right can hand over the same to Bidder and there upon it will be the responsibility of Bidder to store the material in an orderly and proper manner. The Bidder shall be responsible for making suitable indoor storage facilities, to store all equipment which require indoor storage. The words erection and installation used in the specification are synonymous. Exposed live parts shall be placed high enough above ground to meet the requirements of electrical and other statutory safety codes. 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 4.7.1 the Bidder shall immediately proceed to correct the discrepancy at his risks and cost. 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 HVPNL. 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.
13.7
13.8 13.9 13.10 13.11
13.12
14.0
TOOLS AND TACKLES The Bidder 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.
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15.0 15.1
AUXILIARY SUPPLY 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, airconditioning, 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 connection 415V 240V 220V Variation in Voltage Frequency in HZ Phase /Wire Neutral
+/- 10% +/- 10% 190V to240V
50 +/- 5% 50 +/- 5% DC
3/ 4 Wire 1/ 2 Wire -
Solidly Earthed. Solidly Earthed. Isolated 2 wire System
48V
DC
2 wire system (+) earthed
Combined variation of voltage and frequency shall be limited to +/- 10%. 16.0 16.1 SUPPORT STRUCTURE HVPNL has standardized the design of support structure and other control dimensions as given in standard structural (design) drawings enclosed with Section-Project. The Bidder shall strictly adhere to these dimensions. The Bidder is required to supply standard structures of various equipment. Bidder may also refer relevant Clauses of Section (Structure) in this regard. All brackets, angels, stool or other members necessary for attaching the operating mechanism to the supporting structure shall be engineered and supplied by the Bidder. The Support structures for all equipments shall be supplied by the Bidder. The support structures should be hot dip galvanised with minimum 610 gram/sq.m net of zinc.
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16.2
16.3
In case of any deviation in this regard the bid is liable to be considered technically non responsive and shall be liable to be rejected. Support structure shall meet the following mandatory requirements : 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. CLAMPS AND CONNECTORS INCLUDING TERMINAL CONNECTORS 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 terminals made of copper with ACSR conductors c) For connecting G.I wire Bimetallic connectors made from aluminum alloy casting, conforming to designation A6 of IS 617 with 2mm thick bimetallic liner and all test shall conform to IS:617 Galvanised mild steel shield i) Electrogalvanised for sizes below M12, for others hot dip galvanised.
16.4 16.4.1
17.0 17.1
d) i) Bolts, nuts & Plain, washers ii) Spring washers for items a to c
17.2
Electro-galvanised mild steel suitable for atleast service condition-3 as per IS:1573 Each equipment shall be supplied with the necessary terminals and connectors, as required by the ultimate design for the particular installation. The conductor terminations of equipment shall be either expansion, sliding or rigid type suitable for single/twin Tarantulla Conductor. The requirement regarding external corona and RIV as
ii)
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specified for any equipment shall include its terminal fittings and the equipment shall be factory tested with the connectors in position. 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. The design details of the joint shall be furnished to the HVPNL by the Bidder. 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. No current carrying part of any clamp shall be less than 10 mm thick. All ferrous parts shall be hot dip galvanised. Copper alloy liner of minimum 2 mm thickness shall be cast integral with aluminum body for Bi-metallic clamps. All casting shall be free from blow holes, surface blisters, cracks and cavities. All sharp edges and corners shall be blurred and rounded off. 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. 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. All current carrying parts shall be designed and manufactured to have minimum contact resistance. 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 on three samples of similar type shall be submitted for approval as per clause 9.2 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 five years shall not be applicable). i) ii) Temperature rise test (maximum temperature rise allowed is 35C over 50C ambient) Short time current test
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17.4
17.5
17.6 17.7
17.8
17.9 17.10 17.10.1
iii) 18.0 18.1
Resistance test and tensile test
CONTROL CABINETS, JUNCTION BOXES, TERMINAL BOXES & MARSHALLING BOXES FOR OUTDOOR EQUIPMENT All types of boxes, cabinets etc. shall generally conform to & be tested in accordance with IS-5039/IS-8623, IEC-439, as applicable, and the clauses given below: 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 at least 2.0 mm thick cold rolled or 2.5 mm hot rolled. 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. Cabinet/boxes shall be free standing floor mounting type, wall mounting type or pedestal mounting type as per requirements. A canopy and sealing arrangements for operating rods shall be provided in marshalling boxes / Control cabinets to prevent ingress of rain water. 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. All doors, removable covers and plates shall be gasketed all around with suitably profiled EPDM gaskets. The gasket shall be tested in accordance with approved quality plan. The quality of gasket shall be such that it does not get damaged/cracked during the ten years of operation of the equipment or its major overhaul whichever is earlier. All gasketed surfaces shall be smooth straight and reinforced if necessary to minimize distortion and to make a tight seal. Ventilating Louvers, if provided, shall have screen and filters. The screen shall be fine wire mesh made of brass. All boxes/cabinets shall be designed for the entry of cables from bottom by means of weather proof and dust-proof connnections. 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.
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18.2
18.3
18.4
18.5
18.6
Suitable cable gland plate projecting at least 150 mm 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. The gland shall project at least 25mm above gland plate to prevent entry of moisture in cable crutch. Gland plate shall have 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. For illumination of a 20 Watts flourscent tube or 15 watts CFL shall be provided. The switching of the fittings shall be controlled by the door switch. All control switches shall be of rotary switch type and Toggle/piano switches shall not be accepted. 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. 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. a) The following routine tests alongwith the routine tests as per IS:5039 shall also be conducted: i) ii) b) Check for wiring Visual and dimension check
18.8
18.9 18.10
18.11
18.12
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. (Applicable for isolators and circuit
19.0
Auxiliary Switches breakers)
The following type test reports on auxiliary switches shall be submitted for approval: (a) Electrical endurance test - A minimum of 2000 operation for 2A D. C. with a time constant greater than or equal to 20
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millisecond with a subsequent examination of mV drop/visual defects/temperature rise test. (b) Mechanical endurance test. A minimum of 1,00,000 operations with a subsequent checking of contact pressure test/visual examination. Heat run test on contacts.
(c) 20.0 20.1
(d) IR/HV test etc. TERMINAL BLOCKS AND WIRING 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. Terminal blocks shall be 650 V grade and have continuous rating to carry the maximum expected current on the terminals. 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 terminal blocks shall be nondisconnecting stud type equivalent to Elmex type CATM4, Phoenix cage clamp type of Wago or equivalent. 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. 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. 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. The terminal blocks shall be of extensible design. The terminal blocks shall have locking arrangement to prevent its escape from the mounting rails. 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.
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20.2
20.3
20.4
20.5
20.6 20.7 20.8
20.9
Unless otherwise specified terminal blocks shall be connecting the following conductors on each side. a) All circuits except CT,PT,Aux AC, DC circuits b) All CT, PT, Aux AC,DC circuits
suitable for
Minimum of two of 2.5 sq mm copper flexible. Minimum of 2 nos. of 4 sq mm copper flexible.
20.10
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. Atleast 20 % spare terminals shall be provided on each panel/cubicle/box and these spare terminals shall be uniformly distributed on all terminals rows. There shall be a minimum clearance of 250 mm between the First/bottom row of terminal block and the associated cable gland plate. Also the clearance between two rows of terminal blocks shall be a minimum of 150 mm. The Bidder shall furnish all wire, conduits and terminals for the necessary inter phase electrical connections (where applicable) as well as between phases and common terminal boxes or control cabinets. 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 Bidder 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 LAMPS AND SOCKETS Lamps All incandescent lamps shall use a socket base as per IS-1258, except in the case of signal lamps.
20.11
20.12
20.13
20.14
21.0 21.1
21.2
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.
21.3
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.
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21.4 21.4.1
Switches and Fuses: 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 switchfuse 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. 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. Bushings, Hollow Column Insulators, Support Insulators: Bushings shall be manufactured and tested in accordance with IS: 2099 & IEC: 137 while hollow column insulators shall be manufactured and tested in accordance with IEC 233/IS 5621. The support insulators shall be manufactured and tested as per IS 2544/IEC 168 and IEC 273. The insulators shall also conform to IEC 815 as applicable. The bidder may also offer composite silicon insulator, conforming to IEC-1109.
21.4.2
22.0 22.1
22.2
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 imperfections that might affect the mechanical or dielectric quality and shall be thoroughly vitrified tough and impervious to moisture. Glazing of the porcelain shall be uniform brown in colour, free from blisters, burrs and similar other defects. 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. When operating at normal rated voltage there shall be no electric discharge between the conductors and bushing which would cause corrsion or injury to conductors, insulators or supports by the
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22.3 22.4
22.5
formation of substances produced by chemical action. No radio interference shall be caused by the insulators/bushings when operating at the normal rated voltage. 22.6 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. 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. Tests In bushing, hollow column insulators and support insulataors shall conform to type tests and shall be subjected to routine tests in accordance with IS: 2099 & IS: 2544 & IS : 5621. The type test reports shall be submitted for approval. 23.0 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. 23.1 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. Two independent earthing points shall be provided on opposite sides of the motor for bolted connection of earthing conductor. 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.
22.7
22.8
b) c)
d) Motors weighing more than 25 Kg. shall be provided with eyebolts, lugs or other means to facilitate lifting.
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23.2
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. All induction motors shall be suitable for full voltage direct-online 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. 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. 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. 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. 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. The maximum permissible temperature rise over the ambient temperature of 50 degree C shall be within the limits specified in
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23.3
Starting Requirements: a)
b)
c)
d)
e)
23.4
Running Requirements: a)
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. 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.
c)
23.5
TESTING AND COMMISSIONING An indicative list of tests is given below. Bidder shall perform any additional test based on specialties of the items as per the field Q.P./Instructions of the equipment Bidder or HVPNL without any extra cost to the HVPNL. The Bidder shall arrange all instruments required for conducting these tests along with calibration certificates and shall furnish the list of instruments to the HVPNL for approval. (a) Insulation resistance. (b) Phase sequence and proper direction of rotation. (c) Any motor operating incorrectly shall be checked the cause and the conditions corrected. to determine
24.0 24.1
TECHNICAL REQUIREMENT OF EQUIPMENTS Circuit Breakers a. The manufacturer(s) whose SF6 Circuit Breaker are offered should have designed, manufactured tested as per IEC/IS or equivalent standard supplied the same for the specified system voltage and which are in satisfactory operation for at least 2 (two) years as on the date of bid opening. Or b. The manufacturer(s) whose SF6 Circuit Breaker are offered who have recently established production line in India for the specified system voltage or above class, based on technological support of a parent company or collaborator for the respective equipment(s) can also be considered provided the parent company (Principal) or collaborator meets qualifying requirements stipulated under clause no 24.1.a given above. And Furnishes (jointly with parent company or collaborator) a legally enforceable undertaking to guarantee quality, timely supply,
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performance equipment(s)
and
warranty
obligations And
as
specified
for
the
Furnishes a confirmation letter from the parent company or collaborator along with the bid stating that parent company or collaborator shall furnish performance guarantee for an amount of 10% of the cost of such equipment(s). This performance guarantee shall be in addition to contract performance guarantee to be submitted by the Bidder 24.2 Isolators The manufacturer whose isolators are offered, should have designed, manufactured, tested as per IEC/IS or equivalent standard and supplied the isolator for the specified system voltage and fault level and should be in satisfactory operation for at least 2 (two) years as on the date of bid opening. 24.3 Instrument Transformers The manufacturer whose instrument transformers are offered, should have designed, manufactured & tested as per IS/IEC or equivalent standard and supplied the same for the specified system voltage for NCT,CT & CVT, PT and fault level in case of NCT, CT. These equipment should be in satisfactory operation for at least 2 (two) years as on the date of bid opening. 24.4 Surge Arresters The manufacturer whose Surge Arresters are offered should have designed, manufactured and tested as per IEC/IS or equivalent standard and supplied the Surge Arrester for the specified energy capability with rated system voltage and which are in satisfactory operation for at least 2 (two) years as on the date of bid opening. 24.5 1.1 kV Grade Power & Control Cables The manufacturers, whose PVC control cables are offered, should have designed, manufactured, tested and supplied in a single contract at least 100 Kms of 1.1 kV grade PVC insulated control cables as on the date of bid opening . Further the manufacturer should also have designed, manufactured, tested and supplied at least 1 km of 16C x 2.5 Sq.mm or higher size as on the date of bid opening. 24.5.2 Applicable for PVC Power Cable The manufacturer, whose PVC Power Cables are offered, should have designed, manufactured, tested and supplied in a single contract
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24.5.1 Applicable for PVC Control Cable
at least 100 Kms of 1.1 kV or higher grade PVC insulated power cables as on the date of bid opening . Further the manufacturer should also have designed, manufactured, tested and supplied at least 1 km of 1C x 150 Sq. mm or higher size as on the date of bid opening. 24.5.3 Applicable for XLPE Power Cables The Manufacturer, whose XLPE Power cables are offered, should have designed, manufactured, tested and supplied in a single contract atleast 25 Kms of 1.1 kV or higher grade XLPE insulated power cables as on the date of bid opening . Further the manufacturer should also have designed, manufactured, tested and supplied at least 1 km of 1C x 630 Sq. mm or higher size as on the date of bid opening. 24.6 24.6.1 LT Switchgear The Manufacturer whose LT Switchgear are offered, should be a manufacturer of LT Switchboards of the type and rating being offered. He should have designed, manufactured, tested and supplied at least 50 nos. draw out circuit breaker panels, out of which at least 5 nos. should have been with relay and protection schemes with current transformer. He should have also manufactured at least 50 nos. motor control center panels of the type and rating being offered which should be in successful operation as on date of bid opening. The Switchgear items (such as circuit breakers, fuse switch units, contactors etc.), may be of his own make or shall be procured from reputed manufacturers and of proven design. At least one hundred circuit breakers of the make and type being offered shall be operating satisfactory as on date of bid opening. Battery and Battery Charger Requirements for Battery Manufacturers The manufacturer whose Batteries are offered should have designed, manufactured and supplied DC Batteries of the type specified and being offered, having a capacity of at least 600 AH and these shall be operating satisfactorily for two years in power sector and/or industrial installations as on date of bid opening. 24.7.2 Requirements for Battery Charger Manufacturers The manufacturer, whose Battery Chargers are offered, should have designed, manufactured and supplied Battery Chargers generally of the type offered, with static automatic voltage regulators and having a continuous output of at least ten (10) KW and these should be in successful as on the date of bid opening.
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24.6.2
24.7 24.7.1
24.8
LT Transformers The manufacturer, whose transformers are offered should have designed, manufactured, type tested including short circuit test as per IEC/IS or equivalent standards and supplied transformers of at least 33 kV class of 800 kVA or higher. The transformer should have been in successful operation for at least 2 years as on the date of bid opening.
24.9
Fire Fighting System The bidder or his sub-vendor should have designed, supplied, tested, erected and commissioned at least one number fire protection system of the each type described in (i), (ii) and (iii) below in installations such as power plants, substations, refineries, fertilizer plants or other industrial or commercial installations. Such systems must have been designed to the recommendations of Tariff Advisory Committee of India or any other international accredited authority like (FOC, London or NFPA, USA etc.) executed during last ten (10) years and should have been in successful operation for at least 2 years as on the date of bid opening. (i) (ii) Automatic hydrant type fire protection system Automatic high velocity or automatic medium velocity water spray type fire protection system
(iii) Smoke detection system. In case bidder himself do not meet the requirement of design, he can engage a consultant(s) who must have designed i) Automatic hydrant type fire protection system, ii) Automatic high velocity or automatic medium velocity water spray type fire protection system and iii) Smoke detection system, which must be in successful operation for at least two years as on the date of bid opening. 24.10 24.10.1 Control and Relay Panels The C&R Panels from a manufacturer who has designed, manufactured, tested, installed and commissioned C&R panels which are in satisfactory operation for at least 2 (two) years on the date of bid opening can be offered. The Bidder shall arrange C&R panels along with main relays from the same manufacturer. The manufacturer own make relays includes the relays manufactured by their Principals /Associates.
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24.11 24.11.1
PLCC The manufacturer whose PLCC panels are offered should have designed, manufactured, tested, supplied and commissioned PLCC panels for the specified voltage level and the same should be in successful operation for atleast 2 (two) years as on the date of bid opening. The manufacturer whose line traps are offered should have designed, manufactured tested, supplied and commissioned similar line traps for the specified voltage and fault level and should be successful operation for at least 2 (two) years as on the date of bid opening. PLCC Panels/line traps manufactured by the the manufacturer meeting the requirements at Clause No. 24.11.1 & 24.11.2 except that the PLCCPanels/line traps manufactured, tested and supplied by them is not in operation for the stipulated period can also be offered provided the manufacturer furnishes an undertaking jointly executed by him and his collaborator, who in turn fully meets the requirement specified at 24.11.1 / 24.11.2 above as per the format enclosed in the bid document for successful performance of the equipment offered. Operating and maintenance instructions: These instructions shall give sufficient details to enable the HVPNL to maintain, dismantle, reassemble and adjust all parts of the equipment and shall contain the following information.
table of content list of illustration introduction
24.11.2
24.11.3
25 .
the instruction shall contain: -General technical characteristics - a brief general description of the equipment and - a definition of the technical terms used in subsequent pharagraphs of the instruction book Detail description: This shall contain a complete and accurate description of the equipment, its assembly and dismantling, as well as components and accessories. An accurate list stating clearance, tolerances, temperatures, fits, etc. is required.
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Operating principles: A brief summary of the technical operating basis of the equipment, including diagrams, circuit diagrams and similar ones. Operating instructions: The instructions shall be accurate and easy to understand and shall contain the sequence of individual manipulations required for operation of the equipment, table lists and graphic presentation, should be used as far as possible for making the description understood more readily. The operating and maintenance instructions shall be written and prepared in English by the Bidder. All labels, instructions on equipment shall be written in English by the Bidder. The following information for secondary equipment (distance relays, bus bar and breaker failure relay, differential relay, pilot wire differential relay, over current relays etc) shall be given in CD-ROMs in English 1. Operating manuals 2. Maintenance and setting instructions 3. Electrical circuits 4. Soft ware required for local and remote setting, testing, tele metering and getting information from the relays. Bidder shall give 5 sets of CD-ROM for secondary and primary equipment. Testing and adjustment: The entire testing and adjustment procedure for equipment after overhauls and during operation shall be dealt with Maintenance instructions are to be divided in to three parts. 1. Preventive maintenance indicating the inspection required at regular intervals, the inspection procedure, the routine cleaning and lubricating operations, the regular safety check and similar steps. 2. Repair and adjustment, describing the inspections fitting and dismantling of parts, fault tracing as well as repair and adjustment procedure. 3. Spare parts list, containing all the necessary data for ordering spare part. 26. MONTHLY PROGRESS REPORTS For the control of the works by the HVPNL, the Bidder shall prepared detailed monthly progress reports in following form: These reports show the progress of material orders and procurement, material shipments, construction and assembly works included in the contract. It will also include but not limited to commencement dates, percentage of completion (with regards to the affected payments vs. Total contract amount excluding escalation and to the physical realisation of works) and expected completion dates. Progress reports shall show manufacture of goods and construction operations for each item of work the time work under the contract started to the anticipated completion date, there by indicating the periods during which was previously underway as well as estimated future periods of manufacture and construction operations.
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Monthly progress reports which are prepared at the end of each calendar month by the Bidder shall be submitted to the HVPNL in three (3) copies and two (2) of them shall be given to the HVPNL after approval of the regional department not later than seven (7) days after the close of the reporting period. The HVPNL has the right to withhold an amount not exceeding 1000 US$ or equivalent Rs which are calculated by using selling exchange rates of the Central Bank of India per month from the earnings of the Bidder if proper monthly progress report are not submitted to the HVPNL in due course MONTHLY PROGRESS REPORT 1 st page Bidder Sub-Bidder Contract No Bidders Site Engineering(s) name, telephone and fax number 1. Civil Engineer(s) 2. Electrical Engineer (s) 3. Supervisor(s) 4. Site test engineer(s) 5. Commissioning engineer(s) HVPNLs Control Engineer(s) name, Telephone and fax number 1. Civil Engineer: 2. Electrical Engineer Second and the following page Project Report No: Month from.......to..... CHAPTER-I CHAPTER-II a) List of letters submitted by Consortium b) List of letters send by the HVPNL c) Photocopies of minutes of meeting
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General
d) list of project submitted and stage (indicate revision) CHAPTER-III Work activity
Delivery of goods (shipped, arrived to port, At customs, arrived to side in good condition not) * Supplied by Bidder a) Local b) Foreign
Civil Works Erection Site test Overall function test
CHAPTER-IV Problem and difficulties confronted with indicating agreements and disagreements CHAPTER V Work program expected to be done next month
CHAPTER VI Monetary realization of the project and monthly monetary projection up to completion.
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ANNEXURE-A 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. 3.1 Test Methods for RIV: 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. Alternatively, RIV tests shall be in accordance with NEMA standard Publication No. 107-1964, except otherwise noted herein. 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. 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%, 115% and 130% of the specified RIV test voltage for all equipment unless otherwise specified. The specified RIV test voltage is listed in the detailed specification together with maximum permissible RIV level in micro volts.
Page - 44
3.2 3.3
3.4
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. 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 noise meter. 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 130% of RIV test voltage and maintained there for five minutes. In case corona inception does not take place at 130 %, 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%, 115% and 130%. 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. 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. In addition to photographs of the test object preferably four photographs shall be taken of the complete test assembly showing
Page - 45
3.6
4.
4.1
4.2
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 of camera shall be approved by HVPNLs inspector, after determining the best camera locations by trial energisation of test object at a voltage which results in corona. 4.3 4.4 The test to determine the visible corona extinction voltage need not be carried out simultaneously with test to determine RIV levels. 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 HVPNLs inspector if, in his opinion, it will not prejudice other test. 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) b) c) d) e) f) Background noise before and after test. Detailed procedure of application of test voltage. Measurements of RIV levels expressed in micro volts at each level. Results and observations with regard to location interference sources detected at each step. Test voltage shall be recorded when measured through 100 microvolts in each direction. and type of RIV passes
5.
Onset and extinction of visual corona for each of the four tests required shall be recorded.
Page-46-
ANNEXURE - B LIST OF SPECIFICATIONS GENERAL STANDARDS AND CODES Wherever Indian Standards have been mentioned, equivalent IEC or any other Internationally recognized standard will also be applicable. India Electricity Rules Indian Electricity Act Indian Indian Factories Act IS-5, IS-335, IS-617, IS-1448 (P1 to P 145) IS-2071 (P1 to P3) IS-12063 Colors for Ready Mixed Paints and Enamels. New Insulating Oils. Aluminium and Aluminium Alloy Ingots and Castings for General Engineering Purposes Methods of Test for Petroleum and its Products. Methods of High Voltage Testing. Classification of degrees provided by enclosures equipment. Insulation Coordination. Code of Practice for Earthing Method of Test for Specific Resistance (Resistivity) of Electrical Insulating Liquids Method of Test for Interfacial Tension of Oil against Water by the Ring Method Method of test for Power factor & Dielectric Constant of Electrical Insulating Liquids. Method for determination of electric strength of insulating oils. Guide for marking of insulated conductors. Guide for uniform system of marking & identification of conductors & apparatus terminals. Methods for Radio Interference Test on High voltage Insulators.
Page - 47-
Electricity
(Supply)
Act
of protection of electrical
IS-2165 P1:1997 P2:1983 IS-3043 IS-6103 IS-6104 IS-6262 IS-6792 IS-5578 IS-11353 -
IS-8263
IS-9224 (Part 1,2&4) IEC-60060 (Part 1 to P4) IEC 60068 IEC-60117 IEC-60156, IEC-60270, IEC-60376 IEC-60437 IEC-60507 IEC-60694 IEC-60815 IEC-60865 (P1 & P2) ANSI-C.1/NFPA.70 ANSI-C37.90A ANSI-C63.21, C63.3 C36.4ANSI-C68.1 ANSI-C76.1/EEE21 ANSI-SI-4 ANSI-Y32-2/C337.2 ANSI-Z55.11 NEMA-107T NEMA-ICS-II
Low Voltage Fuses High Voltage Test Techniques Environmental Test Graphical Symbols Method for the Determination of the Electrical Strength of Insulation Oils. Partial Discharge Measurements. Specification and Acceptance of New Sulphur Hexafloride Radio Interference Test on High Voltage Insulators. Artificial Pollution Tests on High Voltage Insulators to be used on AC Systems. Common Specification for High Voltage Switchgear & Control gear Standards. Guide for the Selection of Insulators in respect of Polluted Conditions. Short Circuit Current - Calculation of effects. National Electrical Code Guide for Surge Withstand Capability (SWC) Tests Specification for Electromagnetic Noise and Field Strength Instrumentation 10 KHz to 1 GHZ Techniquest for Dielectric Tests Standard General Requirements and Test Procedure for Outdoor Apparatus Bushings. Specification for Sound Level Metres Drawing Symbols Gray Finishes for Industrial Apparatus and Equipment No. 61 Light Gray Methods of Measurements of RIV of High Voltage Apparatus General Standards for Industrial Control and Systems Part ICSI-109
Page 48-
CISPR-1
Specification for CISPR Radio Interference Measuring Apparatus for the frequency range 0.15 MHz to 30 MHz Quality Assurance Program Requirements Quality Control Program Requirements Quality Verification Program Requirements Inspection Program Requirements Code of practice for selection, installation & maintenance of Transformers (P1:1993), (P2:1991), (P3:1991) Power Transformers Dimensions for Porcelain transformer Bushings for use in lightly polluted atmospheres. Fittings and Accessories for Power Transformers Guide for Loading Transformers. Power Transformers On-Load Tap-Changers. Loading Guide for Oil - Immersed power trans formers Determination of Transformer Sound Levels General requirements for Distribution, Power and Regulating Transformers Test Code for Distribution, Regulation Transformers Power and of OIl immersed
CSA-Z299.1-1978h CSA-Z299.2-1979h CSA-Z299.3-1979h CSA-Z299.4-1979h TRANSFORMERS IS:10028 (Part 2 & 3)
IS-2026 (P1 to P4) IS-3347 (part 1 to Part 8) IS-3639 IS-6600 IEC-60076 (Part 1 to Part 5) IEC-60214 IEC- 60354 IEC-60076-10 ANSI-C571280 ANSI-C571290 ANSI-C5792
Guide for Loading Oil-Immersed Power Transformers upto and including 100 MVA with 55 deg C or 65 deg C Winding Rise
Page 49-
ANSI-CG,1EEE-4 CIRCUIT BREAKERS IEC-62271-100 IEC-60427 IEC-61264
Standard Techniques for High Voltage Testing High Voltage Breakers Alternating Current Circuit
Synthetic Testing of High Voltage alternating current circuit Breakers. Pressurized Hollow Column Insulators
CURRENT TRANSFORMERS, VOLTAGE TRANSFORMERS AND COUPLING CAPACITOR VOLTAGE TRANSFORMERS IS-2705- (P1 to P4) IS:3156- (P1 to P4) IS-4379 IEC-60044-1 IEC-60044-2 IEC-60358 IEC-60044-4 IEC-60481 ANSI-C5713 ANSIC92.2 ANSI-C93.1 BUSHING IS-2099 IEC-60137 SURGE ARRESTERS IS-3070 (PART2) Lightning arresters for alternating current systems : Metal oxide lightning arrestors without gaps. Metal oxide surge arrestors without gaps
Page 50-
Current Transformers. Voltage Transformers. Identification of the Contents of Industrial Gas Cylinders Current transformers. Voltage Transformers. Coupling capacitors and capacitor dividers. Instrument Transformes : Measurement of Partial Discharges Coupling Devices for power Line Carrier Systems. Requirements for Instrument transformers Power Line Coupling voltage Transformers Requirements for Power Line Carrier Coupling Capacitors
Bushings for Alternating 1000V
Voltages
above
Insulated Bushings for Alternating Voltages above 1000V
IEC-60099-4
IEC-60099-5 ANSI-C62.1 NEMA-LA 1

IS-722, IS-1248, IS-3231, 3231 (P-3) -
Selection and application recommendation IEE Standards for S A for AC Power Circuits Surge Arresters Electrical relays for power system protection
CUBICLES AND PANELS & OTHER RELATED EQUIPMENTS IS:5039 IEC-60068.2.2 IEC-60529 IEC-60947-4-1 IEC-61095 IEC-60439 (P1 & 2) ANSI-C37.20 ANSI-C37.50 ANSI-C39 ANSI-C83 IS: 8623: (Part I to 3) NEMA-AB NEMA-CS NEMA-PB-1 NEMA-SG-5 NEMA-SG-3 NEMA-SG-6 NEMA-5E-3 1248 (P1 to P9) Distributed pillars for Voltages not Exceeding 1000 Volts. Basic environmental testing procedures Part 2: Test B: Dry heat Degree of Protection provided by enclosures. Low voltage switchgear and control gear. Electromechanical Contactors for household and similar purposes. Low Voltage Swtichgear and control gear assemblies Switchgear Assemblies, enclosed bus. including metal
Test Procedures for Low Voltage Alternating Current Power Circuit Breakers Electric Measuring instrument Components Specification Assemblies. for Electric for Switchgear Equipment & Control
Moulded Case Circuit and Systems Industrial Controls and Systems Panel Boards Low voltage Power Circuit breakers Power Switchgear Assemblies Power switching Equipment Motor Control Centers Direct acting indicating analogue electrical measuring instruments & their accessories.
Page 51-
Disconnecting switches IEC-60129 IEC-1129 IEC-60265 (Part 1 & Part 2) ANSI-C37.32 Alternating Current Disconnectors (Isolators) and Earthing switches Alternating Current Earthing Switches Induced Current switching High Voltage switches Schedule of preferred Ratings, Manufacturing Specifications and Application Guide for high voltage Air Switches, Bus supports and switch accessories Test Code for high voltage air switches Power switching equipment Line traps for AC power system. Methods of tests for line traps. Coupling devices for PLC systems. Methods of test for coupling devices for PLC systems. Line traps for A.C. power systems. Coupling Devices for power line carrier systems. Single sideboard power line carrier terminals Planning of (single Side-Band) power line carrier systems. Teleprotection report by Committee 34 & 35. Guide on power Radio line carrier & 1979. International Consultative Committee Telephone
ANSI-C37.34 NEMA-SG6 PLCC and line traps IS-8792 IS-8793 IS-8997 IS-8998 IEC-60353 IEC-60481 IEC-60495 IEC-60683 CIGRE CIGRE CCIR CCITT EIA IEC-60051 : (P1 to P9)
International Telegraph Consultative Committee Electric Industries Association
Protection and control equipment Recommendations for Direct Acting indicating analogue electrical measuring instruments and their accessories. Electrical relays.
IEC-60255 (Part 1 to part 23) IEC-60297
Page 52-
(P1 to P4) IEC-60359 IEC-60387 IEC-60447 IEC-60521 IEC-60547
Dimensions of mechanical structures of the 482.6mm (19 inches) series. Expression of the performance of electrical & electronic measuring equipment. Symbols for Alternating-Current Electricity meters. Man machine interface (MMI) - Actuating principles. Class 0.5, 1 and 2 alternating current watt hour metres Modular plug-in Unit and standard 19-inch rack mounting unit based on NIM Standard (for electronic nuclear instruments) Screw threads Bolts and Nuts Relays, Station Controls etc. Manual and automatic station control, supervisory and associated telemetering equipment Relays and relay systems associated with electric power apparatus Requirements for electrical analog indicating instruments Three phase induction motors. Degree of protection provided by enclosure for rotating electrical machinery. Rotating electrical machines Three phase induction motors Motors and Generators
ANSI-81 ANSI-B18 ANSI-C37.1 ANSI-C37.2
ANSI-C37.2 ANSI-C39.1 MOTORS IS-325 IS-4691 IEC-60034 (P1 to P19:) IEC-Document 2 (Central Office) NEMA-MGI MIL-21B, MIL-833 & MIL-2750 IEC-60068 IEC-60326 (P1 (P1 to to
Electronic equipment and components P5) P2) Environmental : Printed testing boards
Material and workmanship standards

Page 53-
IS-1363 (P1 to P3) IS-1364 (P1 to P5) IS-3138 ISO-898 ASTM Clamps & connectors IS-5561 NEMA-CC1 NEMA-CC 3
Hexagon headbolts, screws and nuts of product grade C. Hexagon head bolts, screws and nuts of products grades A and B. Hexagonal Bolts and Nuts (M42 to M150) Fasteners: Bolts, screws and studs Specification and tests for materials Electric power connectors. Electric Power connectors for sub station Connectors for Use between aluminium or aluminum- Copper Overhead Conductors Fittings for Aluminum and steel cored Al conductors for overhead power lines. Porcelain insulators for overhead power lines with a nominal voltage greater than 1000 V. Insulator fittings for overhead power lines with a nominal voltage greater than 1000 V. Dimensions of Ball and Socket Couplings of string insulator units. Insulated bushings for alternating voltages above 1000 V. Tests on indoor and outdoor post insulators of ceramic material or glass for Systems with Nominal Voltages Greater than 1000 V. Tests on Hollow Insulators for use in electrical equipment. Characteristices of indoor and outdoor post insulators for systems with nominal voltages greater than 1000V. 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 pintype.
Bus hardware and insulators IS: 2121 IS-731 IS-2486 (P1 to P4) IEC-60120 IEC-60137 IEC-60168 -
IEC-60233 IEC-60273
IEC-60305
Page 54-
IEC-60372 (1984)
Locking devices for ball and socket couplings of string insulator units : dimensions and tests. Insulators for overhead lines with a nominal voltage above 1000 V. Characteristics of string insulator units of the long rod type. Dimensions of Clevis and tongue couplings of string insulator units. Wet process porcelain insulators Test methods for electrical power insulators For insulators, wet-process porcelain and toughened glass suspension type For wet-process apparatus, post-type Iron and steel hardware Recommendations of the CISPR, tolerances of form and of Position, Part 1 Zinc Coating (Hot-Dip) on iron and steel hardware Dimensions & tolerances for Wrought Aluminum and Aluminum Alloys drawn round tube. Wrought Aluminum and Aluminum Alloy Bars. Tubes and Sections for Electrical Rods, purposes. Aluminum purposes 1350 H19 Wire for electrical porcelain insulators
IEC-60383 (P1 and P2) IEC-60433 IEC-60471 ANSI-C29 ANSI-C29.1 ANSI-C92.2 ANSI-C29.8 ANSI-G.8 CISPR-7B ASTM A-153
Strain and rigid bus-conductor IS-2678 -
IS-5082
ASTM-B 230-82 ASTM-B 231-81 ASTM-B 221 ASTM-B 236-83
Concentric - lay - stranded, aluminum 1350 conductors Aluminum - Alloy extruded bar, road, wire, shape Aluminum bars for electrical purpose (Busbars)
Page 55-
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 IS:1652 IS:1146 IS:6071 IS:266 IS:1069 IS:3116 IS:1248 Battery Charger IS:3895 IS:4540 IS:6619 IS:2026 IS:2959 IS:1248 IS:2208 IS:13947 (Part-3) Mono-crystalline Semiconductor Rectifier Cells and Stacks Mono-crystalline Semiconductor Assemblies and Equipment. Rectifier Stationary Cells and Batteries, Lead-Acid Type (with Tubular Positive Plates) Stationary Cells and Batteries, Lead-Acid Type (with Plante Positive Plates) Rubber and Plastic Containers for Lead-Acid Storage Batteries Synthetic Separators for Lead-Acid Batteries Specification for Sulphuric Acid Specification for Water for Storage Batteries Specification for Sealing Compound for LeadAcid Batteries Indicating Instruments
Safety Code for Semiconductor Rectifier Equipment Power Transformers AC Contactors for Voltages not Exceeding 1000 Volts Indicating Instruments HRC Fuses Air break switches, air break disconnectors & fuse combination units for voltage not exceeding 1000V AC or 1200V DC Degree of protection provided by enclosures for low voltage switchgear and controlgear. Code of practice for phosphating of Iron and Steel
Page 56-
IS:2147 IS:6005
IS:3231 IS:3842 IS:5 IEEE-484
Electrical relays for power system protection Electrical relay for AC Systems Colours for ready mix paint Recommended Design for installation design and installation of large lead storage batteries for generating stations and substations. Sizing large lead storage batteries generating stations and substations for
IEEE-485 Wires and cables ASTMD-2863
Measuring the minimum oxygen concentration to support candle like combustion of plastics (oxygen index) PVC insulated cables for working voltages upto and including 1100 Volts. Code of practice for installation and maintenance of power cables, upto and including 33 kV rating 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. Aluminium Copper conductor Conductor current for in insulated insulated ratings for cables cables. cables.
IS-694 IS-1255
IS-1554 (P1 and P2)
IS:1753 IS:2982 IS-3961 (P1 to P5) IS-3975 IS-5831 IS-6380 IS-7098 -
Recommended
Mild steel wires, formed wires and tapes for armouring of cables. PVC insulating and sheath of electric cables. Elastometric insulating and sheath of electric cables. Cross linked polyethylene insulated PVC sheathed cables for working voltage upto and including 1100 volts. Cross-linked polyethyle insulated PVC sheathed cables for working voltage from 3.3kV upto and including 33 kV.
IS-7098
Page 57-
IS-8130 IS-1753 IS-10418 IEC-60096 (part 0 to p4) IEC-60183 IEC-60189 (P1 to P7) IEC-60227 (P1 to P7) IEC-60228 IEC-60230 IEC-60287 (P1 to P3) IEC-60304 IEC-60331 IEC-60332 (P1 to P3) IEC-60502 IEC-754 (P1 and P2)
Conductors for insulated electrical cables and flexible cords. Aluminum Conductors for insulated cables. Specification for drums for electric cables. Radio Frequency cables. Guide to the Selection of High Voltage Cables. Low frequency cables and wires with PVC insulation and PVC sheath. Polyvinyl Chloride insulated cables of rated voltages up to and including 450/750V. Conductors of insulated cables Impulse tests on cables and their accessories. Calculation of the continuous current rating of cables (100% load factor). Standard colours for insulation for lowfrequency cables and wires. Fire resisting characteristics of Electric cables. Tests on electric cables under fire conditions. Extruded solid dielectric insulated power cables for rated voltages from 1 kV upto to 30 kV Tests on gases evolved during combustion of electric cables. Safety code for air conditioning Safety code for Mechanical Refrigeration Standard for Positive Displacement RefrigerationCompressor and Condensing Units Shell and tube type heat exchanger Method of testing for rating of liquid coolers Refrigeration Piping Steel for general structural purposes Specification for Metal Air Dust Specification for Galvanised Steel Sheets
AIR conditioning and ventilation IS-659 IS-660 ARI:520 -
IS:4503 ASHRAE-24 ANSI-B-31.5 IS:2062 IS:655 IS:277
Page 58-
IS-737 IS-1079 IS-3588 IS-2312 BS-848 BS-6540 Part-I BS-3928
Specification for Wrought Aluminium and Aluminium Sheet & Strip Hot rolled cast Type of steel AC sheet & strip Fans Fans Specification for Electrical Axial Flow Fans Propeller Methods Ventilation Sodium Flame Test for Air Filters (Other than for Air Supply to I.C. Engines and Compressors) Method of cold DOP & hot DOP test DOP smoke penetration method Air cleaning device used in general ventilation for removing particle matter Glossary of Terms, Symbols and Units Relating to Thermal Insulation Materials. Expanded Polystyrene for Thermal Insulation Purposes Bonded Mineral Wool Evaluation of Thermal Conductivity properties by means of guarded hot plate method Standard specification for rigid preformed cellular urethane thermal insulation Centrifugal Fans Method of Performance Test for Centrifugal Fans Induction motors, three-phase Rotating electrical machines Three phase foot mounted Induction motors, dimensions of Designations of types of construction and mounting arrangements of rotating electrical machines Vertical shaft motors for pumps, dimensions of
Page 59-
Ventilation Test for
Performance
Air Filters used in Air Conditioning and General
US-PED-2098 MIL-STD-282 ASHRAE-52 IS:3069 IS:4671 IS:8183 IS:3346 ASTM-C-591-69 IS:4894 BS:848 IS:325 IS:4722 IS:1231 IS:2233
IS:2254
IS:7816 IS:4029 IS:4729 IS:4691 IS:7572 IS:2148 BS:4999 (Part-51) Galvanizing IS-209 IS-2629 IS-2633 ASTM-A-123
Guide for testing insulation resistance of rotating machines Guide for testing three phase induction motors Rotating electrical machines, vibration of, Measurement and evaluation of Degree of protection provided by enclosures for rotating electrical machinery Guide for testing single-phase a.c. motors Flame proof enclosure for electrical apparatus Noise levels
Zinc Ingot Recommended Practice galvanizing on iron and steel. for Hot-Dip
Methods for testing uniformity of coating of zinc coated articles. Specification for zinc (Hot Galvanizing) Coatings, on products Fabricated from rolled, pressed and forged steel shapes, plates, bars and strips. Zinc-coated (Galvanized) steel barbed wire Code of practice for phosphating of iron and steel. Gray finishes for industrial apparatus and equipment Steel structure painting council
ASTM-A-121-77 Painting IS-6005 ANSI-Z551 SSPEC Fire protection system
Fire protection manual issued by tariff advisory committee (TAC) of India HORIZONTAL CENTRIFUGAL PUMPS IS:1520 IS:9137 Horizontal centrifugal pumps for clear, cold and fresh water Code for acceptance test for centrifugal & axial pumps
Page 60-
IS:5120 API-610 BS:599 PTC-8.2 DIESEL ENGINES IS:10000 IS:10002
Technical requirement - Rotodynamic special purpose pumps Centrifugal pumps for general services Hydraulic Institutes Standards Methods of testing pumps Power Test Codes - Centrifugal pumps Methods of tests for internal combustion engines Specification for performance requirements for constant speed compression ignition engines for general purposes (above 20 kW) The performance of reciprocating compression ignition (Diesel) engines, utilising liquid fuel only, for general purposes Reciprocating internal combustion engines performance Dimensions tight joints Internal Codes of Association, for pipe threads where pressure are required on threads combustion engine PTC-17 Diesel Engine Manufacturers USA
BS:5514
ISO:3046 IS:554 ASME Power Test Code
PIPING VALVES & SPECIALITIES IS:636 IS:638 IS:778 IS:780 IS:901 IS:902 Non percolating flexible fire fighting delivery hose Sheet rubber jointing and rubber inserting jointing Gun metal gate, globe and check valves for general purpose Sluice valves for water works purposes (50 to 300 mm) Couplings, double male and double female instantaneous pattern for fire fighting Suction hose couplings for fire fighting purposes
Page 61-
IS:903 IS:1538 IS:1903 IS:2062 IS:2379 IS:2643 IS:2685 IS:2906 IS:3582 IS:3589
Fire hose delivery couplings branch pipe nozzles and nozzle spanner Cast iron fittings for pressure pipes for water, gas and sewage Ball valve (horizontal plunger type) including floats for water supply purposes SP for weldable structural steel Colour Code for the identification of pipelines Dimensions of pipe threads for fastening purposes Code of Practice for selection, installation and maintenance of sluice valves Sluice valves for water-works purposes (350 to 1200 mm size) Basket strainers for fire fighting purposes (cylindrical type) Electrically welded steel pipes for water, gas and sewage (150 to 2000 mm nominal diameter) Foot valves for water works purposes Unlined flax canvas hose for fire fighting Landing valves (internal hydrant) Swing check type reflex (non-return) valves Code of practice for fire extinguishing installations and equipment on premises Hydrant systems, hose reels and foam inlets Sprinkler systems Specification for cast iron gate valves Three phase induction motors Code of practice for installation maintenance of induction motors and
IS:4038 IS:4927 IS:5290 IS:5312 (Part-I) IS:5306 Part-I Part-II BS:5150 IS:325 IS:900 IS:996
MOTORS & ANNUNCIATION PANELS
Single phase small AC and universal electric motors
Page 62-
IS:1231 IS:2148 IS:2223 IS:2253
Dimensions of three phase foot mounted induction motors Flame proof enclosure of electrical apparatus Dimensions of flange mounted AC induction motors Designations for types of construction and mounting arrangements of rotating electrical machines Dimensions of vertical shaft motors for pumps Code of practice for climate proofing of electrical equipment Guide for testing three phase induction motors Degree of protection provided by enclosure for rotating electrical machinery Rotating electrical machines Measurement and evaluation of vibration of rotating electrical machines Classification of hazardous areas for electrical (Part-I) installations (Areas having gases and vapours) Designation of methods of cooling for rotating electrical machines Construction and testing of apparatus with type of protection e electrical
IS:2254 IS:3202 IS:4029 IS:4691 IS:4722 IS:4729 IS:5572
IS:6362 IS:6381 IS:7816 IS:4064 IEC DOCUMENT 2 (Control Office) 432 VDE 0530 Part I/66 IS:9224 (Part-II) IS:6875 IS:694 IS:1248
Guide for testing insulation for rotating machine Air break switches Three Phase Induction Motor Three Phase Induction Motor HRC Fuses Push Button and Control Switches PVC Insulated cables Indicating instruments
Page 63-
IS:375 IS:2147 IS:5 IS:2959 PG Test Procedures NFPA-13 NFPA-15 NFPA-12A NFPA-72E NFPA-12 IS:3034 IS:2878 IS:2171 IS:940 D.G. SET IS:10002
Auxiliary wiring & busbar markings Degree of protection Colour Relay and timers Contactors Standard for the installation of sprinkler system Standard for water spray fixed system for the fire protection Standard for Halong 1301 Fire Extinguishing System Standard on Automatic Fire Detectors Standard on Carbon dioxide extinguisher systems Fire of industrial building: CO2 (Carbon dioxide) Type Extinguisher DC (Dry Chemical Powder) type Pressurised Water Type Specification for performance requirements for constant speed compression ignition (diesel engine) for general purposes Method of tests for internal combustion engines Rotating electrical machines-specification Degree of protection provided by enclosures Permissible limit of noise levels for rotating electrical machines. Indian Explosive Act 1932 Method of Chemical Analysis of pig iron, cast iron and plain carbon and low alloy steels.
Fire Protection Manual by TAC (Latest Edition)
Electrical generating and distributing stations code of practice
IS:10000 IS:4722 IS:12063 IS:12065
Steel structures IS-228 (1992) -
Page 64-
Code of practice for use of structural steel in overhead transmission line towers. IS-802 (P1 to 3:) IS-806 IS-808 IS-814 IS-816 IS-817 Code of practice for use of steel tubes in general building construction Dimensions for hot rolled steel beam, column channel and angle sections. Covered electrodes for manual arc welding of carbon of carbon manganese steel. Code of Practice for use of metal arc welding for general construction in Mild steel Code of practice for training and testing of metal arc welders. Part 1 : Manual Metal arc welding. Code of practice for design loads (other than earthquake) for buildings and structures. Steel tubes for structural purposes. Recommended practice for radiographic examination of fusion welded butt joints in steel plates. Hexagonal head bolts, screws & nuts of products grade C. Hexagon headbolts, screws and nuts of product grades A and B. Technical supply condition for threaded steel fasteners. Methods for bend test. Method for tensile testing of steel products. Criteria for earthquake resistant design of structures. Line Pipe. Steel coil for general structural purposes. Code of practice for Radiographic testing. Single IS-1978 IS-2062 IS-2595 IS-3063 IS-3664 rectagular section spring washers for bolts, nuts and screws. Code of practice for ultrasonic pulse echo testing by contact and immersion methods.
IS-875 (P1 to P4) IS-1161 IS-1182
IS-1363 (P1 to P3) IS-1364 IS-1367 (P1 to P18) IS-1599 IS-1608 IS-1893
Page 65-
Safety code for erection of structural steel work. IS-7205 IS-9595 ANSI-B18.2.1 ANSI-B18.2.2 ANSI-G8.14 ASTM-A6 Recommendations for metal arc welding of carbon and carbon manganese steels. Inch series square and Hexagonal bolts and screws Square and hexagonal nuts Round head bolts Specification for General Requirements for rolled steel plates, shapes, sheet piling and bars of structural use Specifications of structural steel Specification for malleable iron castings Practice for safeguarding against embilement of Hot Galvanized structural steel products and procedure for detaching embrilement Specification for high strength low alloy structural steel Specification for low and intermediate tensile strength carbon steel plates of structural quality Specification for Galvanized steel transmission tower bolts and nuts Specification for High strength low alloy structural manganese vanadium steel. Specification for High strength low alloy colombium- Vanadium steel of structural quality Code for welding in building construction welding inspection Structural welding code AWS D1-0 AWS D1-1 AISC NEMA-CG1 IS-1239 (Part 1 and 2) Mild steel tubes, tubulars and other wrought steel fittings American institute of steel construction Manufactured graphite electrodes
ASTM-A36 ASTM-A47 ASTM-A143
ASTM-A242 ASTM-A283
ASTM-A394 ASTM-441 ASTM-A572
Piping and pressure vessels

Page 66-
IS-3589 IS-6392 ASME ASTM-A120
Seamless Electrically welded steel pipes for water, gas and sewage. Steel pipe flanges Boiler and pressure vessel code Specification for pipe steel, black and hot dipped, zinc-coated (Galvanized) welded and seamless steel pipe for ordinary use Specification for pipe, steel, black, and hotdipped, zinc coated welded and seamless Seamless carbon steel pipe for high temperature service Low and intermediate tensile strength carbonsilicon steel plates for machine parts and general construction. Pipe fittings of wrought carbon steel and alloy steel for moderate and elevated temperatures Specification for forgings, carbon steel for general purpose piping Forgings, carbon steel for piping components Carbon steel externally threated standard fasteners Alloy steel and stainless steel bolting materials for high temperature service Flat rolled applications electrical steel for magnetic
ASTM-A53 ASTM-A106 ASTM-A284
ASTM-A234 ASTM-S181 ASTM-A105 ASTM-A307 ASTM-A193 ASTM-A345 ASTM-A197 ANSI-B2.1 ANSI-B16.1 ANSI-B16.1 ANSI-B16.5 ANSI-B16.9 ANSI-B16.11
Cupola malleable iron Pipe threads (Except dry seal) Cast iron pipe flangesand glanged fitting. Class 25, 125, 250 and 800 Malleable iron threaded fittings, class 150 and 300 Pipe flanges and flanged fittings, steel nickel alloy and other special alloys Factory-made wrought steel butt welding fittings Forged steel fittings, threaded socket-welding and
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ANSI-B16.14 ANSI-B16.25 ANSI-B18.1.1 ANSI-B18.2.1 ANSI-B18.2.2 NSI-B18.21.1 ANSI-B18.21.2 ANSI-B31.1 ANSI-B36.10 ANSI-B36.9 Other civil works standards IS-269 IS2721 IS-278 IS-383 IS-432 (P1 and P2)
Ferrous pipe plug, bushings and locknuts with piple threads Butt welding ends Fire hose couplings screw thread. Inch series square and hexagonal bolts and screws Square and hexagonal nuts Lock washers Plain washers Power piping Welded and seamless wrought steel pipe Stainless steel pipe 43 grade ordinary steel chain port-land link fence cement. fabric
Galvanized
Galvanized steel barbed wire for fencing. Coarse and fine aggregates from natural sources for concrete. Mild steel and medium tensile steel bars and hard-dawn steel wire for concrete reinforcement. Code of practice for plain and reinforced concrete. Method of test for strength of concrete. Code of practice for general construction in steel. Steel tubes for structural purposes. Basic requirements for water supply, drainage and sanitation. Methods of sampling and analysis of concrete. Hard-dawn steel wire fabric for concrete reinforcement. Code of Practice for Building drainage. Plain hard-drawn steel wire for pre stressed concrete.
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IS-456 IS-516 IS-800 IS-806 IS-1172 IS-1199 IS-1566 IS-1742 IS-1785
IS-1786 IS-1811 IS-1893 IS-2062 IS-2064 IS-2065 IS-2090 IS-2140 IS-2470 (P1 & P2) IS-2514 IS-2645 IS-3025 (Part 1 to Part 48) IS-4091
High strength deformed Steel Bars and wires for concrete reinforcement. Methods of sampling Foundry sands. Criteria for earthquake resistant design of structures. Steel for general structural purposes. Selection, installation and maintenance of sanitary appliances-code of practices. Code of practice for water supply in buildings. High tension steel bars used in prestressed concrete. Standard Galvanized steel wire for fencing. Code of practice for installation of septic tanks. Concrete vibrating tables. Integral cement waterproofing compounds. Methods of sampling and test (Physical and chemical) for water and waste water. Code of practice for design and construction of foundations for transmission line towers and poles. Code of practice for ancillary structures in sewerage system. Plywood for concrete shuttering work. Sewage and drainage pumps. Earth Manual by United States Department of the interior Bureau of Reclamation Zinc/Coated steel chain link fence fabric test for moisture-density relation of soils using 10-lb (4.5 kg) rame land 18-in. (457 mm) Drop.
IS-4111 (Part 1 to P5) IS-4990 IS-5600 USBR E12 ASTM-A392-81 ASTM-D1557-80 -
National buiding code of India 1970
ASTM-D1586
Penetration Test and Split-Barrel
Page 69-
(1967) ASTM-D2049-69 ASTM-D2435 BS-5075 -
Sampling of Soils Relative Density of
Test Method for Cohesion less Soils
Test method for Unconsolidated, (1982) Undrained Strengths of Cohesive Soils in Triaxial Compression. Specification for accelerating Part I Admixtures, Retarding Admixtures and Water Reducing Admixtures. Latest CPWD specifications Methods for Determination of Mass of zinc coating coated Iron and Steel Articles BS:443-1969 on zinc
CPWD
ACSR MOOSE/AAC TARANTULLA CONDUCTOR IS:6745 IS:8263
Methods for Radio Interference IEC:4371973 Test on High Voltage Insulators NEMA:107-1964 CISPR Zinc Ingot BS:3436-1961 Aluminum Conductors for IEC:209-1966 Overhead Transmission Purposes EC grade Aluminium rod produced by continuous casting and rolling. Reels and Drums forBS:1559-1949 Bare Conductors Method for Tensile Testing 1959 of steel wire Recommended Hot dip and Steel. Method of coating for of ISO/R89for Iron
IS:209 IS:398 Part - V IS: 5484 IS:1778 IS:1521 IS:2629
practice Galvanising on Testing zinc Coated
IS:2633 IS:4826 IS:1841 GALVANISED STEEL EARTHWIRE
Uniformity Articles.
Hot dip galvanised coatings on round steel wires ASTMA-472-729 EC grade Aluminium rod produced by rolling.
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IS:1521 IS:1778 IS:2629 IS:2633
Method for Tensile Testing ISO/R:89-1959 of Steel Wire Reels and Drums for Bare Conductors Recommended practice forHot Dip Galvanising on Ironand Steel. Methods for testing Uniformityof Coating of Zinc Coated Articles. Hot dip Galvanised Coatings ASTM:A 47572a on Round Steel Wires BS:443-1969 Method for Determination BS:443-1969of mass of Zinc Coating on Zinc coated Iron and Steel Articles. Zinc ingot BS:3463-1961 Aluminum Conductors for BS:215 (Part-II) overhead transmission purposes. General and safety requirements for electric lighting fittings. Water Dust Dust proof proof tight electric electric proof lighting lighting electric fittings fittings lighting lighting lighting with with fittings. fittings. fittings. metal plastic
IS:4826 IS:6745
IS:209 IS:398 (Pt. I to P5:1992) Lighting Fixtures and Accessories (i) (ii) IS:1913 IS:3528
(iii) IS:4012 (iv) IS:4013 (v) IS:10322 (vi) IS:10322 (vii) IS:2206 (viii) IS:10322 (ix) IS:10322 (x) IS:10322 (xi) IS:2418 (xii) IS:9900 (xiii) IS:1258
Industrial reflectors. Industrial reflectors.
Well glass lighting fittings for use under ground in mines (non-flameproof type). Specification for flood light. Specification for decorative lighting outfits. Lumanaries for street lighting Tubular flourescent lamps High pressure mercury vapour lamps. Specification for Bayonet lamp flourescent lamp.
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(xiv) IS:3323 (xv) IS:1534 (xvi) IS:1569 (xvii)IS:2215 (xviii)IS:3324 (xix) IS:418 (xx) IS:3553 (xxi) IS:2713 (xxii)IS:280 (1) IS:9537 (2) IS:3480 (3) IS:2667 (4) IS:3837 (5) IS:4649 (6) IS:5133 (7) IS:2629 Lighting Panels (1) IS:13947 (2) IS:8828 (3) IS:5 (4) IS:2551 (5) IS:2705 (6) IS:9224 (7)IS:5082 (8)IS:8623
Bi-pin lamp holder tubular flourescent lamps. Ballasts for use in flourescent lighting fittings. (Part-I) Capacitors for use in flourescent lighting fittings. Starters for flourescent lamps. Holders for starters for tubular flourescent lamps GLS lamps Water tight electric fittings Tubular steel poles MS wire for general engg. purposes Rigid steel conduits for electrical wiring Flexible steel conduits for electrical wiring Fittings for rigid steel conduits for electrical wiring Accessories for rigid steel conduits for electrical wiring Adaptors for flexible steel conduits. Steel and Cast Iron Boxes Hot dip galvanising of Iron & Steel. LV Switchgear and Control gear(Part 1 to 5)
Conduits, Accessories and Junction Boxes
Circuit breakers for over current protection for house hold and similar installations. Ready mix paints Danger notice plates Current transformers
HRC Cartridge fuse links for voltage above 650V(Part-2)
Wrought aluminium and Al. alloys, bars, rods, tubes and sections for electrical purposes. Factory built Assemblies of Switchgear and Control Gear for voltages upto and including 1000V AC and 1200V DC. Direct Acting electrical indicating instruments
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(9)IS:1248
Electrical Installation (1) IS:1293 (2) IS:371 (3) IS:3854 (4) IS:5216 (5) IS:732 (6) IS:3043 (7) IS:3646 (8) IS:1944 (9) IS:5571 (10) IS:800 (11) IS:2633 (12) IS:6005 (13) (14) LT SWITCHGEAR IS:8623 (Part-I) IS:13947 (Part-I) IS:13947 (part-2) IS:13947 (part-3) Specification for low voltage switchgear and control gear assemblies Specification for low voltage switchgear and control gear, Part 1 General Rules Specification for low voltage switchgear and control gear, Part 2 circuit breakers. Specification for low voltage switchgear and control gear. Part 3 Switches, Disconnectors, Switch-disconnectors and fuse combination units Specification for low voltage switchgear and control gear. Part 4 Contactors and motors starters.
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3 pin plug Two to three ceiling roses Switches for domestic and similar purposes Guide for safety procedures and practices in electrical work. Code of practice for electrical wiring installation (system voltage not exceeding 650 Volts.) Code of practice for earthing. Code of practice of interior illumination part II & III. Code of practice for lighting of public through fares. Guide for selection of electrical equipment for hazardous areas. Code of practice for use of structural steel in general building construction. Methods of Testing uniformity of coating on zinc coated articles. Code of practice for phosphating iron and steel. INDIAN ELECTRICITY ACT INDIAN ELECTRICITY RULES
IS:13947 (part-4)
IS:13947 (part-5)
Specification for low voltage switchgear and control gear. Part 5 Control-circuit devices and switching elements Specification for low voltage switchgear and control gear. Part 6 Multiple function switching devices. Specification for low voltage switchgear and control gear. Part 7 Ancillary equipments Degree of protection provided by enclosures Current Transformers Voltage Transformers Electrical relays for power system protection Electrical indicating instruments AC Electricity meters Guide for Marking of apparatus terminals of insulated conductors
IS:13947 (part-6)
IS:13947 (part-7)
IS:12063 IS:2705 IS:3156 IS:3231 IS:1248 IS:722 IS:5578 IS:13703 (part 1) IS:13703 (part 2)
Low voltage fuses for voltage not exceeding 1000V AC or 1500V DC Part 1 General Requirements Low voltage fuses for voltage not exceeding 1000V AC or 1500V DC Part 2 Fuses for use of authorized persons Code of practice of phosphating iron and steel Wrought Aluminum and Aluminum alloys for electrical purposes Hot dip galvanizing
IS:6005 IS:5082 IS:2633
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SECTION-3 CHAPTER-1 TECHNICAL SPECIFICATION FOR 20/25 MVA 132/33kV POWER TRANSFORMERS 1.00 SCOPE: a) This specification covers the Design, Engineering, manufacture, testing, supply on CIP basis, transportation to site, insurance, storage, testing and commissioning of 20/25 MVA 132/33 kV Power Transformers. All drawings, schedules and annexures appended to this specification shall form part of the specification and supplement the requirements specified. The equipment/materials offered by the Bidder shall be complete in all respects and, whether called for specifically or not, all accessories, hardware and services required for normal satisfactory operation of the system shall be deemed to be included in unit rates quoted. Design and manufacture shall also be such that equipment/ accessories of the same type and rating would be interchangeable. Specific reference in this specification and documents to any material by trade name, make or catalogue number shall be construed as establishing standard of quality and performance and not as limiting competition. All equipment/ accessories offered shall also be of proven design and manufacture. The make of all accessories and hardware shall be subject to purchasers approval. 2.00 CODES & STANDARDS: All standards, specifications and codes of practice referred to herein shall be the latest editions including all applicable official amendments and revisions as on date of opening of bid. The following standards and codes shall be applicable: IS:5 IS:325 IS:335 IS:375 IS:1866 IS:2026 &IEC:76 IS:2099 & 3347 IS:2147 IS:2705 IS:3637 IS:3639 Degree of protection provided by enclosures for low voltage switchgear & control gear. Current transformer Gas operated relay. Fittings and accessories for Power Transformers.
1
b)
Colour for ready mix paints. Three phase induction motors. New insulating oils for transformer. Marking & arrangement of Switch-gear bus bars main connections and auxiliary wiring. Code of practice for maintenance of insulation oil Specification for Power Transformers. Bushing for alternating voltages above 1000 volts
BS:148/IEC-296
IS:6600 &IEC-354 IS:8468 &IEC:214 IS:5561 IS:617 IS:2629 IS:8478 IS:8603
Guide for loading of oil immersed transformers. On load tap changer. Electric power connectors. Aluminium Alloy grade. Recommended practice for hot-dip Galvanising. On load tap changer application guide. Dimensions for porcelain transformer bushings for use in heavily polluted atmosphere(36 kV Class). Dimensions for oil filled porcelain transformer bushings for use in medium polluted atmosphere. Guide for sampling and analysis of free and dissolved gas in oil filled equipment. Code of practice for selection, installation and transformers. Dimensions for OIP insulated condenser bushings. Manual on transformer. maintenance of
IS:9434 IS:10028 IS:12676 CBIP
Equipment complying with other internationally accepted standards will also be considered if these ensure performance and constructional features equivalent or superior to standards listed above. In such a case the Bidder shall clearly indicate the standards adopted, furnish a copy in English of the latest revision of standard alongwith copies of all official amendments and revisions in force as on date of opening of bid and clearly bring out the salient features for comparison. 3.0 CLIMATIC CONDITIONS: The transformers are required to operate satisfactorily under the following site conditions: 3.1 Max. temperature 50 C 3.2 Min. temperature -2.5 C 3.3 Max. relative humidity 100% 3.4 Min. relative humidity 26 % 3.5 Average number of rainy days per annum Nearly120 days 3.6 Average annual rain fall 900mm 3.7 Average number of dust storm days per annum. 35 3.8 Isoceraunic level 45 3.9 Max. Wind pressures 195 kg/sqmt. 3.10 Altitude above mean sea level Less than 1000 mt. 4.0 TYPE AND RATING : 4.1 The transformer shall be of two winding, 3 phase oil immersed core type with ONAN/ONAF cooling suitable for outdoor service as step down transformers. The transformer shall not be provided with the tertiary delta winding.
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4.2 4.2.1
The ratings and other characteristics which are not covered elsewhere shall be, as detailed in following clauses: Max. Continuous capacity: a) b) ONAN ONAF 20 MVA 25 MVA 3 50 Hz (5%)
4.2.2 4.2.3 4.2.4
Number of phases Frequency Rated Voltage : a) b) HV side LV side HV side LV side
132kV 33kV Star Star YYO 10% at 25 MVA base 132 kV 550 kV 230 kV (rms) 650 kV 275 kV (rms) 33 kV 170kV 70 kV (rms) 170kV 70 kV (rms)
4.2.5
Connections : a) b)
4.2.6 4.2.7 4.2.8 4.2.9
Vector group %age Impedance
ON load taps on HV side +5% to -15% in steps of 1.25% each a) i) ii) b) i) ii) Insulation level Lighting withstand Power frequency withstand voltage Insulation level of Bushings Lighting Impulse voltage Power frequency voltage
4.2 10 Total Creepage Distance : a) b) 5. 5.1 Total: 25mm per kV corresponding to highest system voltage i.e. 145 kV, 36 kV, 12 kV. Protected: 50% of the total Creepage distance
GENERAL DESIGN OF TRANSFORMER: The transformer and accessories shall be so designed as to facilitate inspection, cleaning and repairs. The requirement of Indian Electricity Rules shall be kept in view. The design shall ensure satisfactory operation under severe working conditions due to fluctuating load of steel furnaces and voltage variations in the system including
-3-
5.2
those, due to short circuits. The transformers shall be designed as to minimize the risk of accidental short circuits caused by animals, birds or vermins. The design shall incorporate every reasonable precaution and provision for the safety of all those concerned in the operation and maintenance of the equipment keeping in the view the requirement of Indian Electricity Board. 5.3 All material used shall be of the best quality and of class most suitable for working under specified conditions and shall withstand the atmospheric conditions and temperature variations without undue deterioration or distortion or setting up of undue stress in any part thereof. Cast iron shall not be used for any parts other than the radiator valve bodies. Corresponding parts liable to replace shall be interchangeable. All taper pins to be used in the mechanism shall be split types as per latest edition of IS: 2393. All mechanism should be rust and corrosion proof. lubrication of moving parts not immersed in oil. Means shall be provided for
5.4 5.5 5.6 5.7 5.8 5.9
The construction shall be such as to avoid air or water pockets. Special care shall be exercised to reduce noise and vibration to the minimum level. Steel bolts of suitable finish will be used for diameters above 6mm. Brass bolts or studs used for electrical connections shall not be of less than 6mm dia. On outdoor equipment, all bolts, nuts & washers in contact with current carrying non-ferrous parts shall be phosphor bronze: All nuts bolts and pins shall be locked except those which are external to the transformer. If bolts and nuts are so placed as to be inaccessible by means of ordinary spanners, suitable special spanners shall be provided by the supplier. Labels shall be provided for all apparatus like relays, switches, fuses, etc. housed in any cubicle or marshaling kiosks. These shall be of incorrodible material with matt/satin finish and permanent lettering. Labels mounted on black surface shall have white letters & danger notices shall have red lettering on a white background. The labels shall be secured by means of brass screws or rust protected steel screws. Surface in contact with oil shall not be galvanized or cadmium plated. Before painting, all ungalvanised parts shall be cleaned made free from rust, scale and grease and external rough surfaces smoothened filled with metal deposition. The interior of the tank and other oil filled chambers shall be cleaned by shot blasting or any other suitable method. All external surfaces shall be given three coats of paints except for nuts, bolts and washers which may be given one coat after erection. The final coat shall be a glossy oil and weather proof, non-fading paints of shade 631 of IS:5. The interior of mechanism chambers and kiosks shall be given 3 coats of paint, the final coat being of a light coloured anti-condensation mixture. LOCKING OF OUTER RADIAL SPACERS :The outer most radial spacers of the winding shall be locked in position by means of vertical strips so that the same can not fall off/got displaced.
5.10
5.11
5.12 5.13
5.14
5.15 5.16
5.17
TIGHTENING OF THE NUTS OF THE COIL CLAMPING BOLTS :The proper & complete tightening of the nuts of the coil clamping bolts must be ensured by the manufacturers. The tightening of the nuts to the designed value and
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that the nuts of all the coils clamping bolts are tightened to same extent, should be carried out with torque spanners. The devices used for locking the nuts of coil clamping bolts must be of such a quality and such care should be taken first in tightening the nuts and next in locking them in position that the arrangement does not work loose due to vibrations caused by short circuits and fluctuating loads etc. 5.18 5.19 6. The noise level shall not be more than 5db above NEMA standard publication TR-1. The transformers shall be designed to have short circuit rating of two seconds as per ISS-2026. INSULATING OIL:Sufficient insulating oil of Napthenic type (made from Naphthenic crude) in which paraffinic content should be less than 50% and aromatic content 4 to 12% conforming to BS: 148/IEC:296 class-1 shall be supplied for first filling of each transformer. Particular attention shall be paid to deliver the oil at site free from moisture and of uniform quality through out in non-returnable steels drums. The quantity of oil for first filling of each transformer shall be stated in tender along-with trade mark of the oil to be supplied. Use of inhibitors in oil shall not be resorted to. 10% extra oil of the total quantity of oil shall be supplied along with the transformer. LIMIT OF TEMPERATURE RISE:With the above climatic conditions given in clause-3 each transformer shall be capable of operating continuously on any tap at their normal rating without exceeding the following temperature rises (i) (ii) (iii) (iv) 7.2 50 deg C in oil by thermometer 55 deg C in winding by resistance Winding Gradient i.e the difference between average winding average oil temperature not to exceed 13 deg C. Temperature of hot spot in windings not to exceed 98 deg C when calculated over max annual weighted average temperature of 32 deg C.
7. 7.1
The limits of temperature rise mentioned above will have to be satisfied by the manufacturer by carrying out the heat run test at the lowest negative tap. This test shall be carried out by feeding 1.1 times the total losses at 75 deg C at highest current tap. OVERLOAD CAPACITY & CONTINOUS RATING The safe overload capacity of the transformer and the duration of overload under maximum temperature conditions without any damage to the winding or harmful effects on the insulation shall be clearly stated in the tender which must be asper IEC354/IS6600,guide for loading of oil immersed transformer.
7.3
8.0
IMPEDANCE The transformer shall have 10% impedance on 25 MVA base respectively with tolerance as per IS:2026/Part-I(1983). Impedance shall include positive and zero sequence and shall be expressed in terms of the branches of star connected equivalent diagram, all on the same kVA base and range shall be given for each branch of the equivalent circuit in turn.
9.0
FREQUENCY:The transformer shall be suitable for continuous operation with a 5% frequency

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variation from a normal of 50 HZ without exceeding the temperature rise as specified in clause-7.1 above. 10.0 10.1 10.2 10.3 FLUX DENSITY, CORE CONSTRUCTION and INSPECTION The transformer should be so designed that the working flux density should not exceed 1.57 Tesla at normal voltage, frequency. Tenders with higher flux density than specified limit shall not be considered. The core shall be built up with thin laminations of high grade. non-ageing, low loss, high permeability cold rolled super grain oriented silicon steel. Known as MOH High B Grade or superior grade CRGO steels of maximum 0.27 mm or low lamination thickness especially suitable for transformer core.
10.4(a) (i)Bidder should have in house core cutting facility for proper monitoring & control on quality and also to avoid any possibility of mixing of prime material with defective/second grade material. The purchaser may witness the core-cutting operation. In case the in house core cutting facility for core cutting is not available then the same shall be carried out in the presence of the representative of HVPN. (ii)Inspection call notice for the purpose should be accompanied with the following documents as applicable as a proof toward use of Prime core materials :a) Invoice of supplier. b) Mills test certificates. c) Packing list. d) Bill of loading. e) Bill of entry certificates by customs. Core material shall be directly procured either from the manufacturer or through their accredited marketing organisation of repute and not through any agent. 10.4(b) After being sheared, the laminations shall be treated to remove all burrs. They shall be coated with a baked enamel insulation coating. The insulation shall be inert to the action of hot transformer oil and shall be perfectly adhesive. Paper and varnish insulation shall not be accepted. Particulars of proposed insulation shall be stated in the tender. Laminations shall be checked for burrs during stage inspection. 10.5 The core shall be rigidly clamped and/or bolted to ensure adequate mechanical strength and to prevent vibrations during operation. The bolts used in the assembly of the core shall be suitably insulated and the clamping structure shall be constructed that the eddy currents will be minimum. Construction of the core shall be such that number of steps in the limb and yoke shall be matching and dimensionally identical to minimize the effect of cross fluxing and better mechanical strength. The core shall be provided with Lugs suitable for lifting the complete core and coil assembly of transformer. The Core & coil shall be fixed in the tank such that its shifting will not occur when the transformer in moved or when a short circuit occurs. The design of magnetic circuit shall be such as to avoid static discharge development of short circuit paths within itself or to the earthing clamping structure and the production of flux components at right angles to the plane of the lamination which may cause local heating.
10.6
10.7
10.8
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10.9
Every care shall be exercised in the selection treatment and handling of core steel to ensure that the laminations are flat and that finally assembled core is free from distortions. The supporting frame work of the core shall be so designed as to avoid the presence of pockets which would prevent complete emptying of the tank through the drain valve or cause trapping of air during filling. Oil ducts where necessary should be formed across the plane of the lamination and be given a suitable slope to assist oil circulation. The overall design of core and winding should be such that free flow of oil is not obstructed. The frame work and clamping arrangement shall be earthed by connecting to the tank body through a copper strip. Yoke bolt area should be compensated if bolts are used for fastening of the core. The insulation of core to bolts and core to clamp plates shall be able to withstand a voltage of 2 KV RMS for one minute. Core and windings shall be capable of withstanding shocks during transport, installation, service and adequate provision shall be made to prevent movement of core and winding relative to tank during these conditions. All steel sections used for supporting the core shall be thoroughly sand blasted after cutting drilling and welding. CRGO used shall be strictly as per approved vendor as below:a) Nippon Steel Corp.Japan b) Kawasaki Corp. Ltd.,Japan
10.10
10.11
10.12
10.13
10.14
10.15
10.16
10.17 The tenderers should indicate the maximum flux density allowable continuously as well as for time intervals of 1 minute and 5 secs. and the limit of flux density at which core material used by them saturates. 10.18 The name of the core material must be mentioned in the tender. The successful tenderer shall be required to furnish magnetization curves of the core material/design calculations and such other data/documents deemed fit by the Purchaser for being satisfied that flux density is as desired.
10.19 Purchaser shall inspect the built-up core for verification of flux density for which all facilities shall be provided. The purchaser shall inspect/test the core material for various tests as per relevant IEC/IS to ensure quality. Core may also be inspected during horizontal assembly, built-up assembly. NOTES : i) The above flux density has been specified to meet with the over fluxing of the core due to temporary over voltage of the order of 31% for l min, 44%for 5 sec. that may appear abnormal conditions such as those following sudden loss of large loads. ii) iii) Yoke bolt area and flitch plate areas shall not be counted in the net core area if these are provided for fastening core. The design of limb and yoke shall be so co-ordinate that there is no cross fluxing at the joints.
-7-
11.
SUPPRESSION OF HARMONICS: The transformer shall be so designed as to suppress the harmonics voltage specially the 3rd & 5th, to eliminate wave form distortion and interference with communication circuits due to high frequency disturbances. Limiting percentage of harmonics at normal voltage and at maximum system voltage shall be stated in the tender.
12. 12.1
WINDINGS:The 132kV windings shall have graded insulation whereas all other windings shall be fully insulated and the neutral points shall be insulated as amended in IS:2026. The transformers shall be capable of operation without danger on any particular tapping at the rated kVA when the voltage may vary by 10% of the voltage corresponding to the tapping. The windings and connections, insulation material shall not soften, ooze out, shrink or collapse during service. No strip conductor wound on edge shall have a width exceeding six times its thickness. The conductors shall be transposed at sufficient intervals to minimize eddy currents and equalize the current and temperature distribution along the windings. The windings and connections shall be properly brazed to withstand shocks during transportation or transient conditions during service. The adequate pre-shrinkage of the coil assembly using pre-compressed press board material having low moisture content for the radial spacer blocks shall be ensured by the manufacturers so that there is no displacement of the radial spacer blocks due to frequent short circuits on the transformers. All windings after being wound and all fibrous hygroscopic materials used in the construction of the transformer shall be dried under vacuum and impregnated with hot oil. In addition to this the drying process be sufficiently extended for proper stabilization of the coil assembly. More than one cycle of soaking in oil followed by retightening of the coil assembly should be adopted.
12.2
12.3
12.4
12.5
12.6
12.7
12.8 12.9
The coil clamping rings wherever used, shall preferably be of flat insulated steel laminations. Auxiliary laminated material except bakelised paper shall not be used. The clamping arrangement shall exert equal pressure on all columns of spacers of the transformer windings built of sections or disc-coils separated by spacers. In no case, spiral winding will be used either for HV or LV windings.
12.10 The radial spacer blocks must be made of pre-compressed pressboard material, which will not soften while in contact with oil or fray out into fibers or edges. The slots should be so dimensioned that the blocks will not come out of the slots. Uniform distribution of coil clamping force shall be designed by using an adequately large number of coil clamping bolts and by transferring the clamping force from clamping bolts to the clamping plates through intermediate members which can spread the clamping force over a large area. 12.11 All joints shall be brazed/crimped considering the vibrations due to short circuits and load fluctuations.
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13.
CURRENT DENSITY: The purchaser shall be at liberty to inspect built-up winding for its quality, weight of copper, insulation and overall weight of coil assembly. The size of conductor used for different windings shall also be checked during stage inspection to check the current density. The transformer shall be so designed that the current density of all the windings and the regulating winding at the lowest tap should not exceed 250 A/cm.Sq.
14.
TANK CONSTRUCTION:-
14.1.1 The tank shall be fabricated of a suitable grade steel and strong enough to allow the lifting of complete transformer with oil by means of a crane or jacks and transported to site without over-straining the joints etc. 14.1.2 The main tank body shall be capable of withstanding a vacuum of 100.64 KN/m2 (760mm of Hg.) 14.1.3 The base shall be so designed as to allow the transformer to be moved by skidding without any injury. 14.1.4 All channeled constructions and stiffeners shall be designed to avoid retention of water. 14.1.5 The tank construction shall be free of air pockets, where such pockets cannot be avoided vent pipes of 15 mm internal dia shall be provided to vent gases into the main expansion pipes. In case of short branch pipes, however, minimum diameter may be taken as 6mm. 14.1.6 All joints other than those, which may have to be broken, shall be welded. When required they shall be double welded. All bolted joints to the tank shall be fitted with suitable oil tight gaskets, which shall give satisfactory service under the operating conditions and guaranteed temperature rise conditions. Special attention shall be given to the methods of making hot oil tight joints between the tank and the cover and also, between the cover and the bushings and all other out-lets to ensure that the joints can be remade satisfactorily at site and with ease by semi-skilled labour. 14.1.7 Suitable lifting lugs for lifting the transformer filled with oil shall be provided on the tank. 14.1.8 Four jacking lugs shall be provided to enable the transformer complete with oil to be lifted or lowered by means of jacks. The lugs shall be fitted at a minimum height (excluding under base if detachable) of 300mm for transformer upto 10 tonnes weight and of 500mm for transformer above 10 tonnes weights. 14.1.9 The transformer shall be provided with detachable steel flanged wheels of 250mm dia and suitable for moving transformer complete with oil. These shall be bi-directional and mounted on swivels which may be turned through 90o when the tank is jacked up and capable of being locked in position parallel to and at right angles to the longitudinal axis. The wheel be suitable for standard gauge track of 1676mm. 14.2 TANK COVER 14.2.1 The tank cover shall be of bolted type and of adequate strength so as not to distort, when lifted. Suitable inspection cover shall be provided with lifting arrangements to give access to bushings, winding connections or testing the earth connections. The weight of each inspection cover shall not exceed 25 Kg. 14.2.2 Pockets shall be provided in the position of Max. oil temperature at CMR for fitting a thermometer and for bolts of oil and winding temperature indicators. The thermometer pockets shall be fitted with a captive screwed cap to prevent ingress of water.
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14.2.3 14.3 14.3.1
Suitable No. of jacking bolts shall be provided on tank cover, inspection covers/windows including OLTC. CONSERVATOR TANK, OIL GAUGE AND BREATHER An adequate conservator tank of air cell type complete with sump and drain valves shall be provided in such a position as not to obstruct the electrical connections to the transformer. If the sump is formed by extending the feed pipe inside the conservator, this extension shall be atleast 25mm. One end of the conservator shall be bolted type to facilitate cleaning. The conservator shall be provided with a magnetic oil level gauge. The oil connections from the transformer tank to the conservator shall be at rising angle of 3 to 9 degrees to the horizontal upto Buchholz relay. The inside diameter of the pipe shall be 80mm. The Buchholz relay will have suitable valves on its both side so as to facilitate its testing at site as well as cut off oil supply to the transformer. The conservator shall be provided with oil preservation system, which should be suitable either to remove moisture continuously from air entering the air space with which they are connected or may not allow direct contact of atmospheric air with oil during operation, in addition to silicagel-breather. VALVES: The transformers shall be provided with 2 No. filter valve each of 50 mm size one mounted close to the top of the main tank & the other close to bottom of the tank oil circulation and one drain valve of 80mm size with plug. The conservator shall have drain plug of 25mm size. Two robust sampling valves with spouts suitable for taking samples of top, and bottom oil. The top sampling valves shall be brought down by internal pipe connections. Suitable name plates shall be affixed to the sampling valves. The sampling device shall not be fitted on the filter valve. Two air release plug of 15mm shall be provided. Plugs shall be supplied for all valves opening to atmosphere. All valves shall be of gun metal and comply with the latest edition of IS: 3639. PRESSURE RELIEF DEVICES: A suitable pressure relief device of 6" diameter shall be provided on the main tank and of 3" diameter shall be provided on OLTC for rapid release of any pressure in transformer, which may endanger the equipment. The device (s) shall operate at static pressure less than hydraulic test pressure for transformer tank of OLTC chamber. If the device is mounted on tank cover, it shall be fitted with a skirt projecting 25mm inside the tank and of such construction as to avoid gas accumulation. In addition to pressure relief device(s) the provision of explosion vent should also be made and the diaphragm shall be situated above max. oil level or second PRD on the opposite side of the first PRD be provided.
14.3.2 14.3.3 14.3.4 14.3.5
14.3.6
14.4 14.4.1
14.4.2
14.4.3 14.4.4 14.4.5 14.5
14.6 14.6.1
EARTHING TERMINALS: Two earthing pads suitable for connecting 50x8mm mild steel flat shall be provided at positions close to the two diagonally opposite bottom corners of tank. These
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grounding terminals shall be suitable for bolted connection. Two earthing terminals shall also be provided each on marshalling box and any other equipment mounted separately. 14.7 14.7.1 JOINTS AND GASKETS: All gaskets used for making oil tight joints shall be of granulated cork bonded with synthetic rubber. Metal tops shall be provided for preventing over compression wherever compressible gaskets are provided. RATING AND DIAGRAM PLATES: Each transformer shall carry a diagram plate showing internal connections, voltage vector relationship of different windings, plan view of the transformer showing physical relationship of the terminals and no load voltage and corresponding current for each tap. Each transformer shall be provided with a rating plate data as specified in IS: 2026. I.R. values alongwith oil temperature at the time of testing at manufacturer's works shall be indicated on rating plate or separate plate, to be provided on transformer. THERMOSYPHON FILTER ARRANGEMENT Thermosyphon filter arrangement shall be provided on the transformer for preserving the quality of Transformer Oil. The filter assembly shall be mounted on the Transformer as well as ground supported and connected with pipes and shut off valves. Suitable instructions required to be followed for commissioning, dismantlement & maintenance of the filter arrangement, re-generation and storage of the adsorbent etc. must be included in the instruction manual. A detailed drawing showing internal arrangement, shall also be required to be submitted. Suitable capacity pump (alongwith motor) shall also be provided to boost circulation of oil. The pump and motor should not be in main pipe line. It should be in bypass pipe line having suitable valve to isolate from main pipe line. The main pipe line should have two shut off valves at the bottom. NOTE: The pump and motor should be weather proof(Flow well Type).
14.8 14.8.1
14.8.2 14.8.3 14.9
The oil & sorbent capacity required in the Thermosyphon Filter is as under: (i) (ii) 15. 15.1 Quantity of oil Quantity of adsorbent 2.0% of total oil by weight. 1.25% of total oil by weight.
COOLING PLANT:Detachable radiators shall be fitted on the main tank with machined flanged outlet and inlet. Each radiator shall be provided with 19mm drain plug at Bottom and 19mm air release plug at the top. Valves shall be provided on the tank at each point of connection to radiators. In case separate cooler banks are used, they shall be suitable for mounting on a flat concrete base. These shall be provided with a valve (25 mm) at each point of connection to the transformer tank, removable blanking plates to blank off main oil connections to each cooler. 25 mm drain valve. Thermometer pockets with captive screwed cap at inlet and outlet of each separate cooler, filter valve at top and bottom and air release plug of 15mm.
15.2
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15.3
The motor blowers shall be direct driven suitable for continuous out door operation and complete with necessary air dusting. These shall be mounted independently from the radiator and in the case, these are radiator mounting type, use shall be made of some anti-vibration means. Care shall be taken that the blower unit is capable of being removed without disturbing the radiator structure. The blades shall be suitably painted and shall not be of hollow sections. Suitably painted wire mesh guards with mesh not greater than 25mm shall be provided to prevent accidental contact with the blades. MOTORS:-
15.4
15.4.1 The motor shall be squirrel cage totally enclosed weather proof type suitable for direct starting and for continuous running from 415-240 volts, three phase/single phase 50 C/S supply. The motors shall comply with IS as applicable for continuous rated machine. 15.4.2 All motors shall be capable of continuous operation at frequency 50Hz with variation of 5 % and 415/240 V AC 10 % variation of the normal voltage without injurious over heating. 15.4.3 All motors shall have ball or roller bearing with hexagonal nipples for greasing. In case of vertical spindle, motor shall have bearing capable of withstanding thrust, due to weight of the moving parts. 15.4.4 Varnished cambric or glass insulator shall be used for connections from stator winding to the terminal suitable for external wiring. The motor terminals shall be of stud type and totally enclosed. 15.5 COOLER CONTROL:15.5.1 Each motor or group of motors shall be provided with a 3 pole electrically operated contactor with control gear for motor operation by hand and automatically through winding temperature indicator. Provision shall be made for over load protection but no volt release shall not be provided. 15.5.2 All connection shall be so arranged as to allow either individual or collective operation of the motors, Alarm indication (audio and visual) for failure of fans and to indicate failure of power supply shall be provided. 15.5.3 The control equipment shall be installed in the marshaling box as specified in Cl.20 in readily accessible position. 15.5.4 The alarm indication for failure of power supply and failure of individual fans be provided through independent non trip alarm scheme conforming to the following:i) ii) iii) The closing of an initiating contact shall actuate a buzzer and will be accompanied by a flag indication on the concerned auxiliary relay. The closing of an initiating contact shall glow a lamp, which will not reset until the fault has cleared. It shall be possible to silence the buzzer by pressing 'Accept' push button. If after canceling the alarm but before resetting the visual signal, the same fault persists the buzzer shall be suppressed. If after canceling the alarm but before resetting the visual signal, some other fault takes place, the alarm accompanied by flag indication on appropriate auxiliary relay shall taken place.
iv)
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v)
If after canceling the alarm and after resetting the visual signal, the same fault appears or some other fault take place, the alarm, flag indication and non-trip lamp indication shall reappear as usual. The non-trip alarm acceptance shall be by means of push button and resetting of visual signal may also preferably be done through a push button. Means shall be provided for test checking the lamp and alarm circuit at frequent intervals. The equipment shall be suitable for 220 Volts DC operation. Static facia aunnuciator conforming to the foregoing requirements of non trip alarm scheme too would be acceptable.
vi) vii) viii)
16. 16.1
VOLTAGE CONTROL (ON LOAD TYPE):The transformer shall be provided with voltage control equipment of the tap changing type for varying its effective transformation ratio while the T/Fs are on load and without producing phase displacement. Equipment for 'local' and 'remote' electrical and 'local' manual operation shall be provided and shall comply with the following conditions. Local/ remote switch may be housed in remote control panel or in tap changer drive mechanism. It shall not be possible to operate the electric drive when the manual operating gear is in use. It shall not be possible for any two electric controls to be in operation at the same time. The equipment suitable for supervisory control and indication on a multi way switch, make-before break, having one fixed contact for each tap position, shall be provided and wired to the tap changer drive gear. This switch shall be provided in addition to any, which may be required for remote tap change position indication purpose. Supervisory indication shall also be provided in the form of contacts to close on. "Tap change incomplete" condition. All other components of the supervisory gear if required be specified separately. Operation from the local or remote control switch shall cause one tap movement only. The control switch shall be returned to the 'neutral' position between successive operations. All Electrical control switch on the local operation gear shall be clearly labeled in a suitable manner to indicate the direction of tap changing. The equipment shall be so arranged as to ensure that when a tap change has commenced, it shall be completed independent of the operation of the control relays or switches. In case of failure of the auxiliary supply while tap change is in progress or any other contingency such as stuck tap changer, adequate means shall be provided to safe guard the transformers and its auxiliary equipment. Suitable apparatus shall be provided for each transformer to give indications as follows: To give indication, mechanically at the transformer and electrically at the remote control cubicle of the position of tap in use. To give an indication at the remote control cubicle that a tap change is in-progress, by means of an illuminated lamp.
16.2
16.2.1 16.2.2 16.2.3
16.2.4
16.2.5 16.3
16.4 16.4.1 16.4.2
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16.5 16.6 16.7 16.8
For remote control, the switches, tap position indicator, etc. shall be supplied duly mounted on remote control cubicle. All relays and operating devices shall be operated correctly at any voltage between the limits specified in the relevant ISS. The tap changing mechanism and mechanism shall be mounted in the oil tank or compartment mounted in an accessible position on the transformer. Any non oil filled enclosed compartment shall be adequately ventilated, Thermostatically controlled heaters shall be provided in the driving mechanism chamber and in the marshaling box. All contactor & auxiliary relay coils or other parts shall be suitably protected against corrosion or deterioration due to condensation, fungi etc. The tap changer contacts which are not used for making or breaking current like separate selector switch contacts can be located inside main transformer tank where tap changer construction permits such an arrangement. The oil in case of on load tap changer having separate compartment for selector contacts shall be maintained under conservator head by means of pipe connection from the highest point of the chamber to the conservator. Such connection shall be controlled by suitable valve and shall be arranged so that any gas leaving the chamber will pass into the gas and oil actuated relay. A separate buchholz relay may be provided for this compartment. It shall not be possible for the oil in these compartments of the tap change equipment which contain contacts used for making or breaking current, to mix with the oil in the compartments containing contacts and not used for making or breaking current. Any 'DROP DOWN' tanks associated with the tap changing apparatus shall be fitted with guide rods to control the movement during lifting or lowering operations. The guide rods shall be so designed as to take support of the associated tank when in the fully lowered position with oil. Lifting gear fitted to 'Drop Down' tanks shall include suitable device to prevent run-away during lifting and lowering operations. They shall be provided with adequate breathing arrangement. The tap changer shall be mounted in such a way that the cover of the transformer can be lifted without removing connections between windings and tap changer. Each compartment in which the oil is not maintained under conservator head shall be provided with a suitable direct reading oil gauge. The alternating supply for electrical operation of the control and indicating gear shall be standard 415 Volts, three-phase, 3 wire, 50 Hz. alongwith 240 Volts single phase, 2 wire 50 Hz, subject to a variation of 5 percent so that the equipment offered can withstand variation in AC Limit switches shall be provided to prevent over-running of the mechanism and except where modified in clause 18.15 shall be directly connected in the circuit of the operating motor. In addition a mechanical stopper or other approved device shall be provided to prevent over-running of the mechanism under any condition. Limit switches may be connected in the control circuit of the operating motor provided that a mechanical declutching mechanism is incorporated. Thermal devices or other means like motor circuit breakers with shunt trip coil shall be provided to protect the motor and control circuits. All relays, switches fuses, etc. shall be mounted in the marshaling box or driving gear housing. These shall be
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16.9
16.10
16.11
16.12 16.13
16.14
16.15 16.16
clearly marked for purpose of identification. They shall withstand the vibration associated with tap changer gear operation. 16.17 The control circuits shall operate at 110V single phase to be supplied from a transformer having a ratio of 415 or 240/55-0-55 V with the center point earthed through a removable link mounted in tap changer drive. The whole of the apparatus shall be of robust design and capable of giving satisfactory service under conditions to be met in service including frequent operation. A five-digit counter shall be fitted to the tap changing mechanism to indicate the number of operations completed by the equipment. A permanently legible lubrication chart shall be fitted within the driving mechanism chamber, where applicable. The indigenous make OLTC suitable for 132 KV voltage class insulation (graded) but the voltage class insulation should not be less than 66 KV and current rating as 300 Amp. The OLTC should be type tested from CPRI or other Govt. test house or from reputed Lab. Abroad to the extent the facilities of type test are available with CPRI. PARALLEL OPERATION In addition to individual control of tap changer, provision shall be made to enable parallel operation of the tap changer when one unit is running in parallel with another similar unit of same rating. Suitable selector switch and controls shall be provided so that any transformer of the group can at a time be selected as master, follower or independent. Arrangement shall be made that only one of the transformers can be selected as master at a time. An out of step device shall be provided for each transformer indicating out of step condition by an indicating lamp and buzzer. It shall be arranged to prevent further tap changing when transformers in a group operating in parallel control are one tap out of step. BUSHING INSULATORS AND TERMINALS: Transformer shall be fitted with bushing insulators as follows: HV bushing: 145 kV class, condenser bushing of 800 Amp. rating with arcing horns. L.V. Bushing: 36 kV class, oil communicating type porcelain bushing of 1000 Amp. rating but with suitable arcing horns. L.V.-N Bushing: 36 kV class, oil communicating type porcelain bushing of 1000 Amp. rating but without arcing horns. H.V-N Bushing: 36 kV class, oil communicating type porcelain bushing of 630 Amp. rating but without arcing horns. The characteristics of the bushings shall be in accordance with IS: 2099 and IS: 3347. The bushing insulators except for neutral bushing shall be provided with adjustable arcing horns and the bidder shall furnish calibration gap to decide actual gap setting. A continuous flexible pull through lead suitably sweated to the end of winding copper shall be connected to the connector in the helmet of the 220/132 kV Bushing. The bushings may be filled with oil, which may not be in communication with the oil in transformer.
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16.18
16.19 16.20 16.21
17. 17. 1
17.2
17.3
18. 18.1
All porcelain shall be free from defects and thoroughly vitrified with a smooth, hard and uniform brown glaze. It should be capable of satisfactory use under the climatic conditions as specified in clause-3.0. In case of paper insulation care shall be taken to prevent ingress of moisture and a final coat of non-hygroscopic varnish shall be given to them. All clamps and fittings made of malleable iron or steel shall be galvanized as per IS: 2629. The bushings flanges shall not be of re-entrant shape which may trap air. Bi-metallic terminal connectors shall be supplied suitable for single 0.4 Sq. inch ACSR Zebra conductor for HV, LVN & HVN and twin ACSR Zebra conductor for LV side . The take off for H.V. & L.V. connectors will be Vertical and for Neutral it should be suitable for horizontal take off. The connectors shall have six number bolts provided with check nuts & washers. The connectors shall have rating corresponding to those of equipment or higher and shall be designed most liberally with a higher factor of safety to comply in all respects with temperatures rise, resistance, tensile strength short-circuit withstand capability tests as specified in IS: 5561-1970 or amendment thereof (Latest edition). Aluminum alloy used in the manufacture of Bi-metallic connectors shall conform to designation Grade 4600 of IS: 617-1975. The steel bolts, nuts washers and check nuts shall be hot dip galvanized marked with ISI certification mark or of GKWmake.
19. 19.1
TEMPERATURE INDICATING DEVICES: All transformers shall be provided with a dial type thermometer for indicating oil temperature. The indicator shall be fitted with a pointer to register maximum temp recorded and adjustable set of mercury contact for alarm and trip. In addition, all the transformers shall be provided with a dial type Hot Spot winding temperature indicator in HV & LV winding. The indicator shall have a pointer to register maximum temperature reached and four sets of adjustable mercury contacts for alarm, trip, automatic control of fans & remote indication. The static remote repeater (for winding temperature indicator) suitable for flush mounting shall be installed on remote tap charge control cubicle. The temperature indicators shall be housed in marshaling box. The alarm (mercury) contact of WTI & OTI shall be adjustable between 50oC to 100oC where as their trip (mercury) contacts shall be adjustable between 60oC and 120oC. The temperature difference between opening & closing of these mercury contacts shall not be more than 10oC. The mercury contacts used for controlling cooling plant motors shall be adjustable to close between 50oC and 100oC. The temperature differential between opening & closing of this mercury contract shall be between 10oC to 15oC. All contacts should be accessible on removal of the cover adjustable to scale. It shall also be possible to move the pointers by hand for checking the operation of contacts and associated equipment. In addition each transformer shall be provided with a dial type thermometer for indicating the ambient temperature. GAS AND OIL ACTUATED RELAYS: The transformer shall be provided with a gas and oil actuated relay fitted with alarm and trip contacts for main tank & oil surge relay for its OLTC as per IS:3637.
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19.2
19.3 19.4
19.5
19.6
19.7 20. 20.1
20.2 20.3 20.4
Each such relay shall be provided with a test cock to take a flexible connection for checking relay operation A machined surface shall be provided on top of relay for checking mounting angles in the pipe cross level of relay and its setting. The pipe work shall be such as to allow any gas formed in the tank to pass through the relay. The oil circuit through the relay shall not form a parallel delivery path with any circulating oil pipe, nor shall it be tied into or connected through the pressure relief vent. Adequate clearance between oil pipe work and live metal parts shall be provided. MARSHALING BOX: A sheet steel (of 10 SWG size) vermin proof well ventilated and weather proof marshaling box of suitable construction shall be provided for the transformer auxiliary apparatus. The box shall have domed or sloping roofs. Ventilation louvers, suitably padded with felt, shall also be provided. It shall be painted as per Cl.5.14. The marshaling box shall accommodate temperature indicators. Local electrical control of tap changer (if same cannot be housed in motor drive housing.), Control & protection equipment for cooling plant, terminal boards and gland plates for cable etc. The equipment shall be mounted on panels and panels wiring shall be done at the back for interconnections. The temperature indicators shall be mounted at about 1600mm from ground level. A metal clad heater with thermostat, controlled by a waterproof rotary switch on the outside of the box, shall be provided. The incoming cables shall enter from the bottom with gland plate not less than 450mm from the base of the box. Care shall be taken to avoid ingress of water from the cable trench. CONTROL CONNECTIONS, INSTRUMENTS WIRING, TERMINAL BOARD AND FUSES: All cables and wiring shall be suitable for use under the conditions as specified in Section -I. Any wiring liable to come in contact with oil shall be of oil resisting insulation. The bare ends of stranded wire shall be sweated together to prevent oil from creeping along the wire. The instrument and panel wiring shall be run in PVC or non rusting metal cleats of limited compression type. The box wiring shall be as per relevant ISS. All wiring shall be of stranded copper of 660V grade and size not less than 4 Sq. mm. for CT leads and not less than 2.5 Sq. mm for other connections. The panel wires and multi core cable shall bear ferrules of white insulation material with indelible marking in black and as per relevant ISS. Same ferrule number shall not be used on wires in different circuits. Double ferrule may be provided where a change in number is required. Stranded wires shall be terminated with tinned Ross Courtney terminals, washers or crimped tubular lugs. Separate washers shall be used for each wire. Wire shall not be jointed/tied between terminal points. Where apparatus is mounted on panels all metal cases shall be separately earthed by copper wire or strip not less than 2.5 sq. mm. The screens of screened pairs of multi core cables shall be earthed at one end of the cable only.
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20.5 21.0 21.1
21.2
21.3 21.4 21.5
22. 22.1
22.2 22.3
22.4
22.5
22.6
All terminal boards shall be of stud-type & mounted obliquely towards the rear door and these boards shall be spaced not less than 100mm apart. Suitable insulation barriers shall be provided between adjacent connections. No live metal shall be exposed at the back of terminal boards. All fuses shall be of cartridge type and fuses and links shall be properly labeled. EQUALIZATION FORMULA: The losses of each transformer shall be stated in the tender ONAF rating at full load at 750C. For the purpose of arriving at comparable prices, the iron, copper and auxiliary losses shall be capitalised as per capitalization formula given below: =3,86,700( Wi + 0.45 Wc + 0.45 Wp) Where Wi Wc Wp = = = Iron (No load) Losses Copper (Load Losses) Auxiliary Losses
22.7 23.
Losses as are subject to IS tolerance, the component losses shall be increased by 15% tolerance permissible as per ISS-2026.In case firm losses are quoted, the tenders should clearly state that under no circumstances the losses will not be more than the quoted firm losses. Please note that the capitalisation of losses as are subject to tolerance, the component losses would be increased by 15%. If it is question of acceptance of supplies the tolerance would be limited to Total losses Component losses : : 10% of total losses 15% of each component losses
Provided that the tolerance for total losses is not to exceed 10%. Total losses comprises of no load, load and auxiliary losses. In case during testing the losses of transformer's are found on higher side then the quoted one than transformer shall be liable to be rejected. 24. Losses:The losses of each transformer shall be stated in the tender for OFAF rating (at full load at 75 deg. C ) which shall be less than:Sr. No. 1 2 3 24.1 Noise level Type of Losses No Load Losses Load Losses Auxiliary Losses : 80 dB 25 MVA, 132/33 KV T/F 23 KW (Max) 100 KW(Max) 2.2 KW (Max)
Transformer offers shall be rejected if audible sound level is higher than max.80 dB. 25. 25.1 TESTS: ROUTINE TESTS: All routine test shall be carried out on each transformer as per IS-2026/ IEC-76. In the presence of purchasers representative.
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25.2
TYPE TEST Following type test shall be carried out on one transformer as per ISS 2026 in the presence of purchasers representative. (i) Temperature rise test (along with DGA). (ii) Impulse voltage withstand test as per clause 13 of ISS-2026 /1981 Part-III on one limb.
25.3 25.3.1
In addition, the following tests shall be carried out on the Transformer Tank: OIL LEAKAGE TEST: All tanks and oil filled compartments shall be tested for oil tightness by being completely filled with oil of viscosity not greater than that of insulating oil to IS: 335 at ambient temperature and subjected to a pressure equal to normal pressure plus 35KN/M2 (5 lbs sq. inch) measured at the base of the tank. This pressure shall be maintained for a period not less than 12 hours, during which period no leakage shall occur.
25.3.2
Following tests shall be carried out on each transformer as reference test i. ii. iii. iv. Measurement of tan delta and capacitor of T/F Winding and bushings at 5 kV & 10 kV. Magnetic balance test. Magnetising current at low voltage Measurement of percentage impedance at all taps at low voltage.
25.3.3
TRANSFORMER OIL: Sufficient quantity (along with 10% extra) of insulating oil of napthenic type (as per Clause-6 of specification) conforming to BS:148/IEC-296 Class-1 shall be put up for inspection, at least 3 weeks before putting up the transformer for testing/inspection, at sub-supplier works as per IS:335/BS/IEC. One sample of the oil shall also be got tested from CPRI or any other Govt. approved testing house. The inspected oil shall be dispatched to site as per dispatch instructions of purchaser.
25.3.4
SHORT CIRCUIT TEST Short circuit test in accordance with clause 16 of ISS-2026 or latest edition shall be got conducted on one of the units at any test Agencies where facilities exist in the presence of Purchaser's representative .However, in case of those manufacturers who have already got short circuit test in accordance with Cl. 16 of ISS-2026 or latest edition conducted during the last 5 years on same design and capacity of the Transformer, fresh short circuit test is not required to be conducted. The bidder in such a case shall submit the copy of type test report along with the bid. If this test is not conducted by the firm earlier, then charges for this test shall be borne by the bidder. The warranty in case of Power Transformer shall be 18 months from the date of commissioning or 24 months from the date of receipt whichever is earlier. All other stipulations of Warranty Clause as per Schedule-D of purchase regulation shall remain same.
25.4
The purchaser reserves the right to have any other, reasonable test carried out at his expense either before shipment or at site to ensure that the transformer complies with the requirement of this specification.
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25.5
STAGE INSPECTION: Stage inspection of built up core (in horizontal/vertical position), windings, tank and radiators shall be carried-out as detailed below:a. CORE: i) Measurement of flux Density. ii) No Load Loss Measurement by providing dummy oils. iii) Tests of CRGO sample taken from the core shall be carried-out for Carlite test (Resistance Measurement), Watt Loss Test, Lamination Thickness & Aging Tests. iv) Physical inspection for quality of workmanship. v) Slitting/Cutting of core. b. WINDINGS: i. ii. iii. c. i) Measurement of cross-sectional area for current density. Measurement of weight of bare copper/ cover by resistance methods. Test may be carried out on sample of copper for assessing its quality. TANK: Vacuum Test: One transformer tank out of the lot shall be subjected to vacuum pressure of 100.64 kN (760 mm of hg). The tanks to be designed for full vacuum shall be tested at an internal pressure of 3.33 KN/M2 (25mm of Hg.) for one hour. The permanent deflection of flat plates after the vacuum has been released shall not exceed the values given below without affecting the performance of the Transformer. ---------------------------------------------------------------------------------------------Horizontal length of flat plate(mm). Permanent deflection(mm). ------------------------------------------------------------------------------------------------Upto & including 750 5.0 751-1250 6.5 1251-1750 8.0 1751-2000 9.5 2001-2250 11.0 2251-2500 12.5 2501-3000 16.0 above 3000 19.0 --------------------------------------------------------------------------------------------ii) PRESSURE TEST: One transformer out of the lot shall be subject to the pressure corresponding to twice the normal head of oil or normal pressure plus 35KN/M2 (which ever is lower) measured at the base of the tank and maintained for one hour. The permanent deflection of flat plates after removal of excess pressure shall not exceed the figures specified as above.
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d.
RADIATORS: Radiator shall be routine and type tested at sub suppliers' work as per relevant standard. Test reports are required to be supplied at the time of final inspection.
NOTE:
a.
The insulation resistance values of the transformer windings will be recorded at the time of carrying out routine tests, for 20 seconds, one minute, two minutes with the help of 5000V motorized meggar. (Preferably EVERSHED/ AVO & VIGNOLE MAKE). The polarisation index values (ratio of 120/20 sec. value) will be accordingly calculated and recorded in the test certificates and it should not be less than 1.5. Dissolved gas analysis test shall be got carried-out before and after heat run test at CPRI. Capacitance and Tan Delta values for each transformer and condenser bushings will be taken and recorded in the test certificates at 5 kV & 10 kV. Insulation resistance value of condenser bushings shall also be recorded. Lightening impulse test with the chopped wave applications as per clause 13 of IS: 2026/ 1981 (Part-III) amended upto date. This test will be carried out on one of the limbs of HV and LV winding with positive polarity. The tender should clearly indicate the testing facilities available with them and tests which are to be arranged outside. Supplier shall submit in house test certificates at least 15 days in advance for final testing of T/F. For testing T/F, all measuring instruments shall be of highest efficiency and best quality. These shall be got calibrated from NPL/ Govt. Agency and be got sealed by calibrating agency. HVPN reserves the right to calibrate the instruments in the manner it desires. Losses shall be measured with 3-wattmeter method only. Resistance shall be taken with Double-Kelvin Bridge. Losses can be measured directly from CTs and PTs and not through the panel. Ratio of the measuring instrument shall be such that the multiplying factor is the minimum. All tests shall be carried out in the presence of the Purchaser before dispatching the material. Test certificates in quadruplicate will be submitted to the Purchaser for approval. No material shall be despatched without prior inspection and approval of test certificates unless otherwise agreed to. Type and routine test certificates of all bought out items from recognised testing agency shall be submitted for approval before commencing supplies. OLTC scheme including the master follower functioning shall also be checked. Only fully assembled transformer including mounting of radiators shall be put-up for inspection.
b. c.
d.
e.
26. 26.1 26.1.1
DRAWINGS: The following drawings shall be supplied as part of the tender. Outline dimensional drawing of transformer and accessories.
26.1.2.1 Bushing and terminal connectors drawing. 26.2 The successful bidder shall submit final version of drawings complete in all respects as detailed in the following sub-clauses, in quadruplicate, within four weeks of placement of order for purchasers approval. The purchaser shall communicate his comments/approval on the drawings to the supplier within four weeks of their receipt. The manufacturer shall, if necessary, modify the drawings
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and resubmit the same for purchasers approval within two weeks of receipt of comments. Such duly revised drawings will be approved by the purchaser within two weeks of the receipt. After receipt of purchasers approval to drawings, the manufacturer will submit a set of re-producible of all the approved drawings and will also supply five sets of all approved drawings and five sets of manual of instructions per transformer to substation Design Directorate, HVPNL, Panchkula. ONE SET OF ALL THE APPROVED DRAWINGS AND MANUAL OF INSTUCTIONS WILL BE SUPPLIED ALONGWITH EACH TRANSFRMER WITHOUT WHICH THE SUPPLY WILL NOT BE CONSIDERED AS COMPLETE SUPPLY. Outline general arrangement drawings showing plan, front elevation & side elevation with all fittings and accessories etc. The following information must be specifically included on the drawings. a. b. c. d. e. f. g. h. 26.2.2 Make of transformer oil. Electrical clearances, minimum as well as actual. No. of radiator headers, number of radiator element in each header. Small sketch showing un-tanking details. Thickness of transformer tank bottom, side & top plates. Type, shade, shade No. and thickness of transformer paint. Roller, rail gauge sketch. Weight of oil, bare copper weight windings, core, un-tanking mass, transportation mass and dimensions etc.
26.2.1
Detailed of bushings showing plan, elevation, terminal details, mounting details make and type number incorporating electrical characteristics, description of various parts, total creepage/ & protected creepage distance, weight of oil, total weight of bushing , dimensions, short time current rating etc. Drawing showing HV & LV windings with arrangement of insulation and terminal connections. Schematic control and wiring diagram for auxiliary equipment like OLTC control gear, cooler control gear, Marshaling Kiosk. Detailed write-up for schematic shall also be supplied Combined Rating & Diagram Plate. Valve schedule plate. Core assembly drawing with flux density calculations. Interconnection diagram between OLTC panel, Drive mechanism and marshalling kiosk. Detailed calculations showing short circuit with stand capability due to radial and axial forces during short circuit. Also calculation for thermal withstand capability during short circuit. Cable arrangement on the transformers. Drawing showing connection of HV, LV lead with the respective bushing and their place of storage during transportation.
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26.2.3 26.2.4
26.2.5 26.2.6 26.2.7 26.2.8 26.2.9
26.2.10 26.2.11
SECTION-3 CHAPTER-2 TECHNICAL SPECIFICATION FOR 16/20 MVA, 132/11kV POWER TRANSFORMERS 1.00 SCOPE: a) This specification covers the design, manufacture, assembly testing at manufacturers works before despatch, supply and delivery FOR destination of 16/20 MVA, 132/11 Power Transformers. All drawings, schedules and annexures appended to this specification shall form part of the specification and supplement the requirements specified. The equipment/materials offered by the Bidder shall be complete in all respects and, whether called for specifically or not, all accessories, hardware and services required for normal satisfactory operation of the system shall be deemed to be included in unit rates quoted. Design and manufacture shall also be such that equipment/ accessories of the same type and rating would be interchangeable. Specific reference in this specification and documents to any material by trade name, make or catalogue number shall be construed as establishing standard of quality and performance and not as limiting competition. All equipment/ accessories offered shall also be of proven design and manufacture. The make of all accessories and hardware shall be subject to employers approval. 2.00 CODES & STANDARDS: All standards, specifications and codes of practice referred to herein shall be the latest editions including all applicable official amendments and revisions as on date of opening of bid. The following standards and codes shall be applicable: IS:5 IS:325 IS:335 IS:375 IS:1866 IS:2026 &IEC:76 IS:2099 & 3347 IS:2147 IS:2705 IS:3637 IS:3639 IS:6600 &IEC-354
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b)
Colour for ready mix paints. Three phase induction motors. New insulating oils for transformer. Marking & arrangement of Switch-gear bus bars main connections and auxiliary wiring. Code of practice for maintenance of insulation oil Specification for Power Transformers. Bushing for alternating voltages above 1000 volts Degree of protection provided by enclosures for low voltage switchgear & control gear. Current transformer Gas operated relay. Fittings and accessories for Power Transformers. Guide for loading of oil immersed transformers.
BS:148/IEC:296
IS:8468 &IEC:214 IS:5561 IS:617 IS:2629 IS:8478 IS:8603
On load tap changer. Electric power connectors. Aluminium Alloy grade. Recommended practice for hot-dip Galvanising. On load tap changer application guide. Dimensions for porcelain transformer bushings for use in heavily polluted atmosphere(36 kV Class). Dimensions for oil filled porcelain transformer bushings for use in medium polluted atmosphere. Guide for sampling and analysis of free and dissolved gas in oil filled equipment. Code of practice for selection, installation and transformers. Dimensions for OIP insulated condenser bushings. Manual on transformer. maintenance of
IS:9434 IS:10028 IS:12676 CBIP
Equipment complying with other internationally accepted standards will also be considered if these ensure performance and constructional features equivalent or superior to standards listed above. In such a case the Bidder shall clearly indicate the standards adopted, furnish a copy in English of the latest revision of standard alongwith copies of all official amendments and revisions in force as on date of opening of bid and clearly bring out the salient features for comparison. 3.0 CLIMATIC CONDITIONS: The transformers are required to operate satisfactorily under the following site conditions: 3.1 Max. temperature 50 C 3.2 Min. temperature -2.5 C 3.3 Max. relative humidity 100% 3.4 Min. relative humidity 26 % 3.5 Average number of rainy days per annum Nearly120 days 3.6 Average annual rain fall 900mm 3.7 Average number of dust storm days per annum. 35 3.8 Isoceraunic level 45 3.9 Max. Wind pressures 195 kg/sqmt. 3.10 Altitude above mean sea level Less than 1000 mt TYPE AND RATING : 4.1 The transformer shall be of two winding, 3 phase oil immersed core type with ONAN/ONAF cooling suitable for outdoor service as step down transformers. The transformer shall not be provided with the tertiary delta winding. The ratings and other characteristics which are not covered elsewhere shall be, as detailed in following clauses :
4.0
4.2
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4.2.1
Max. Continuous capacity : a) b) ONAN ONAF 16 MVA 20 MVA 3 50 Hz (5%)
4.2.2 4.2.3 4.2.4
Number of phases Frequency Rated Voltage : a) b) HV side LV side HV side LV side
132kV 11kV Star Star YYO 10% at 20 MVA base ON load taps on HV side +5% to -15% in steps of 1.25% each
4.2.5
Connections : a) b)
4.2.6 4.2.7 4.2.8 4.2.9
Vector group %age Impedance
a) i) ii) b) i) ii)
Insulation level Lighting withstand Power frequency withstand voltage Lighting Impulse voltage Power frequency voltage
132 kV 550 kV 230 kV (rms) 650 kV 275 kV (rms)
11 kV 75 kV 28 kV (rms) 75 kV 28 kV (rms)
Insulation level of Bushings
4.2 10 Total Creepage Distance : a) b) 5. 5.1 5.2 Total: 25mm per kV corresponding to highest system voltage i.e. 145 kV, 36 kV, 12 kV. Protected: 50% of the total Creepage distance
GENERAL DESIGN OF TRANSFORMER: The transformer and accessories shall be so designed as to facilitate inspection, cleaning and repairs. The requirement of Indian Electricity Rules shall be kept in view. The design shall ensure satisfactory operation under severe working conditions due to fluctuating load of steel furnaces and voltage variations in the system including those, due to short circuits. The transformers shall be designed as to minimize the risk of accidental short circuits caused by animals, birds or vermins
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The design shall incorporate every reasonable precaution and provision for the safety of all those concerned in the operation and maintenance of the equipment keeping in the view the requirement of Indian Electricity Board. 5.3 All material used shall be of the best quality and of class most suitable for working under specified conditions and shall withstand the atmospheric conditions and temperature variations without undue deterioration or distortion or setting up of undue stress in any part thereof. Cast iron shall not be used for any parts other than the radiator valve bodies. Corresponding parts liable to replace shall be interchangeable. All taper pins to be used in the mechanism shall be split types as per latest edition of IS: 2393. All mechanism should be rust and corrosion proof. lubrication of moving parts not immersed in oil. Means shall be provided for
5.4 5.5 5.6 5.7 5.8 5.9
The construction shall be such as to avoid air or water pockets. Special care shall be exercised to reduce noise and vibration to the minimum level. Steel bolts of suitable finish will be used for diameters above 6mm. Brass bolts or studs used for electrical connections shall not be of less than 6mm dia. On outdoor equipment, all bolts, nuts & washers in contact with current carrying non-ferrous parts shall be phosphor bronze: All nuts bolts and pins shall be locked except those which are external to the transformer. If bolts and nuts are so placed as to be inaccessible by means of ordinary spanners, suitable special spanners shall be provided by the contractor. Labels shall be provided for all apparatus like relays, switches, fuses, etc. housed in any cubicle or marshaling kiosks. These shall be of incorrodible material with matt/satin finish and permanent lettering. Labels mounted on black surface shall have white letters & danger notices shall have red lettering on a white background. The labels shall be secured by means of brass screws or rust protected steel screws. Surface in contact with oil shall not be galvanized or cadmium plated. Before painting, all ungalvanised parts shall be cleaned made free from rust, scale and grease and external rough surfaces smoothened filled with metal deposition. The interior of the tank and other oil filled chambers shall be cleaned by shot blasting or any other suitable method. All external surfaces shall be given three coats of paints except for nuts, bolts and washers which may be given one coat after erection. The final coat shall be a glossy oil and weather proof, non-fading paints of shade 631 of IS:5. The interior of mechanism chambers and kiosks shall be given 3 coats of paint, the final coat being of a light coloured anti-condensation mixture. LOCKING OF OUTER RADIAL SPACERS :The outer most radial spacers of the winding shall be locked in position by means of vertical strips so that the same can not fall off/got displaced.
5.10
5.11
5.12 5.13
5.14
5.15 5.16
5.17
TIGHTENING OF THE NUTS OF THE COIL CLAMPING BOLTS |The proper & complete tightening of the nuts of the coil clamping bolts must be ensured by the manufacturers. The tightening of the nuts to the designed value and that the nuts
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of all the coils clamping bolts are tightened to same extent, should be carried out with torque spanners. The devices used for locking the nuts of coil clamping bolts must be of such a quality and such care should be taken first in tightening the nuts and next in locking them in position that the arrangement does not work loose due to vibrations caused by short circuits and fluctuating loads etc. 5.18 5.19 6. The noise level shall not be more than 5db above NEMA standard publication TR-1. The transformers shall be designed to have short circuit rating of two seconds as per ISS-2026. INSULATING OIL:Sufficient insulating oil of Napthenic type (made from Naphthenic crude) in which paraffinic content should be less than 50% and aromatic content 4 to 12% conforming to BS: 148/IEC:296 class-1 shall be supplied for first filling of each transformer. Particular attention shall be paid to deliver the oil at site free from moisture and of uniform quality through out in non-returnable steels drums. The quantity of oil for first filling of each transformer shall be stated in tender along-with trade mark of the oil to be supplied. Use of inhibitors in oil shall not be resorted to. 10% extra oil of the total quantity of oil shall be supplied along with the transformer. LIMIT OF TEMPERATURE RISE:With the above climatic conditions given in clause-3 each transformer shall be capable of operating continuously on any tap at their normal rating without exceeding the following temperature rises (i) (ii) (iii) (iv) 7.2 35 deg C in oil by thermometer 45 deg C in winding by resistance Winding Gradient i.e the difference between average winding average oil temperature not to exceed 13 deg C. Temperature of hot spot in windings not to exceed 95 deg C when calculated over max annual weighted average temperature of 40 deg C.
7. 7.1
The limits of temperature rise mentioned above will have to be satisfied by the manufacturer by carrying out the heat run test at the lowest negative tap.This test shall be carried out by feeding 1.1 times the total losses at 75 deg C at highest current tap. OVERLOAD CAPACITY & CONTINOUS RATING The safe overload capacity of the transformer and the duration of overload under maximum temperature conditions without any damage to the winding or harmful effects on the insulation shall be clearly stated in the tender which must be as per IEC354/IS6600,guide for loading of oil immersed transformer.
7.3
8.0
IMPEDANCE The transformer shall have 10% impedance on 20MVA base with tolerance as per IS:2026/Part-I(1983). Impedance shall include positive and zero sequence and shall be expressed in terms of the branches of star connected equivalent diagram, all on the same kVA base and range shall be given for each branch of the equivalent circuit in turn.
9.0
FREQUENCY:The transformer shall be suitable for continuous operation with a 5% frequency variation from a normal of 50 HZ without exceeding the temperature rise as specified in clause-7.1 above.
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10.0
FLUX DENSITY, CORE CONSTRUCTION AND INSPECTION
10.1 The transformer should be so designed that the working flux density should not exceed 1.57 Tesla at normal voltage, frequency. 10.2 Tenders with higher flux density than specified limit shall not be considered. 10.3 The core shall be built up with thin laminations of high grade. non-ageing, low loss, high permeability cold rolled super grain oriented silicon steel. Known as MOH High B Grade or superior grade CRGO steels of maximum 0.27 mm or low lamination thickness especially suitable for transformer core. 10.4(a) (i)Bidder should have in house core cutting facility for proper monitoring & control on quality and also to avoid any possibility of mixing of prime material with defective/second grade material. The purchaser may witness the core-cutting operation. In case the in house core cutting facility for core cutting is not available then the same shall be carried out in the presence of the representative of HVPN. (ii)Inspection call notice for the purpose should be accompanied with the following documents as applicable as a proof toward use of Prime core materials :a) Invoice of supplier. b) Mills test certificates. c) Packing list. d) Bill of loading. e) Bill of entry certificates by customs. Core material shall be directly procured either from the manufacturer or through their accredited marketing organisation of repute and not through any agent. 10.4(b) After being sheared, the laminations shall be treated to remove all burrs. They shall be coated with a baked enamel insulation coating. The insulation shall be inert to the action of hot transformer oil and shall be perfectly adhesive. Paper and varnish insulation shall not be accepted. Particulars of proposed insulation shall be stated in the tender. Laminations shall be checked for burrs during stage inspection. 10.5 The core shall be rigidly clamped and/or bolted to ensure adequate mechanical strength and to prevent vibrations during operation. The bolts used in the assembly of the core shall be suitably insulated and the clamping structure shall be constructed that the eddy currents will be minimum. Construction of the core shall be such that number of steps in the limb and yoke shall be matching and dimensionally identical to minimize the effect of cross fluxing and better mechanical strength. The core shall be provided with Lugs suitable for lifting the complete core and coil assembly of transformer. The Core & coil shall be fixed in the tank such that its shifting will not occur when the transformer in moved or when a short circuit occurs. The design of magnetic circuit shall be such as to avoid static discharge development of short circuit paths within itself or to the earthing clamping structure and the production of flux components at right angles to the plane of the lamination which may cause local heating.
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10.6
10.7
10.8
10.9
Every care shall be exercised in the selection treatment and handling of core steel to ensure that the laminations are flat and that finally assembled core is free from distortions. The supporting frame work of the core shall be so designed as to avoid the presence of pockets which would prevent complete emptying of the tank through the drain valve or cause trapping of air during filling. Oil ducts where necessary should be formed across the plane of the lamination and be given a suitable slope to assist oil circulation. The overall design of core and winding should be such that free flow of oil is not obstructed. The frame work and clamping arrangement shall be earthed by connecting to the tank body through a copper strip. Yoke bolt area should be compensated if bolts are used for fastening of the core. The insulation of core to bolts and core to clamp plates shall be able to withstand a voltage of 2 KV RMS for one minute. Core and windings shall be capable of withstanding shocks during transport, installation, service and adequate provision shall be made to prevent movement of core and winding relative to tank during these conditions. All steel sections used for supporting the core shall be thoroughly sand blasted after cutting drilling and welding. CRGO used shall be strictly as per approved vendor as below:a) Nippon Steel Corp.Japan b) Kawasaki Corp. Ltd.,Japan
10.10
10.11
10.12
10.13
10.14
10.15
10.16
10.17 The tenderers should indicate the maximum flux density allowable continuously as well as for time intervals of 1 minute and 5 secs. and the limit of flux density at which core material used by them saturates. 10.18 The name of the core material must be mentioned in the tender. The successful tenderer shall be required to furnish magnetization curves of the core material/design calculations and such other data/documents deemed fit by the Purchaser for being satisfied that flux density is as desired. 10.19 Purchaser shall inspect the built-up core for verification of flux density for which all facilities shall be provided. The purchaser shall inspect/test the core material for various tests as per relevant IEC/IS to ensure quality. Core may also be inspected during horizontal assembly, built-up assembly. NOTES : i) The above flux density has been specified to meet with the over fluxing of the core due to temporary over voltage of the order of 31% for l min, 44%for 5 sec. that may appear abnormal conditions such as those following sudden loss of large loads. ii) Yoke bolt area and flitch plate areas shall not be counted in the net core area if these are provided for fastening core. iii) The design of limb and yoke shall be so co-ordinate that there is no cross fluxing at the joints.
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11.
SUPPRESSION OF HARMONICS: The transformer shall be so designed as to suppress the harmonics voltage specially the 3rd & 5th, to eliminate wave form distortion and interference with communication circuits due to high frequency disturbances. Limiting percentage of harmonics at normal voltage and at maximum system voltage shall be stated in the tender.
12. 12.1 12.2
WINDINGS:The 132kV windings shall have graded insulation whereas all other windings shall be fully insulated and the neutral points shall be insulated as amended in IS:2026. The transformers shall be capable of operation without danger on any particular tapping at the rated kVA when the voltage may vary by 10% of the voltage corresponding to the tapping. The windings and connections, insulation material shall not soften, ooze out, shrink or collapse during service. No strip conductor wound on edge shall have a width exceeding six times its thickness. The conductors shall be transposed at sufficient intervals to minimize eddy currents and equalize the current and temperature distribution along the windings. The windings and connections shall be properly brazed to withstand shocks during transportation or transient conditions during service. The adequate pre-shrinkage of the coil assembly using pre-compressed press board material having low moisture content for the radial spacer blocks shall be ensured by the manufacturers so that there is no displacement of the radial spacer blocks due to frequent short circuits on the transformers. All windings after being wound and all fibrous hygroscopic materials used in the construction of the transformer shall be dried under vacuum and impregnated with hot oil. In addition to this the drying process be sufficiently extended for proper stabilization of the coil assembly. More than one cycle of soaking in oil followed by retightening of the coil assembly should be adopted.
12.3 12.4
12.5 12.6
12.7
12.8 12.9
The coil clamping rings wherever used, shall preferably be of flat insulated steel laminations. Auxiliary laminated material except bakelised paper shall not be used. The clamping arrangement shall exert equal pressure on all columns of spacers of the transformer windings built of sections or disc-coils separated by spacers. In no case, spiral winding will be used either for HV or LV windings.
12.10 The radial spacer blocks must be made of pre-compressed pressboard material, which will not soften while in contact with oil or fray out into fibers or edges. The slots should be so dimensioned that the blocks will not come out of the slots. Uniform distribution of coil clamping force shall be designed by using an adequately large number of coil clamping bolts and by transferring the clamping force from clamping bolts to the clamping plates through intermediate members which can spread the clamping force over a large area. 12.11 All joints shall be brazed/crimped considering the vibrations due to short circuits and load fluctuations.
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13.
CURRENT DENSITY: The employer shall be at liberty to inspect built-up winding for its quality, weight of copper, insulation and overall weight of coil assembly. The size of conductor used for different windings shall also be checked during stage inspection to check the current density. The transformer shall be so designed that the current density at any tap should not exceed 250A/cm. sq. in HV & regulating winding and 200 A/cm.sq in LV winding.
14.1
TANK CONSTRUCTION:-
14.1.1 The tank shall be fabricated of a suitable grade steel and strong enough to allow the lifting of complete transformer with oil by means of a crane or jacks and transported to site without over-straining the joints etc. 14.1.2 The main tank body shall be capable of withstanding a vacuum of 100.64 KN/m2 (760mm of Hg.) 14.1.3 The base shall be so designed as to allow the transformer to be moved by skidding without any injury. 14.1.4 All channeled constructions and stiffeners shall be designed to avoid retention of water. 14.1.5 The tank construction shall be free of air pockets, where such pockets cannot be avoided vent pipes of 15 mm internal dia shall be provided to vent gases into the main expansion pipes. In case of short branch pipes, however, minimum diameter may be taken as 6mm. 14.1.6 All joints other than those, which may have to be broken, shall be welded. When required they shall be double welded. All bolted joints to the tank shall be fitted with suitable oil tight gaskets, which shall give satisfactory service under the operating conditions and guaranteed temperature rise conditions. Special attention shall be given to the methods of making hot oil tight joints between the tank and the cover and also, between the cover and the bushings and all other out-lets to ensure that the joints can be remade satisfactorily at site and with ease by semi-skilled labour. 14.1.7 Suitable lifting lugs for lifting the transformer filled with oil shall be provided on the tank. 14.1.8 Four jacking lugs shall be provided to enable the transformer complete with oil to be lifted or lowered by means of jacks. The lugs shall be fitted at a minimum height (excluding under base if detachable) of 300mm for transformer upto 10 tonnes weight and of 500mm for transformer above 10 tonnes weights. 14.1.9 The transformer shall be provided with detachable steel flanged wheels of 250mm dia and suitable for moving transformer complete with oil. These shall be bi-directional and mounted on swivels which may be turned through 90o when the tank is jacked up and capable of being locked in position parallel to and at right angles to the longitudinal axis. The wheel be suitable for standard gauge track of 1676mm. 14.2 TANK COVER 14.2.1 The tank cover shall be of bolted type and of adequate strength so as not to distort, when lifted. Suitable inspection cover shall be provided with lifting arrangements to give access to bushings, winding connections or testing the earth connections. The weight of each inspection cover shall not exceed 25 Kg. 14.2.2 Pockets shall be provided in the position of Max. oil temperature at CMR for fitting a thermometer and for bolts of oil and winding temperature indicators. The thermometer pockets shall be fitted with a captive screwed cap to prevent ingress of water.
14.2.3 Suitable No. of jacking bolts shall be provided on tank cover, inspection covers/windows including OLTC.
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14.3 14.3.1
CONSERVATOR TANK, OIL GAUGE AND BREATHER An adequate conservator tank of air cell type complete with sump and drain valves shall be provided in such a position as not to obstruct the electrical connections to the transformer. If the sump is formed by extending the feed pipe inside the conservator, this extension shall be atleast 25mm. One end of the conservator shall be bolted type to facilitate cleaning. The conservator shall be provided with a magnetic oil level gauge. The oil connections from the transformer tank to the conservator shall be at rising angle of 3 to 9 degrees to the horizontal upto Buchholz relay. The inside diameter of the pipe shall be 80mm. The Buchholz relay will have suitable valves on its both side so as to facilitate its testing at site as well as cut off oil supply to the transformer. The conservator shall be provided with oil preservation system, which should be suitable either to remove moisture continuously from air entering the air space with which they are connected or may not allow direct contact of atmospheric air with oil during operation, in addition to silicagel-breather. VALVES: The transformers shall be provided with 2 No. filter valve each of 50 mm size one mounted close to the top of the main tank & the other close to bottom of the tank oil circulation and one drain valve of 80mm size with plug. The conservator shall have drain plug of 25mm size. Two robust sampling valves with spouts suitable for taking samples of top, and bottom oil. The top sampling valves shall be brought down by internal pipe connections. Suitable name plates shall be affixed to the sampling valves. The sampling device shall not be fitted on the filter valve. Two air release plug of 15mm shall be provided. Plugs shall be supplied for all valves opening to atmosphere. All valves shall be of gun metal and comply with the latest edition of IS: 3639. PRESSURE RELIEF DEVICES: A suitable pressure relief device of 6" diameter shall be provided on the main tank and of 3" diameter shall be provided on OLTC for rapid release of any pressure in transformer, which may endanger the equipment. The device (s) shall operate at static pressure less than hydraulic test pressure for transformer tank of OLTC chamber. If the device is mounted on tank cover, it shall be fitted with a skirt projecting 25mm inside the tank and of such construction as to avoid gas accumulation. In addition to pressure relief device(s) the provision of explosion vent should also be made and the diaphragm shall be situated above max. oil level or second PRD on the opposite side of the first PRD be provided.
14.3.2 14.3.3 14.3.4 14.3.5
14.3.6
14.4 14.4.1
14.4.2
14.4.3 14.4.4 14.4.5 14.5
14.6 14.6.1
EARTHING TERMINALS: Two earthing pads suitable for connecting 50x8mm mild steel flat shall be provided at positions close to the two diagonally opposite bottom corners of tank. These grounding terminals shall be suitable for bolted connection. Two earthing terminals shall also be provided each on marshalling box and any other equipment mounted separately.
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14.7 14.7.1
JOINTS AND GASKETS: All gaskets used for making oil tight joints shall be of granulated cork bonded with synthetic rubber. Metal tops shall be provided for preventing over compression wherever compressible gaskets are provided. RATING AND DIAGRAM PLATES:
14.8
14.8.1 Each transformer shall carry a diagram plate showing internal connections, voltage vector relationship of different windings, plan view of the transformer showing physical relationship of the terminals and no load voltage and corresponding current for each tap. 14.8.2 Each transformer shall be provided with a rating plate data as specified in IS: 2026. 14.8.3 I.R. values alongwith oil temperature at the time of testing at manufacturer's works shall be indicated on rating plate or separate plate, to be provided on transformer. 14.9 THERMOSYPHON FILTER ARRANGEMENT Thermosyphon filter arrangement shall be provided on the transformer for preserving the quality of Transformer Oil. The filter assembly shall be mounted on the Transformer as well as ground supported and connected with pipes and shut off valves. Suitable instructions required to be followed for commissioning,dismantlement & maintenance of the filter arrangement, re-generation and storage of the adsorbent etc. must be included in the instruction manual. A detailed drawing showing internal arrangement, shall also be required to be submitted. Suitable capacity pump (alongwith motor) shall also be provided to boost circulation of oil. The pump and motor should not be in main pipe line. It should be in bypass pipe line having suitable valve to isolate from main pipe line. The main pipe line should have two shut off valves at the bottom. NOTE : The pump and motor should be weather proof(Flow well Type).
The oil & sorbent capacity required in the Thermosyphon Filter is as under : (i) Quantity of oil (ii) Quantity of adsorbent COOLING PLANT:2.0% of total oil by weight. 1.25% of total oil by weight.
15. 15.1
Detachable radiators shall be fitted on the main tank with machined flanged outlet and inlet. Each radiator shall be provided with 19mm drain plug at Bottom and 19mm air release plug at the top. Valves shall be provided on the tank at each point of connection to radiators. In case separate cooler banks are used, they shall be suitable for mounting on a flat concrete base. These shall be provided with a valve (25 mm) at each point of connection to the transformer tank, removable blanking plates to blank off main oil connections to each cooler. 25 mm drain valve. Thermometer pockets with captive screwed cap at inlet and outlet of each separate cooler, filter valve at top and bottom and air release plug of 15mm. The motor blowers shall be direct driven suitable for continuous out door operation and complete with necessary air dusting. These shall be mounted independently from the radiator and in the case, these are radiator mounting type, use shall be made of some anti-vibration means. Care shall be taken that the blower unit is capable of being removed without disturbing the radiator structure. The blades shall be suitably painted and shall not be of hollow sections. Suitably painted wire mesh guards with mesh not greater than 25mm shall be provided to prevent accidental contact with the blades.
15.2
15.3
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15.4
MOTORS:-
15.4.1 The motor shall be squirrel cage totally enclosed weather proof type suitable for direct starting and for continuous running from 415-240 volts, three phase/single phase 50 C/S supply. The motors shall comply with IS as applicable for continuous rated machine. 15.4.2 All motors shall be capable of continuous operation at frequency 50Hz with variation of 5 % and 415/240 V AC 10 % variation of the normal voltage without injurious over heating. 15.4.3 All motors shall have ball or roller bearing with hexagonal nipples for greasing. In case of vertical spindle, motor shall have bearing capable of withstanding thrust, due to weight of the moving parts. 15.4.4 Varnished cambric or glass insulator shall be used for connections from stator winding to the terminal suitable for external wiring. The motor terminals shall be of stud type and totally enclosed. 15.5 COOLER CONTROL:15.5.1 Each motor or group of motors shall be provided with a 3 pole electrically operated contactor with control gear for motor operation by hand and automatically through winding temperature indicator. Provision shall be made for over load protection but no volt release shall not be provided. 15.5.2 All connection shall be so arranged as to allow either individual or collective operation of the motors, Alarm indication (audio and visual) for failure of fans and to indicate failure of power supply shall be provided. 15.5.3 The control equipment shall be installed in the marshaling box as specified in Cl.20 in readily accessible position. 15.5.4 The alarm indication for failure of power supply and failure of individual fans be provided through independent non trip alarm scheme conforming to the following:i) ii) iii) The closing of an initiating contact shall actuate a buzzer and will be accompanied by a flag indication on the concerned auxiliary relay. The closing of an initiating contact shall glow a lamp, which will not reset until the fault has cleared. It shall be possible to silence the buzzer by pressing 'Accept' push button. If after canceling the alarm but before resetting the visual signal, the same fault persists the buzzer shall be suppressed. If after canceling the alarm but before resetting the visual signal, some other fault takes place, the alarm accompanied by flag indication on appropriate auxiliary relay shall taken place. If after canceling the alarm and after resetting the visual signal, the same fault appears or some other fault take place, the alarm, flag indication and non-trip lamp indication shall reappear as usual. The non-trip alarm acceptance shall be by means of push button and resetting of visual signal may also preferably be done through a push button. Means shall be provided for test checking the lamp and alarm circuit at frequent intervals. The equipment shall be suitable for 220 Volts DC operation.
iv)
v)
vi) vii) viii)
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Static facia aunnuciator conforming to the foregoing requirements of non-trip alarm scheme too would be acceptable. 16. 16.1 VOLTAGE CONTROL (ON LOAD TYPE):The transformer shall be provided with voltage control equipment of the tap changing type for varying its effective transformation ratio while the T/Fs are on load and without producing phase displacement. Equipment for 'local' and 'remote' electrical and 'local' manual operation shall be provided and shall comply with the following conditions. Local/ remote switch may be housed in remote control panel or in tap changer drive mechanism. It shall not be possible to operate the electric drive when the manual operating gear is in use. It shall not be possible for any two electric controls to be in operation at the same time. The equipment suitable for supervisory control and indication on a multi way switch, make-before break, having one fixed contact for each tap position, shall be provided and wired to the tap changer drive gear. This switch shall be provided in addition to any, which may be required for remote tap change position indication purpose. Supervisory indication shall also be provided in the form of contacts to close on. "Tap change incomplete" condition. All other components of the supervisory gear if required be specified separately. Operation from the local or remote control switch shall cause one tap movement only. The control switch shall be returned to the 'neutral' position between successive operations. All Electrical control switch on the local operation gear shall be clearly labeled in a suitable manner to indicate the direction of tap changing. The equipment shall be so arranged as to ensure that when a tap change has commenced, it shall be completed independent of the operation of the control relays or switches. In case of failure of the auxiliary supply while tap change is in progress or any other contingency such as stuck tap changer, adequate means shall be provided to safe guard the transformers and its auxiliary equipment. Suitable apparatus shall be provided for each transformer to give indications as follows: To give indication, mechanically at the transformer and electrically at the remote control cubicle of the position of tap in use. To give an indication at the remote control cubicle that a tap change is in-progress, by means of an illuminated lamp. For remote control, the switches, tap position indicator, etc. shall be supplied duly mounted on remote control cubicle. All relays and operating devices shall be operated correctly at any voltage between the limits specified in the relevant ISS. The tap changing mechanism and mechanism shall be mounted in the oil tank or compartment mounted in an accessible position on the transformer. Any non oil filled enclosed compartment shall be adequately ventilated, Thermostatically controlled heaters shall be provided in the driving mechanism chamber and in the marshaling box. All contactor & auxiliary relay coils or other parts
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16.2
16.2.1 16.2.2 16.2.3
16.2.4
16.2.5 16.3
16.4 16.4.1 16.4.2 16.5 16.6 16.7 16.8
shall be suitably protected against corrosion or deterioration due to condensation, fungi etc. 16.9 The tap changer contacts which are not used for making or breaking current like separate selector switch contacts can be located inside main transformer tank where tap changer construction permits such an arrangement. The oil in case of on load tap changer having separate compartment for selector contacts shall be maintained under conservator head by means of pipe connection from the highest point of the chamber to the conservator. Such connection shall be controlled by suitable valve and shall be arranged so that any gas leaving the chamber will pass into the gas and oil actuated relay. A separate buchholz relay may be provided for this compartment. It shall not be possible for the oil in these compartments of the tap change equipment which contain contacts used for making or breaking current, to mix with the oil in the compartments containing contacts and not used for making or breaking current. Any 'DROP DOWN' tanks associated with the tap changing apparatus shall be fitted with guide rods to control the movement during lifting or lowering operations. The guide rods shall be so designed as to take support of the associated tank when in the fully lowered position with oil. Lifting gear fitted to 'Drop Down' tanks shall include suitable device to prevent run-away during lifting and lowering operations. They shall be provided with adequate breathing arrangement. The tap changer shall be mounted in such a way that the cover of the transformer can be lifted without removing connections between windings and tap changer. Each compartment in which the oil is not maintained under conservator head shall be provided with a suitable direct reading oil gauge. The alternating supply for electrical operation of the control and indicating gear shall be standard 415 Volts, three-phase, 3 wire, 50 Hz. alongwith 240 Volts single phase, 2 wire 50 Hz, subject to a variation of 5 percent so that the equipment offered can withstand variation in AC Limit switches shall be provided to prevent over-running of the mechanism and except where modified in clause 16.15 shall be directly connected in the circuit of the operating motor. In addition a mechanical stopper or other approved device shall be provided to prevent over-running of the mechanism under any condition. Limit switches may be connected in the control circuit of the operating motor provided that a mechanical declutching mechanism is incorporated. Thermal devices or other means like motor circuit breakers with shunt trip coil shall be provided to protect the motor and control circuits. All relays, switches fuses, etc. shall be mounted in the marshaling box or driving gear housing. These shall be clearly marked for purpose of identification. They shall withstand the vibration associated with tap changer gear operation. The control circuits shall operate at 110V single phase to be supplied from a transformer having a ratio of 415 or 240/55-0-55 V with the center point earthed through a removable link mounted in tap changer drive. The whole of the apparatus shall be of robust design and capable of giving satisfactory service under conditions to be met in service including frequent operation. A five-digit counter shall be fitted to the tap changing mechanism to indicate the number of operations completed by the equipment. A permanently legible lubrication chart shall be fitted within the driving mechanism chamber, where applicable.
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16.10
16.11
16.12 16.13
16.14
16.15 16.16
16.17
16.18 16.19 16.20
16.21
17. 17. 1
17.2
17.3
18. 18.1
The indigenous make OLTC suitable for 132 KV voltage class insulation(graded) but the voltage class insulation should not be less than 66 KV and current rating as 300 Amp. The OLTC should be type tested from CPRI or other Govt. test house or from reputed Lab. Abroad to the extent the facilities of type test are available with CPRI. PARALLEL OPERATION In addition to individual control of tap changer, provision shall be made to enable parallel operation of the tap changer when one unit is running in parallel with another similar unit of same rating. Suitable selector switch and controls shall be provided so that any transformer of the group can at a time be selected as master, follower or independent. Arrangement shall be made that only one of the transformers can be selected as master at a time. An out of step device shall be provided for each transformer indicating out of step condition by an indicating lamp and buzzer. It shall be arranged to prevent further tap changing when transformers in a group operating in parallel control are one tap out of step. BUSHING INSULATORS AND TERMINALS: Transformer shall be fitted with bushing insulators as follows: HV bushing: 145 kV class, condenser bushing of 800 Amp. rating with arcing horns. L.V. Bushing: 12 kV class, oil communicating type porcelain bushing of 1200 Amp. rating but with suitable arcing horns. L.V.-N Bushing: 12 kV class, oil communicating type porcelain bushing of 1200 Amp. rating but without arcing horns. H.V-N Bushing: 36 kV class, oil communicating type porcelain bushing of 630 Amp. rating but without arcing horns. The characteristics of the bushings shall be in accordance with IS: 2099 and IS: 3347. The bushing insulators except for neutral bushing shall be provided with adjustable arcing horns and the bidder shall furnish calibration gap to decide actual gap setting. A continuous flexible pull through lead suitably sweated to the end of winding copper shall be connected to the connector in the helmet of the 220/132 kV Bushing. The bushings may be filled with oil, which may not be in communication with the oil in transformer. All porcelain shall be free from defects and thoroughly vitrified with a smooth, hard and uniform brown glaze. It should be capable of satisfactory use under the climatic conditions as specified in clause-3.0. In case of paper insulation care shall be taken to prevent ingress of moisture and a final coat of non-hygroscopic varnish shall be given to them. All clamps and fittings made of malleable iron or steel shall be galvanized as per IS: 2629. The bushings flanges shall not be of re-entrant shape which may trap air. Bi-metallic terminal connectors shall be supplied suitable for single 0.4 Sq. inch ACSR Zebra conductor for HV, LVN & HVN and twin ACSR Zebra conductor for LV side. The take off for H.V. & L.V. connectors will be Vertical and for Neutral it should be suitable for horizontal take off. The connectors shall have six number bolts provided with check nuts & washers. The connectors shall have rating corresponding to those of equipment or higher and shall be designed most liberally with a higher factor of safety to comply in all respects with temperatures rise, resistance, tensile strength short-circuit withstand capability tests as specified in IS: 5561-1970 or amendment thereof (Latest
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edition). Aluminum alloy used in the manufacture of Bi-metallic connectors shall conform to designation Grade 4600 of IS: 617-1975. The steel bolts, nuts washers and check nuts shall be hot dip galvanized marked with ISI certification mark or of GKW make. 19. 19.1 TEMPERATURE INDICATING DEVICES: All transformers shall be provided with a dial type thermometer for indicating oil temperature. The indicator shall be fitted with a pointer to register maximum temp recorded and adjustable set of mercury contact for alarm and trip. In addition, all the transformers shall be provided with a dial type Hot Spot winding temperature indicator in HV & LV winding. The indicator shall have a pointer to register maximum temperature reached and four sets of adjustable mercury contacts for alarm, trip, automatic control of fans & remote indication. The static remote repeater (for winding temperature indicator) suitable for flush mounting shall be installed on remote tap charge control cubicle. The temperature indicators shall be housed in marshaling box. The alarm (mercury) contact of WTI & OTI shall be adjustable between 50oC to 100oC where as their trip (mercury) contacts shall be adjustable between 60oC and 120oC. The temperature difference between opening & closing of these mercury contacts shall not be more than 10oC. The mercury contacts used for controlling cooling plant motors shall be adjustable to close between 50oC and 100oC. The temperature differential between opening & closing of this mercury contract shall be between 10oC to 15oC. All contacts should be accessible on removal of the cover adjustable to scale. It shall also be possible to move the pointers by hand for checking the operation of contacts and associated equipment. In addition each transformer shall be provided with a dial type thermometer for indicating the ambient temperature. GAS AND OIL ACTUATED RELAYS: The transformer shall be provided with a gas and oil actuated relay fitted with alarm and trip contacts for main tank & oil surge relay for its OLTC as per IS:3637. Each such relay shall be provided with a test cock to take a flexible connection for checking relay operation A machined surface shall be provided on top of relay for checking mounting angles in the pipe cross level of relay and its setting. The pipe work shall be such as to allow any gas formed in the tank to pass through the relay. The oil circuit through the relay shall not form a parallel delivery path with any circulating oil pipe, nor shall it be tied into or connected through the pressure relief vent. Adequate clearance between oil pipe work and live metal parts shall be provided. 21. 21.1 MARSHALING BOX: A sheet steel (of 10 SWG size) vermin proof well ventilated and weather proof marshaling box of suitable construction shall be provided for the transformer auxiliary apparatus. The box shall have domed or sloping roofs. Ventilation louvers, suitably
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19.2
19.3 19.4
19.5
19.6
19.7 20. 20.1 20.2 20.3
padded with felt, shall also be provided. It shall be painted as per Cl.5.14. 21.2 The marshaling box shall accommodate temperature indicators. Local electrical control of tap changer (if same cannot be housed in motor drive housing.), Control & protection equipment for cooling plant, terminal boards and gland plates for cable etc. The equipment shall be mounted on panels and panels wiring shall be done at the back for interconnections. The temperature indicators shall be mounted at about 1600mm from ground level. A metal clad heater with thermostat, controlled by a waterproof rotary switch on the outside of the box, shall be provided. The incoming cables shall enter from the bottom with gland plate not less than 450mm from the base of the box. Care shall be taken to avoid ingress of water from the cable trench. CONTROL CONNECTIONS, INSTRUMENTS WIRING, TERMINAL BOARD AND FUSES: All cables and wiring shall be suitable for use under the conditions as specified in Section -I. Any wiring liable to come in contact with oil shall be of oil resisting insulation. The bare ends of stranded wire shall be sweated together to prevent oil from creeping along the wire. The instrument and panel wiring shall be run in PVC or non rusting metal cleats of limited compression type. The box wiring shall be as per relevant ISS. All wiring shall be of stranded copper of 660V grade and size not less than 4 Sq. mm. for CT leads and not less than 2.5 Sq. mm for other connections. The panel wires and multi core cable shall bear ferrules of white insulation material with indelible marking in black and as per relevant ISS. Same ferrule number shall not be used on wires in different circuits. Double ferrule may be provided where a change in number is required. Stranded wires shall be terminated with tinned Ross Courtney terminals, washers or crimped tubular lugs. Separate washers shall be used for each wire. Wire shall not be jointed/tied between terminal points. Where apparatus is mounted on panels all metal cases shall be separately earthed by copper wire or strip not less than 2.5 sq. mm. The screens of screened pairs of multi core cables shall be earthed at one end of the cable only. All terminal boards shall be of stud-type & mounted obliquely towards the rear door and these boards shall be spaced not less than 100mm apart. Suitable insulation barriers shall be provided between adjacent connections. No live metal shall be exposed at the back of terminal boards. All fuses shall be of cartridge type and fuses and links shall be properly labeled. EQUALISATION FORMULA: The losses of each transformer shall be stated in the tender ONAF rating at full load at 750 C. For the purpose of arriving at comparable prices, the iron, copper and auxiliary losses shall be capitalised as per capitalization formula given below:-
21.3 21.4 21.5
22. 22.1
22.2 22.3
22.4
22.5
22.6
22.7 23.0
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=3,86,700 (Wi + 0.45 Wc + 0.45Wp) Where Wi Wc Wp
= = =
Iron (No. Load ) Losses Copper (Load) Losses Auxilary Losses
Losses are subject to IS tolerance, the component losses shall be increased by 15% tolerance permissible as per ISS-2026. In case firm losses are quoted, the tenders should clearly state that under no circumstances the losses will not be more than the quoted firm losses. Please note that the capitalisation of losses as are subject to tolerance, the component losses would be increased by 15% if it is question of acceptance of supplies the tolerance would be limited to Total losses : Component losses : 10% of total losses 15% of each component losses
Provided that the tolerance for total losses is not to exceed 10%. Total losses comprises of no load, load & auxiliary losses. In case, during testing the losses of transformers are found on higher side then the quoted one, than transformer shall be liable to be rejected. 24.0 Losses:The losses of each transformer shall be stated in the tender for OFAF rating (at full load at 75 deg. C ) which shall be less than:Sr. No. Type of Losses 16/20 MVA, 132/11 KV T/F 1 No Load Losses 15.5 KW (Max) 2 Load Losses 78.2 KW(Max) 3 Auxiliary Losses 1.5 KW (Max) Noise level : max. 80 dB
24.1
Transformer offers shall be rejected if audible sound level is higher than max. 80 dB. 25. 25.1 TESTS: ROUTINE TESTS: All routine test shall be carried out on each transformer as per IS-2026/ IEC-76. In the presence of employers representative. 25.2 TYPE TEST Following type test shall be carried out on one transformer as per ISS 2026 in the presence of employers representative. (i) Temperature rise test (along with DGA). (ii) Impulse voltage withstand test as per clause 13 of ISS-2026 /1981 Part-III on one limb.
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There will not be any separate schedule for type test charges. The charges if any may be added in the ex-works price of the equipments. 25.3 25.3.1 In addition, the following tests shall be carried out on the Transformer Tank: OIL LEAKAGE TEST: All tanks and oil filled compartments shall be tested for oil tightness by being completely filled with oil of viscosity not greater than that of insulating oil to IS: 335 at ambient temperature and subjected to a pressure equal to normal pressure plus 35KN/M2 (5 lbs sq. inch) measured at the base of the tank. This pressure shall be maintained for a period not less than 12 hours, during which period no leakage shall occur. 25.3.2 Following tests shall be carried out on each transformer as reference test i. ii. iii. iv. 25.3.3 Measurement of tan delta and capacitor of T/F Winding and bushings at 5 kV & 10 kV. Magnetic balance test. Magnetising current at low voltage Measurement of percentage impedance at all taps at low voltage.
TRANSFORMER OIL: Sufficient quantity (along with 10% extra) of insulating oil of napthenic type (as per Clause-6 of specification) conforming to BS:148/IEC-296 Class-1 shall be put up for inspection, at least 3 weeks before putting up the transformer for testing/inspection, at sub-supplier works as per IS:335/BS/IEC. One sample of the oil shall also be got tested from CPRI or any other Govt. approved testing house. The inspected oil shall be dispatched to site as per dispatch instructions of purchaser.
25.4
SHORT CIRCUIT TEST Short circuit test in accordance with clause 16 of ISS-2026 or latest edition shall be got conducted on one of the units at any test Agencies where facilities exist in the presence of Employer's representative .However, in case of those manufacturers who have already got short circuit test in accordance with Cl. 16 of ISS-2026 or latest edition conducted during the last 5 years on same design and capacity of the Transformer, fresh short circuit test is not required to be conducted. The bidder in such a case shall submit the copy of type test report along with the bid. If this test is not conducted by the firm earlier, then charges for this test shall be borne by the bidder. The warranty in case of Power Transformer shall be 18 months from the date of commissioning or 24 months from the date of receipt whichever is earlier. All other stipulations of Warranty Clause as per Schedule-D of purchase regulation shall remain same The employer reserves the right to have any other, reasonable test carried out at his expense either before shipment or at site to ensure that the transformer complies with the requirement of this specification.
25.5
STAGE INSPECTION: Stage inspection of built up core (in horizontal/vertical position), windings, tank and radiators shall be carried-out as detailed below:-
a. i)
CORE:Measurement of flux Density.

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ii) iii)
iv) v) b. i. ii. iii c. i)
No Load Loss Measurement by providing dummy oils. Tests of CRGO sample taken from the core shall be carried-out for Carlite test (Resistance Measurement), Watt Loss Test, Lamination Thickness & Aging Tests. Physical inspection for quality of workmanship. Slitting/Cutting of core. WINDINGS: Measurement of cross-sectional area for current density. Measurement of weight of bare copper/ cover by resistance methods. Test may be carried out on sample of copper for assessing its quality. TANK: Vacuum Test: One transformer tank out of the lot shall be subjected to vacuum pressure of 100.64 kN (760 mm of hg). The tanks to be designed for full vacuum shall be tested at an internal pressure of 3.33 KN/M2 (25mm of Hg.) for one hour.
The permanent deflection of flat plates after the vacuum has been released shall not exceed the values given below without affecting the performance of the Transformer. ---------------------------------------------------------------------------------------------Horizontal length of flat plate(mm). Permanent deflection(mm). ------------------------------------------------------------------------------------------------Upto & including 750 5.0 751-1250 6.5 1251-1750 8.0 1751-2000 9.5 2001-2250 11.0 2251-2500 12.5 2501-3000 16.0 above 3000 19.0 --------------------------------------------------------------------------------------------ii) PRESSURE TEST: One transformer out of the lot shall be subject to the pressure corresponding to twice the normal head of oil or normal pressure plus 35KN/M2 (which ever is lower) measured at the base of the tank and maintained for one hour. The permanent deflection of flat plates after removal of excess pressure shall not exceed the figures specified as above. d. RADIATORS: Radiator shall be routine and type tested at sub contractors' work as per relevant standard. Test reports are required to be supplied at the time of final inspection. NOTE: a. The insulation resistance values of the transformer windings will be recorded at the time of carrying out routine tests, for 20 seconds, one minute, two minutes with the help of 5000V motorized meggar. (Preferably EVERSHED/ AVO & VIGNOLE MAKE). The polarisation index values (ratio of 120/20 sec. value) will be accordingly calculated and recorded in the test certificates and it should not be less than 1.5.
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b. c.
Dissolved gas analysis test shall be got carried-out before and after heat run test at CPRI. Capacitance and Tan Delta values for each transformer and condenser bushings will be taken and recorded in the test certificates at 5 kV & 10 kV. Insulation resistance value of condenser bushings shall also be recorded. Lightening impulse test with the chopped wave applications as per clause 13 of IS: 2026/ 1981 (Part-III) amended upto date. This test will be carried out on one of the limbs of HV and LV winding with positive polarity. The tender should clearly indicate the testing facilities available with them and tests, which are to be arranged outside. Contractor shall submit in house test certificates at least 15 days in advance for final testing of T/F. For testing T/F, all measuring instruments shall be of highest efficiency and best quality. These shall be got calibrated from NPL/ Govt. Agency and be got sealed by calibrating agency. HVPN reserves the right to calibrate the instruments in the manner it desires. Losses shall be measured with 3-wattmeter method only. Resistance shall be taken with Double-Kelvin Bridge. Losses can be measured directly from CTs and PTs and not through the panel. Ratio of the measuring instrument shall be such that the multiplying factor is the minimum. All tests shall be carried out in the presence of the Employer before dispatching the material. Test certificates in quadruplicate will be submitted to the Employer for approval. No material shall be despatched without prior inspection and approval of test certificates unless otherwise agreed to. Type and routine test certificates of all bought out items from recognised testing agency shall be submitted for approval before commencing supplies. OLTC scheme including the master follower functioning shall also be checked. Only fully assembled transformer including mounting of radiators shall be put-up for inspection.
d.
e.
26. 26.1 26.1.1 26.2
DRAWINGS: The following drawings shall be supplied as part of the tender. Outline dimensional drawing of transformer and accessories. Bushing and terminal connectors drawing. The successful bidder shall submit final version of drawings complete in all respects as detailed in the following sub-clauses, in quadruplicate, within four weeks of placement of order for employers approval. The employer shall communicate his comments/approval on the drawings to the contractor within four weeks of their receipt. The manufacturer shall, if necessary, modify the drawings and resubmit the same for employers approval within two weeks of receipt of comments. Such duly revised drawings will be approved by the employer within two weeks of the receipt. After receipt of employers approval to drawings, the manufacturer will submit a set of re-producible of all the approved drawings and will also supply five sets of all approved drawings and five sets of manual of instructions per transformer to substation Design Directorate, HVPNL, Panchkula. ONE SET OF ALL THE APPROVED DRAWINGS AND MANUAL OF INSTUCTIONS WILL BE SUPPLIED ALONGWITH EACH TRANSFRMER WITHOUT WHICH THE SUPPLY WILL NOT BE CONSIDERED AS COMPLETE SUPPLY.
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Outline general arrangement drawings showing plan, front elevation & side elevation with all fittings and accessories etc. The following information must be specifically included on the drawings. a. b. c. d. e. f. g. h. 26.2.2 Make of transformer oil. Electrical clearances, minimum as well as actual. No. of radiator headers, number of radiator element in each header. Small sketch showing un-tanking details. Thickness of transformer tank bottom, side & top plates. Type, shade, shade No. and thickness of transformer paint.
Roller, rail gauge sketch. Weight of oil, bare copper weight windings, core, un-tanking mass, transportation mass and dimensions etc. Detailed of bushings showing plan, elevation, terminal details, mounting details make and type number incorporating electrical characteristics, description of various parts, total creepage/ & protected creepage distance, weight of oil, total weight of bushing , dimensions, short time current rating etc.
26.2.3 26.2.4
Drawing showing HV & LV windings with arrangement of insulation and terminal connections. Schematic control and wiring diagram for auxiliary equipment like OLTC control gear, cooler control gear, Marshaling Kiosk. Detailed write-up for schematic shall also be supplied Combined Rating & Diagram Plate. Valve schedule plate. Core assembly drawing with flux density calculations. Interconnection diagram between OLTC panel, Drive mechanism and marshalling kiosk. Detailed calculations showing short circuit with stand capability due to radial and axial forces during short circuit. Also calculation for thermal withstand capability during short circuit. Cable arrangement on the transformers. Drawing showing connection of HV, LV lead with the respective bushing and their place of storage during transportation.
26.2.5 26.2.6 26.2.7 26.2.8 26.2.9
26.2.10
26.2.11
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SECTION - 4 CHAPTER - 1 TECHNICAL SPECIFICATION FOR 145 kV SF6 GAS CIRCUIT BREAKERS 1.0 1.1 SCOPE: This specification provides for design, engineering, manufacture, stage testing, inspection and testing before supply, packing, forwarding and delivery at site of 145 kV 3 pole SF6 gas filled outdoor circuit breakers along with terminal connectors, structures, all the accessories and auxiliary equipment and mandatory spares and maintenance equipment for the satisfactory operation in various substations of the state as specified here in. It is not the intent to specify completely all the details of design and construction of the circuit breakers. However, the breakers shall conform in all respects to the high standard of engineering design and workmanship and shall be capable of performing in continuous commercial operation up to the Bidders guarantee in a manner acceptable to the HVPNL. The circuit breakers equipment shall conform in all respects to high standards of engineering design and workmanship and shall be capable of performing in continuous commercial operation up to the bidders guarantee acceptable to the HVPNL. The equipment offered shall be complete in all respect necessary for its effective and trouble free operation. Such components shall be deemed to be within the scope of supply irrespective of whether those are specially brought out in this specification and or the commercial order or not. All similar parts particularly movable ones shall be interchangeable. STANDARDS: The circuit breakers shall conform to the latest revisions with amendments available at the time of testing of relevant standards, rules and codes, some of which are listed herein for ready reference. Title Specification for alternating current circuit breakers. Specification and acceptance of new supply of sulphur hexafluoride. 3. IS-5578& 11353 Making and arrangement for switchgear bus-bar, main connections and auxiliary wiring. 4. IS-2147 Degree of protection provided for enclosures for low voltage switchgear and control gear. 5 IS-325 Specification for three phase induction motors. 6. IS-13118 Specification for circuit breakers. 7. IS-2629 Recommended practice for hot dip galvanizing of iron and steel. 8. IEC-137 Bushings for AC Voltages. 9. IS-2099 High voltage porcelain bushings. 10. IS-4379 Identification of the contents of Industrial Gas Cylinders. 11. IS-7285 Seamless high carbon steel cylinders for permanent and high pressure liquefiable gases 12. IS-802 Code of practice for use of structural steel in (PART-1) overhead transmission line towers. Equipment meeting with the requirement of other authoritative Standards, which ensure equal or better performance than the standards mentioned above, shall also be considered. When the equipment offered by the Bidder conforms to other standards salient points of difference between standards adopted and the standards specified in this specification shall be clearly brought out in the relevant schedule. Four copies of such standards with authentic translation in English shall be furnished along with the offer. SERVICE CONDITIONS: As per section - I Vol. II AUXILIARY POWER SUPPLY: Auxiliary electrical equipment shall be suitable for operation on the following supply system.
-1-
1.2
2.0 2.1
Sl. No. 1. 2.
Standard No. IEC-56 IEC-376
2.2
3.0 3.1 3.2
415 V, 3 phase 4 wire 50 Hz, Neutral grounded AC supply. b. Two independent sources of 220 V DC, ungrounded 2 wire Substation wise exact details shall be furnished to the Successful bidder c. Lighting 240 V, single phase, 50 Hz AC supply. Each of the foregoing supplies shall be made available by the HVPNL at the terminal point for each circuit breaker for operation of accessories and auxiliary equipment. Bidder's scope include supply of interconnecting cables, terminal boxes etc., The above supply voltage may vary as below and all devices shall be suitable for continuous operation over the entire range of voltages. i) AC supply : voltage + 10% & -15%, frequency 5% ii) D.C. Supply : 10%. 4.0 PRINCIPAL PARAMETERS: The SF-6 gas Circuit Breakers covered in this specification shall meet the technical requirements listed hereunder. PRINCIPAL TECHNICAL PARAMETERS: ------------------------------------------------------------------------------------------------------Sl. Item Specification No. 145 kV ------------------------------------------------------------------------------------------------------1. Rated voltage (kV rms), 145 frequency (Hz.) 50 2. Continuous current 1600 rating (A rms) 3. Type 3 pole outdoor SF6 4. Mounting Hot dip galvanised lattice steel support structure, bolted type to be supplied by the Bidder. 5. Number of Poles 3 6. Type of Operation 3 pole gang operated 7. Phase to phase spacing 1700 in the switchyard i.e. Interpole spacing for breaker (mm) Required ground 4000 clearance from the lowest live terminal if both the terminals are not in the same horizontal plane. (mm) Phase to earth 1300 clearance (mm) Height of concrete plinth 150 (to be provided by the HVPNL) (mm) Minimum height of the 2550 support insulator from substantiate the same with adequate ground level (mm). Information on impulse test withstand capability of equipment) Operating mechanism Spring / Pneumatic (with unit compressor) Auto reclosing duty Three phase 14. Rated operating duty 0-0.3 sec. -CO-2-
a.
Power Devices (like drive motors) D.C. Alarm, control Protective Device
8.
9. 10.
11.
12. 13
"First pole to clear" As per IS-13118 factor (Type of tripping) (Trip free) 16. Max. closing time (ms) ------------- 150 -----------17. Max. total break time (ms) Less than 3 cycles or 60 ms 18. 1.2/50 microsecond 650 impulse withstand voltage (kV peak) 19. 1 minute power 275 frequency withstand voltage (kV rms) 20. Rated breaking current capacity:i) Line charging at 50 rated voltage at 90 deg. leading power factor (A) rms ii) Small inductive ----------------- 0.5 to 10 ------------------current (A) rms without exceeding switching o/v 2.0 p.u iii) Cable charging 160 breaking current (A) iv) Short circuit current a) AC component (kA rms) 31.5 b) % DC component Corresponding to minimum opening time as per IEC-56. c) Duration of short circuit 1 sec 22. Rated short circuit 78.75 making current capacity (kA) 23. Permissible limit of As per clause 5.27 temperature rise 24. Max. acceptable difference in the instants of closing/opening of contacts i. Within a pole (ms) 5 ii. Between poles (ms) 10 25. Min. creepage distance of 3625 support insulator (mm) 26. Short time current carrying 31.5 capability for one second (kA) 27. i) Rating of auxiliary contacts ----- 10 A at 220 V D.C. ------ii) No. of auxiliary 10 NO and 10 NC as spare with due contacts provision to add more if required 28. Breaking capacity of 2 A DC with the circuit time auxiliary contacts constant not less than 20 ms 29. Noise level at base ------- 140 db (max.) ----------and upto 50 meters 30 Seismic acceleration ------ 0.3g (horizontal) -------31. Min. Corona extinction voltage kv (rms) --------------------------------------------------------------------------------------------------------------------------------------5.0 5.1 5.2 5.3 GENERAL TECHNICAL REQUIREMENTS: Circuit breakers offered shall be sulphur hexaflouride (SF6) type only. Any part of the breakers, especially the removable ones, shall be freely interchangeable without the necessity of any modification at site. The 145 kV circuit breakers are not meant for single pole re-closure. The units for these
-3-
15.
breakers shall be linked together mechanically. Complete circuit breaker with all the items necessary for successful operation shall be supplied, including but not limited to the following: 5.3.1 Breaker assemblies with bases, support structure for circuit breaker as well as for control cabinet, central control cabinet and foundation bolts for main structure as well as control cabinet and central control cabinet (except concrete foundations), terminals and operating mechanisms are included in the scope of supply. Compressed SF6 gas, pneumatic systems complete including compressors, tanks, piping, fittings, valves and controls and necessary supports for interpole piping for pneumatic systems.
5.3.2
5.3.3 Instruments, gauges and other devices for SF6 gas pressure, pneumatic pressure supervision.
5.3.4 All necessary parts to provide a complete and operable circuit breaker installation such as main equipment, terminal, control parts, connectors and other devices, whether specifically called for herein or not. The support structure of circuit breaker as well as that of control cabinet shall be hot dip galvanised. All other parts can be grey colour painted as per shade 631 of IS-5. Circuit breaker shall be suitable for hot line washing. All breakers shall be supplied with universal type terminal connectors. The current density adopted for the design of the terminal pads shall in no case exceed the following values. For copper pads - 1.6 A/sq.mm. and others - 1.0 A/sq.mm. CONTACTS: All making and breaking contacts shall be sealed free from atmospheric effects. Contacts shall be designed to have adequate thermal and current carrying capacity for the duty specified and to have a life expectancy so that frequent replacements due to excessive burning will not be necessary. Provision shall be made for rapid dissipation of heat generated by the arc on opening. Main contacts shall be the first to open and the last to close so that there will be little contact burning and wear. If arcing contacts are used they shall be the first to close and the last to open. These shall be easily accessible for inspection and replacement. If there are no separately mounted arcing contacts the main contacts shall be easily accessible for inspection and replacements. Tips of arcing contacts and main contacts shall be silver plated or have tungsten alloy tipping.
5.4 5.5 5.6 5.7 5.9 5.9.1
5.9.2 5.9.3
5.9.4 Any device provided for voltage grading to damp oscillations or to prevent restrike prior to the complete interruption of the circuit or to limit over-voltages on closing shall have a life expectancy comparable to that of the breaker as a whole. 5.9.5 Breakers shall be so designed that when operated within their specified rating, the temperature of each part will be limited to values consistent with a long life of the material used. The temperature shall not exceed that indicated in IEC-56 under specified ambient conditions. 5.9.6 Contacts shall be kept permanently under pressure of SF6 gas. The poles shall be partially filled with SF6 gas at the time of despatch and only topping upto required pressure shall be permitted at site. The gap between the open contacts shall be such that it can withstand atleast the rated phase to ground voltage continuously at zero gauge pressure of SF6 gas due to its leakage. 5.10 PORCELAIN HOUSING: 5.10.1 The porcelain housing shall be of single piece construction without any joint or coupling. It shall be made of homogeneous, vitreous porcelain of high mechanical and dielectric strength. Glazing of porcelain shall be uniform brown or dark brown colour with a smooth surface
-4-
arranged to shed away rain water or condensed water particles (fog), free from blisters, burns and similar other defects. 5.11 a) ADDITIONAL REQUIREMENTS: The circuit breakers shall be single pressure type and single break, the design and construction of the circuit breaker shall be such that there is minimum possibility of gas leakage and entry of moisture. There should not be any condensation of SF6 gas on the internal insulating surface of the circuit breaker. All gasketed surfaces shall be smooth, straight and reinforced, if necessary to minimise distortion and to make a tight seal. Where the operating rod of the operating mechanism connected to the arc chamber (SF6 media) adequate suitable Oring seals shall be provided. The test holes for leakage test of the internal seals shall also be provided. In the interrupter assembly there shall be a absorbing product box to eliminate SF6 decomposition products and moisture. The material used in the construction of the circuit breakers shall be fully compatible with SF6 gas. Each pole shall form an enclosure filled with SF6 gas independent of the other two poles. The SF6 gas density of each pole shall be monitored and regulated by individual pressure switches The SF6 gas density monitor shall be adequately temp. compensated. The density monitor shall meet the following requirements: i) It shall be possible to dismantle the density monitor for checking/ replacement without draining the SF6 gas by using suitable interlocked non-return couplings. ii) It shall damp the pressure pulsation while filling the gas in service so that the flickering of the pressure switch contacts does not take place. iii) A pressure indicator shall also be supplied. iv) The alarm and trip setting shall be such that: a) Advance warning can be given for the low pressure below an unacceptable level. b) After alarm, the breaker shall open if the pressure falls below pre-determined value. Means for pressure relief shall be provided in the gas chamber of circuit breaker to avoid damages or distortion during occurrence of abnormal pressure increase or shock waves generated by internal electric faults. The position of vents, diaphragms and pressure relief devices shall be so arranged as to minimise danger to the operators in the event of gas or vapour escaping under pressure. Facility shall also be provided to reduce the gas pressure within the breaker to a value not exceeding 6 millibar for 145 kV within 4 hours or less. Each circuit breaker shall be capable of withstanding this degree of vacuum without distortion or failure of any part. Sufficient SF6 gas shall be provided to fill all the circuit breakers installed. In addition to this 20% of the total gas requirement shall be supplied in separate cylinders as spare requirement. The pressure loss in the breaker shall not be more than 1% per year under normal operating conditions. Provisions shall be made for attaching an operation analyzer after installation at site to record contact travel, speed and making measurement of operation timings and synchronization of contacts in one pole. SULPHUR HEXAFLUORIDE GAS (SF6 GAS): The SF6 gas shall comply with IEC-376, 376A and 376B and be suitable in all respects for use in the switchgear under the worst operating conditions. The high pressure cylinders in which the SF6 gas is shipped and stored at site shall comply with requirements of the following standards and regulations: IS:4379 IS:7285 Identification of the contents of industrial gas cylinders. Seamless high carbon steel cylinders for permanent and high pressure liquefiable gases.
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b)
c)
d)
e)
f)
g)
h)
i)
5.12 a) b)
The cylinders shall also meet Indian Boiler regulations. c) Test: SF6 gas shall be tested for purity, dew point, breakdown voltage, water contents as per IEC-376, 376A and 376B and test certificates shall be furnished to HVPNL indicating all the tests as per IEC-376 for each lot of SF6 gas. DUTY REQUIREMENTS: The circuit breakers shall be totally re-strike free under all duty conditions and shall be capable of performing specified duties without opening resistors. The circuit breakers shall meet the duty requirements for any type of fault or fault location, for line charging and roping when used on an effectively grounded system and perform make and break operations as per stipulated duty cycles satisfactorily. The Circuit Breakers shall be capable of: i) ii) iii) 5.13.4 5.13.5 Clearing short line faults (Kilo metric faults) with source bus equivalent to symmetrical fault current specified. impedance behind the
5.13 5.13.1 5.13.2
5.13.3
Breaking inductive currents of 0.5 to 10A without switching over-voltage exceeding 2.3 p.u. Breaking 25% of the rated fault current at twice rated voltage under phase opposition condition.
The critical current which gives the longest arc duration at lockout pressure of extinguishing medium and the arc duration shall be indicated. The breakers shall satisfactorily withstand the high stresses imposed on them during fault clearing, load rejection and re-energisation of lines with trapped charges. The breakers shall also withstand the voltage specified in clause 4.0 "Principal Parameters" of this specification. TOTAL BREAK TIME: The "Total Break Time" as specified in clause 4.0, "Principal section shall not be exceeded under any of the following duties: i) Test duties 1,2,3,4,5 (with TRV as per IEC-56). ii) Short line fault L90, L75 (with TRV as per IEC-56). Parameters" of this
5.14 5.14.1
5.14.2
The Bidder may please note that there is only one specified break time of the breaker which shall not be exceeded under any duty conditions specified such as with the combined variation of the trip coil voltage, (85-110%) pneumatic pressure and arc extinguishing medium pressure etc., While furnishing the proof for the total break time of complete circuit breaker, the Bidder 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. The values guaranteed shall be supported with the type test reports. OPERATING MECHANISM AND ASSOCIATED EQUIPMENTS: The circuit breakers shall be designed for electrical local as well as remote control The operating mechanism shall be spring closing and spring tripping through electric motor for 145 kV SF-6 Circuit Breakers. The mechanism shall be adequately designed for specified tripping and re-closing duty. The entire operating mechanism control circuitry as required shall be housed in an out-door type,CRCA steel enclosure. The enclosure shall be invariable mounted on a separate concrete plinth of 150 mm height. All working parts in the mechanism shall be of corrosion resistant material. All bearings which require greasing, shall be equipped with pressure grease fittings. The design of the operating mechanism shall be such that it shall be practically maintenance free. The guaranteed years of maintenance- free operation, the number of full load and full rated short circuit current breaking/operation without enquiring any
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5.14.3 5.15 5.15.1 5.15.2
5.15.3 5.15.4
maintenance or overhauling, shall be clearly stated in the bid. As far as possible the need for lubricating the operating mechanism shall be kept to the minimum and eliminated altogether if possible. 5.15.5 The operating mechanism shall be non-pumping (and trip free) electrically pneumatically under every method of closing. There shall be no rebounds in the mechanism and it shall not require any critical adjustments at site. Operation of the power operated closing device, when the circuit breaker is already closed, shall not cause damage to the circuit breaker or endanger the operator. Provision shall be made for attaching an operation analyzer to facilitate testing of breaker at site. 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. The Bidder shall furnish detailed operation and maintenance manual of the mechanism along with the operation manual for the circuit breakers. CONTROL: The close and trip circuits shall be designed to permit use of momentary contact switches and push buttons. Each breaker pole shall be provided with two (2) independent tripping circuits, valves and coils each connected to a different set of protective relays. 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 push buttons shall be provided in the breaker central control cabinet. Remote located push buttons and indicating lamps shall be provided by the HVPNL. The trip coils shall be suitable for trip circuit supervision. The trip circuit supervision relay would be provided by the HVPNL. Necessary terminals shall be provided in the central control cabinet of the circuit breaker by the Bidder. Closing coil shall operate correctly at all values of voltage between 85% and 110% of the rated voltage. Shunt trip 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 85% and 110% of rated voltage. 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. In the absence of adequate details the offer is likely to be rejected. Suitable relay for monitoring of DC supply voltage to the control cabinet shall be provided. The pressure switches used for interlock purposes shall have adequate contact ratings to be directly used in the closing and tripping circuits. In case the contacts are not adequately rated and multiplying relays are used then the interlock for closing/opening operation of breaker shall be with No logic of the relay i.e. if the DC supply to the interlock circuit fails then it is essential that breaker trips in order to protect the switchgear and connected equipment like transformers etc., for any possible faults at that time. Provision for automatic tripping of the breaker shall be made alongwith the flag indication for non-availability of DC supply. The connection must be such that capacitor provided for this purpose gets charged from the DC source provided by the Board only and the capacitor supply is released for the tripping circuit as soon as DC supply fails. It must be possible to close the breaker only after restoration of DC supply. The entire arrangement of CTD must be accommodated in a separate box and it shall be mounted to control cubicle For pneumatically and spring operated mechanisms a local manual closing device which can be easily operated by one man standing on the ground shall also be provided for maintenance purposes and direction of motion of handle shall be clearly marked.
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5.15.6
5.15.7 5.16 5.16.1 5.16.2 5.16.3
5.16.4
5.16.5
5.16.6
5.16.7
5.16.8
The auxiliary switch of the breaker shall be preferably positively driven by the breaker operating rod and where due to construction features, same is not possible a plug-in device shall be provided to simulate the opening and closing operations of circuit breaker for the purpose of testing control circuits. MOTOR COMPRESSED SPRING CHARGING MECHANISM: Spring operated mechanism shall be complete with motor, opening spring, closing spring and all other necessary accessories to make the mechanism a complete unit. Breaker operation shall be independent of motor which shall be used solely for the purpose of charging the closing spring. Motor rating shall be such that it requires only 15 seconds for fully charging the closing spring. Closing operation shall compress the opening spring and keep ready for tripping. The mechanism shall be provided with means for charging the spring by hand. This operation shall be carried out with the doors of the cubicle open. During this process no electrical or mechanical operation of the mechanism shall endanger the operator or damage the equipment. A mechanical indicating device shall be provided to indicate the state of the charge spring and shall be visible with the door of the cubicle closed. An alarm shall be provided for spring failing to be charged by a pre-set time after circuit breaker closing. The spring mechanism shall be fitted with a local manual release, preferably by a push button to avoid in advertent operation. Means shall be provided for discharging the spring when the circuit breaker is in the open position without circuit breaker attempting to close.
5.17
5.18
PNEUMATICALLY OPERATED MECHANISM: a) b) c) Individual compressor units (ICU) shall be provided for pneumatically operated circuit breakers. The ICU shall be complete with air piping and accessories, all stop valves, tees, pressure reducers etc., required for normal operation of the breaker. The breaker local receivers shall comply with the requirements in clause 5.29 and shall have sufficient capacity for two CO operations of the breakers at the lowest pressure for auto reclosing duty without refilling. The Bidder shall ensure that rated pressure. is available at all the breaker locations. Independently adjustable pressure switches with potential free, ungrounded contacts to actuate a lockout device shall be provided. This lockout device with provision of remote alarm indication shall be incorporated in each circuit breaker to prevent operation whenever the pressure of the operating mechanism is below that of parameter required for satisfactory operation of the circuit breakers. The scheme should permit operation of all blocking and alarm relays as soon as the pressure transient present during the rapid pressure dip has been damped and a reliable pressure measurement can be made. Such facilities shall be provided for following conditions: i) Close lockout pressure. ii) Auto reclose lockout pressure. iii) Extreme low pressure. e) 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. The compressed air piping shall comply to requirements given in clause 5.28.8.
d)
f) 5.19
OPERATING MECHANISM HOUSING: The operating mechanism housing/control cabinet shall conform to the requirement specified in clause 5.30.
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5.20
INTERLOCKS: It is proposed to electrically interlock the circuit breaker with HVPNL's associated air break isolating switches in accordance with switchyard safety interlocking scheme. The details of the scheme will be furnished to the successful Bidder. All accessories required on breaker side for satisfactory operation of the scheme shall be deemed to be included in the scope of supply of this specification.
5.21
SUPPORTING STRUCTURE: The Bidder shall indicate the price of support structure alongwith the foundation bolts required separately in the bid proposal sheets and these shall be considered in evaluation. However, in case the equipment offered have integral support structure or the specialities of the breaker are such that support structures have to be provided by the successful Bidder, the prices of these support structures shall be included in the price of the equipment and same shall be indicated clearly in the bid proposal sheet. The support structure shall meet the following requirements: 1) The minimum vertical clearance from any energized metal part to the bottom of the circuit breaker (structure) base, where it rests on the foundation pad, shall be 3.85meters for 145kV. The minimum vertical distance from the bottom of the lowest porcelain part of the bushings, porcelain enclosures or supporting insulators to the bottom of the circuit breaker base, (from the ground level) shall be 2.55 meters for all voltages. The minimum clearance between the live parts and earth shall be 1.3 meters for 145kV.
2)
3) 5.22 5.22.1
FITTINGS AND ACCESSORIES: Following is a partial list of some of the major fittings and accessories to be furnished by Bidder in the central control cabinet. Number and exact location of these parts shall be indicated in the bid. a) i) ii) iii) iv) v) vi) vii) viii) ix) x) xi) xii) xiii) b) c) Central control cabinet in accordance with clause no. 5.30 complete with Cable glands for control cables off sizes will be intimated to the successful bidders . Local/remote changeover switch. Four digit operation counter. Pneumatic pressure gauges SF6 gas pressure gauge. Control switches to cut off control power supply. Fuses and links as required. The number of terminals provided shall be adequate enough to wire out all contacts and control circuits plus 24 terminals spare for HVPNL's use. Operation hour meter for motor. Three pin plug with socket. Illuminating lamp with door switch. Lock and key for mechanism box. Capacitor tripping device. Thermostatically controlled space tubular heater. Anti-pumping relay. Rating plate in accordance with IEC incorporating year of manufacture.
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Note :-
Such components, required for satisfactory operation of breaker, shall be deemed to be within the scope of supply irrespective of whether these are specifically mentioned or not above. Additional fittings for pneumatically operated circuit breaker. a) b) c) d) Unit compressed air system in accordance with clause No.5.28. Breaker local air receivers. Pressure gauge spring loaded safety valve, pressure switch with adjustable contacts and explosion vents in case provision is not in-built. Pressure switch to initiate an alarm if the pressure in the aux.reservoir remains below a preset level for longer than it is normally necessary to refill the reservoir Stop, non-return and other control valves, piping and all accessories upto breaker mechanism housing.
5.22.2
e) 5.23 5.23.1
SURFACE FINISH: All interiors and exteriors of tanks and other metal parts shall be thoroughly cleaned to remove all rust, scales, corrosion, greases or other adhering foreign matter. All steel surfaces in contact with insulating oil, as far as accessible, shall be painted with not less than two coats of heat resistant, oil insoluble, insulating paint. All metal surfaces exposed to atmosphere shall be given two primer coats of zinc chromate and two coats of epoxy paint with epoxy base thinner. All metal parts not accessible for painting shall be made of corrosion resisting material. All machine finished or bright surfaces shall be coated with a suitable preventive compound and suitably wrapped or otherwise protected. All paints shall be carefully selected to withstand tropical heat and extremes of weather within the limits specified. The paint shall not scale off or wrinkle or be removed by abrasion due to normal handling. All external paintings shall be as per shade no. 631 of IS:5. All ferrous hardware, exposed to atmosphere, shall be hot dip galvanized. GALVANISING: All ferrous parts including all sizes of nuts, bolts, plain and spring washers, support channels, structures, etc., shall be hot dip galvanized to conform to latest version of IS:2629 or any other equivalent authoritative standard.
5.23.2
5.23.3 5.24
5.25
EARTHING: The operating mechanism housing, control cabinets, dead tanks, support structure etc., shall be provided with two separate Earthing terminals suitable for bolted connection to 50x8mm MS flat to be provided by the HVPNL for connection to station earth mat.
5.26
NAME AND RATING PLATES: Circuit breaker and its operating device shall be provided with a rating plate or plates marked with but not limited to following data: a) b) c) d) e) f) g) Manufacturer's name or trade mark. Serial number or type designation making it possible to get all the relevant information from the manufacturer. Year of manufacture. Rated voltage. Rated insulation level. Rated frequency. Rated normal current.
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h) i) j) k) l) m) n) o) p)
Rated short circuit breaking current. First pole to clear factor. Rated duration of short circuit. Rated auxiliary DC supply voltage of closing and opening devices. Rated pressure of compressed air gas for operation and interruption. Rated out of phase breaking current Rated supply voltage of auxiliary circuits. Rated supply frequency of auxiliary circuits. Purchase order number and customer's name.
The coils of operating devices shall have a reference mark permitting the data to be obtained from the manufacturer. The rating plate shall be visible in position of normal service and installation. The rating plate shall be weather proof and corrosion proof. 5.27 LIMITS OF TEMPERATURE RISE: The temperature rise on any part of equipment shall not exceed the maximum temperature rise specified below under the conditions specified in test clauses. The permissible temperature rise indicated is for a maximum ambient temperature of 50 C. If the maximum ambient temperature rises, permissible values shall be reduced accordingly. ----------------------------------------------------------------------------------------------------------------------------Sl. No. Nature of the part or of the liquid Maximum value of -----------------------------------------------------------------Temp. at a max air temp Temp. rise ambient not exceeding 50 C
----------------------------------------------------------------------------------------------------------------------------1. Contacts in air. silver-faced 105 55 copper, copper alloy or aluminium alloy {see notes (i) & (ii)} Bare copper or tinned alumi75 25 nium alloy. 2. Contacts in oil: i) Silver-faced copper, copper 90 40 alloy or aluminium alloy (see note ii) ii) Bare copper or tinned alumi80 30 nium alloy. 3. Terminals to be connected to 105 55 external conductors by screws or bolts silver faced 4. 5. (see note iii) Metal parts acting as springs Metal parts in contact with insulation of the following classes: Class Y : (for non-impregnated materials) (See note iv) (See note iv)
90
40
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Class A
Class E
: (for materials immersed in oil or impregnated) : in air in oil : : in air in oil in air in oil
100 120 100 130 100 155 100
50 70 50 80 50 105 50 50 70 50 50
Class B Class F
Enamel : oil base 100 synthetic : in air 120 synthetic : in oil 100 6. Any part of metal or of insul100 ating material in contact with oil except contacts. 7. Oil 90 ---------------------------------------------------------------------------------------------------------Notes: i) ii)
40
When applying the temperature rise of 55 C, care should be taken to ensure that no damage is caused to the surrounding insulating materials. The quality of the silver facing shall be such that a layer of silver remains at the points of contact after the mechanical endurance tests. Otherwise, the contacts shall be regarded as "bare". The values of temperature and temperature rise are valid whether or not the conductor connected to the terminals is silver-faced. The temperature shall not reach a value where the elasticity of the material is impaired. For pure copper, this implies a temperature limit of 75 C.
iii) iv) 5.28 5.28.1
COMPRESSED AIR SYSTEM: Each circuit breaker shall be supplied with individual compressor unit. Each ICU shall be provided with compressor, piping, piping accessories, local air receivers, control valves, filters, coolers of adequate capacity, reducing valves, isolating valves, drain ports etc., The capacity of local air receivers shall be sufficient for two operations of the circuit breaker, at the lowest pressure for auto reclosing duty without refilling. Air Compressor: a) The air compressor shall be oil-less and of air cooled type complete with cylinder, lubrication, drive motor and slide rails. Each compressor shall be rated for the following duty: Total running time of compressor per day ii) iii) b) c) Normal running air charging Air charging time after one close-open operation of all breakers Not exceeding 20 minutes. Not exceeding 15 minutes. Not exceeding 60 minutes.
5.28.2 5.28.3
i)
Compressor shall be driven by automatically controlled motors conforming to this specification. The compressor shall be provided with automatic adjustable unloading device during starting.
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d) 5.28.4.1
Each compressor shall be equipped with a starting operation counter and a running barometer.
Inter-cooler and After Cooler: Inter-cooler between compressor stages and after-cooler at discharge of HP cylinder shall be included in Bidder's scope. These 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 25 times the working pressure. A corrosion allowance of 3 mm shall be included for all steel parts.
5.28.5
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:5197. A corrosion allowance of 3.0 mm shall be provided for shell and dished ends in case the air receiver are not hot dip galvanised . Receivers shall be coated on the inside face with anti-rust medium. Air receivers shall have a manhole with cover for inspection and cleaning. Connections for air inlet and outlet, drain and relief valves shall be flanged type. Pressure gauge and pressure switch connections shall be of screwed type. 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. The receiver shall be rated such that the compressor will not start within less than hour hours for supplying the leakage of air from the compressed air system. This condition shall be met with only one compressor in operation at a time.
b)
c)
d)
5.28.6
Quality of Air: Compressed air used shall be dry and free of dust particles. Arrangement for conditioning the compressed air shall be provided as an integral part of air compressor system. Air shall not condensate at working pressure at a temperature of minus 10 C. Measures of achieving this shall be brought out clearly in the bid. All instruments required for checking the quality of air shall be furnished as special tools alongwith the breakers.
5.28.7
Controls and Control Equipment: a) The compressor control shall be of automatic start/stop type initiated by pressure switches on the main receiver. Supplementary manual control shall also be provided. Duplicate incoming supply of 415 V, AC shall be provided by the HVPNL at switchyard motor control center. The compressor MCC which is in Bidder's scope shall be as per para of this section. Manual change over scheme from the source to other shall be arranged. Facility to annunciate failure of power supply to the compressor motor control center shall be provided. All control equipment shall be housed in a totally enclosed sheet steel cabinet conforming to relevant standards. Pressure gauges, other indicating devices and control switches shall be mounted on the control cabinet. The flow capacity of all valves shall be at least 20% greater than the total compressor capacity.
b)
c)
5.28.8
Compressed Air Piping, Valves and Fittings: a)
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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. All compressed air piping shall be bright annealed, seamless phosphorous Deoxidized Non-Arsenical Copper alloy or stainless steel pipe (C-106 of BS:2871-1957). Compressor air piping in the switchyard trenches shall be laid with a slope of 1 in 1000. All necessary fittings required for this purpose including the drain valves at all the low points shall be included in the proposal. The piping shall be laid horizontally on steel supports in RCC trenches having a slope of 1 in 500. All joints and connections in the piping system shall be brazed or flared as necessary. All compressed air piping shall be carried out in accordance with BS:162. Compressed air piping system shall be complete with saddle clamps to support the piping system at every one meter interval and expansion joint at every 40 meters interval.
c)
d)
e) f) g)
5.28.9
Motor Control Center: The 415 Volt motor control centers conforming to requirements for control cabinets stipulated in clause 5.3 of this specification shall be fixed type and fully sectionalised and shall be equipped with load break switches. Motor feeders shall be provided with isolating switch fuse unit and Bidder with thermal overload relay and open phase protection. The motor Bidder shall have one normally open auxiliary contact for alarm purposes. An ammeter shall be provided on the motor feeders. The motor control circuit shall be independent from all other control circuits.
5.28.10
Fuses: All fuses shall be of the HRC cartridge type, conforming to IS:2208 and suitable for mounting on plug-in type of fuse bases. Fuses shall be provided with visible operation indicators to show that they have operated. All accessible live connections shall be adequately shrouded, and it shall be possible to change fuses with the circuit live, without danger of contact with live conductor. Insulated fuses pulling handle shall be supplied with each control cabinet.
5.29 5.29.1
TERMINAL CONNECTORS: All the circuit breakers shall be provided with terminal connectors suitable for 0.4 Sq.inch ACSR Zebra Conductor. The terminal connectors shall meet the following requirements: a) b) c) d) e) f) g) h) Terminal connectors shall be manufactured and tested as per IS:5561. All castings shall be free from blow holes, surface blisters, cracks and activities. All sharp edges & corners shall be blurred and rounded off. No part of a clamp shall be less than 10 mm thick. All ferrous parts shall be hot dip galvanised conforming to IS:2633. For bimetallic connectors, copper alloy liner of minimum thickness of 2 mm shall be cast integral with aluminium body. Flexible connectors shall be made from tinned copper/ aluminium sheets. All current carrying parts shall be designed and manufactured to have minimum contact resistance. Connectors shall be designed to be corona free in accordance with the requirements stipulated in IS:5561.
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5.30
SPECIFICATION FOR CONTROL CABINETS: 1. Control cabinets shall be sheet steel enclosed and shall be dust, weather and vermin proof. Sheet steel shall be at least 2.6mm thick (2 mm if CRCA) sheet used. Control cabinets shall be provided with a hinged door and padlocking arrangement. The door hinges shall be of union joint type to facilitate easy removal. Door shall be properly braced to prevent wobbling. There shall be provision in the bottom sheet for entrance of cables from below. Equipment and devices shall be suitable for operation on a 415 V, 3 phase 3/4 wire 50 Hz AC system. The wiring shall be of stranded copper with minimum cross section of 2.5 Sq.mm with 1100 V PVC insulation. Bus bars shall be of tinned copper of adequate cross-section to carry the normal current, without exceeding the permissible temperature rise over an ambient temperature of 50 C outside the cubicle. The buses shall be braced to withstand forces corresponding to short circuit current of 25 kA. Motors rated 1 KW and above being controlled from the control cabinet shall be suitable for operation on a 415 V, 3 phase 50 Hz system. Fractional KW motors shall be suitable for operation on a 240 V, 1-phase, 50 Hz supply system. Isolating switches shall be group operated units 3-pole for use on 3-phase supply systems and 2 pole for single phase supply systems) quick make quick break type, capable of breaking safely and without deterioration, the rated current of the associated circuit. Control cabinet door shall be interlocked with the operating handle of the switch so as to prevent opening of the door when the switch is closed. A device for bypassing the door interlock shall also be provided. Switch handle shall have provision for locking in both fully open and fully closed positions. Fuses shall be HRC cartridge link type having prospective current rating of not less than 46 kA (rms). They shall be provided with visible operation indicators to show when they have operated. One fuse pulling handle shall be supplied for every ten fuses or a part thereof. Push button shall be rated for not less than 6 Amps, 415 V AC or 2 Amps, 220V DC and shall be flush mounted on the cabinet door and provided with appropriate name plates. Red, Green and Amber indicating lamps shall be flush mounted and provided with series resistors to eliminate the possibility of short circuiting of control supply in the event of fusing of lamps. For motors upto 5 KW, contactors shall be direct-on-line, air break, single throw type and shall be suitable for making and breaking the starting current of the associated motor which shall be assumed equal to 6.5 times the full load current of the motor at 0.2 p.f. For motors above 5 KW, automatic star delta type starters shall be provided. 3 pole contactors shall be furnished for 3 phase motors and 2-pole contactors for single phase motors. Reversing contactors shall be provided with electrical interlocks between forward and reverse contactors. If possible, mechanical interlocks shall also be provided. Contactors shall be suitable for uninterrupted duty and shall be of duty category class AC4 as defined in IS:2959. The main contacts of the contactors shall be silver plated and the insulation class for the coils shall be class E or better. The dropout voltage of the contactors shall not exceed 70% of the rated voltage. Contactors shall be provided with a three element, positive acting, ambient temperature compensated, time lagged, hand reset type thermal overload relay with adjustable setting. Hand reset button shall be flush with the front door of the cabinet and suitable for resetting with starter compartment door closed.
2.
3.
4.
5.
6.
8.
9.
10.
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Relays shall be either direct connected or CT operated depending on the rated motor current. 11. 12. 13. Single phasing preventer relay shall be provided for 3 phase motors to provide positive protection against single phasing. Mini starters shall be provided with no volt coils whenever required. All necessary cable terminating accessories such as glands, crimp type tinned copper lugs etc., for control cables shall be included in Bidder's scope of supply. Suitable brass cable glands shall be provided for cable entry. Wiring for all control circuits shall be carried out with 1100/650 volts grade PVC insulated tinned copper stranded conductors of sizes not smaller than 2.5 sq. mm atleast 10% spare terminal blocks for control wire terminations shall be provided on each panel. The terminal blocks shall be ELMEK type or equivalent. All terminals shall be provided with ferrules Visibly marked or numbered and these identifications shall correspond to the designations on the relevant wiring diagrams. The terminals shall be rated for adequate capacity which shall not be less than 10 Amps. Control cabinet shall be provided with 240 V, 1-phase 50 fluorescent light fixture and 5 amps, 3 pin socket for handlamp. Hz, 20 W
14.
15. 16.
Space heaters shall be provided inside each cabinet complete with thermostat (preferably differential type) to prevent moisture condensation. Heaters shall be controlled by suitably rated double-pole miniature Circuit Breakers. Signal lamps provided shall be of neon screw type with series resistors, enclosed in bakelite body. Each signal lamp shall be provided with a fuse integrally mounted in the lamp body. All AC control equipment shall be suitable for operation on 240 V, 1 phase 50 Hz system. Items inside the cabinet made of organic material shall be coated with a fungus resistant varnish. All doors, panels, removable covers and breaker openings shall be gasketed all around. All louvers shall have screens and filters. Cabinets shall be dust, moisture and vermin proof.
17.
18. 19. 20.
5.31 5.31.1
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. Stator: a) Stator Frame: The stator frame 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. b) Stator Core: The stator lamination 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 vibrations to minimum. c) Insulation and Winding: i) All insulated winding conductor shall be of copper. The overall motor winding insulation shall be conventional class B type. The winding shall be suitable for successful operation in hot, humid and tropical
- 16 -
5.31.2
climate with the ambient temperature of 50 C. The insulation shall be given fungicidal and tropical treatment as per IS:3202. ii) Any joints in the motor insulation such as at coil connections or between slot and winding section shall have strength equivalent to that of slot section of the coil. For 415 Volt motors, after the coils are placed in slots and all connections are made, entire motor assembly shall be impregnated by completely submerging core and winding in suitable insulating compound or varnish allowed by proper baking. At least two additional submersions and bakes shall be applied either making a total of at least three submersions and bake treatment.
iii)
5.31.3 a) b) c)
Rotor: Rotors shall be adequately designed to avoid overheating during the starting and running conditions. Rotors shall be properly balanced so as to keep the vibration under running condition within the limits. Rotors of induction motors shall be of rigid core construction with bars firmly secured and solidly bonded to the end rings. The end rings assembly shall be such that it is free to move with expansion of the bars without distortion. The connection of the bars to the end ring shall be made by brazing or fusion welding. Rotors shall be so designed as to keep the combined critical speed with the driven equipment away from the running speed by at least 20%. Rotors shall also be designed to withstand 120% of the rated speed for 2 minutes in either direction of rotation. All high speed rotors shall be constructed with provision of re-balancing the rotor on its site position without major disassembly. Depending upon the capacity and loading conditions Bidder suitable grease lubricated or oil lubricated bearings. shall design
d) e) f) 5.31.4
Bearings: a) b)
Greased ball and roller bearings when used shall be of reputed make subject to HVPNL's approval. The minimum standard life of the bearings shall not be less than 30,000 working hours taking all motor and driven loads into account. These shall be pressure grease gun lubricated type fitted with grease nipple and shall have grease relief devices. Bearing shall be so constructed that the loss of grease and its creeping alongwith shaft into motor housing is prevented. It shall also prevent dirt and water from getting into the motor. Unless otherwise approved, bearing lubrication system shall be such that no external forced oil or water is necessary to maintain the required oil supply or to keep bearing temperature within permissible limits.
c)
d)
e) 5.31.5
For oil lubricated bearings, drain plugs shall be provided for draining any residual oil when required. Motors to be installed 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.
- 17 -
Enclosures: a)
b) c) d) 5.31.6
Two independent Earthing points shall be provided on opposite sides of the motor for bolted connection of Earthing conductor. 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. Motors weighing more than 25 kg shall be provided with eyebolts, lugs or other means to facilitate lifting.
Cooling Method: Motors shall be of self ventilated type having TEFC (totally enclosed fan cooled) enclosure.
5.31.7
Rating Plate: The rating plate shall conform to the requirements of IEC incorporating the year of manufacture.
5.31.8
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 overloaded at any operating point of driven equipment that will arise in service. Motors shall be capable of giving rated output without reduction in expected life span when operated continuously in the system having the particulars as given in Annexure-II. 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 85% of the rated voltage. 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. 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. Motors, when started with the driven equipment imposing full starting torque under the supply voltage conditions specified under clause 5.32.9(a) above shall be capable of withstanding at least 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. The locked rotor withstand time under hot condition at 110% of rated voltage shall be more than starting time with the driven equipment at 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 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.
b)
5.31.9
Starting Requirements: a)
b) c) d)
e)
6.0 6.1
TESTS: TYPE TESTS: The equipment should be offered type test. Test reports should not more then seven years old reckoned from date of bid opening in respect of all the tests carried out in accredited laboratories (based on ISO/IEC) by a reputed accreditatic body or
- 18 -
witnessed by HVPN or another electric power utility and be submitted by the successful bidder to HVPNL for approval as schedule given in Bar Chart. i) Impulse withstand voltage test ii) Power frequency voltage withstand dry test on main circuit iii) Short circuit withstand capability test iv) Mechanical endurance test v) Temperature rise test vi) Radio interference voltage (RIV) vii) Measurement of the resistance of main circuit viii) Short time withstand current and peak withstand current test ix) Out of phase making & breaking test x) Shunt reactor current switching test xi) Dielectric test xii) IP-55 test on operating mechanism xiii) Seismic test 6.2 63 ROUTINE TESTS: As per quality assurance program (QAP). ACCEPTANCE TESTS: The following acceptance tests as stipulated in the relevant ISS-13118 shall be carried out by the Supplier in presence of HVPNL representative, unless dispensed with in writing by the HVPNL. i) Power frequency voltage withstand dry test on main circuit ii) Voltage withstand test on control and auxiliary circuits iii) Measurement of resistance of the main circuit iv) Mechanical operating test v) Design and visual test vi) Tightness Test 7.0 7.1 INSPECTION: The HVPNL shall have access at all times to the works and all other all other places of manufacture, where the circuit breaker are being manufactured and the Bidder shall provide all facilities without extra charges, for unrestricted inspection of the Bidder's works, raw materials, manufacture of the equipment., all the accessories and for conducting necessary test as detailed herein. The Bidder shall keep the HVPNL informed in advance, about the manufacturing program so that arrangement can be made for inspection. No material shall be despatched from its point of manufacture unless the material has been satisfactorily inspected and tested. The Bidder shall submit their internal inspection report containing manufacturer's test certificates before offering the material for inspection. The acceptance of any quantity of equipment shall in no way relieve the Bidder of his responsibility for meeting all the requirements of this specification and shall not prevent subsequent rejection if such equipment are later found to be defective. DOCUMENTATION The successful bidder shall submit four sets of following drawings for HVPNL approval. List of Drawings and Documents: The Bidder shall furnish four sets of relevant descriptive and illustrative published literature pamphlets and the following drawings for preliminary study alongwith the offer.
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7.2 7.3 7.4 7.5
8.0 8.1
a) b)
General outline drawings showing dimensions and shipping weights, quantity of insulating media, air receiver capacity etc., Sectional views showing the general constructional features of the circuit breakers including operating mechanism, arcing chambers, contacts etc., with lifting dimensions for maintenance. Schematic diagrams of breakers offered for control supervision and reclosing. Structural drawing, design calculations and loading data for support structures. Foundation drilling plan and loading data for foundation design.
c) d) e) NOTE:
f) Terminal Connector All above drawings should be a minimum space (14x10cm) for stamping the approval of drawings by HVPNL. TEST REPORTS: i) Four copies of acceptance test reports shall be furnished to the HVPNL. One copy will be returned, duly certified by the HVPNL and only there afterwards shall the material be despatched. All records of routine test reports shall be maintained by the Bidder at his works for periodic inspection by the HVPNL. All test reports of tests conducted during manufacture shall be maintained by the Bidder. These shall be produced for verification as and when requested for by the HVPNL.
8.2
ii) iii)
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SECTION-4 CHAPTER-2 TECHNICAL SPECIFICATION FOR 145/36 kV ISOLATORS & LINE - CUM - EARTH SWITCHES 1.0 SCOPE: This specification provides for design, engineering, manufacture, stage testing, inspection and testing before dispatch, packing, forwarding and delivery at site of 145 kV and 36 kV class Isolators and line-cum-earth switch complete with all fittings, accessories and associated auxiliary equipment mandatory spares which are required for efficient and trouble free operation as specified hereunder. It is not the intent to specify completely herein all details of the design and construction of equipments. However, the equipment shall conform in all respects to high standards of engineering, design and workmanship and shall be capable of performing in continuous commercial operation up to the Bidder's guarantee acceptable to the HVPNL. The equipment offered shall be complete with all components necessary for its effective and trouble free operation along with associated equipment, interlocks, protection schemes etc., Such components shall be deemed to be within the scope of supply, irrespective of whether those are specially brought out in this specification and/or commercially ordered or not. All similar parts particularly movable ones shall be interchangeable. STANDARDS: Unless otherwise specified elsewhere in this specification, the rating as well as performance and testing of the isolators shall conform to the latest revisions and amendments of the following standards available at the time of placement of order. -------------------------------------------------------------------------------------------------------------------------Sl. No. Standard No. Title -------------------------------------------------------------------------------------------------------------------------1. IS:9921 Alternating current isolators(dis-connectors) and earthing switches. 2. IEC:129 -do3. 4. 5. 6. 7. 8. 9. 10 . IS:2544 IS:2147 IS:4691 IS:325 IS:4722 IS:2629 IS:4759 IS:2633 Insulators. Degree of protection provided by enclosure. -doThree phase induction motors. Rotating electrical machines. Recommended practice for hot dip galvanizing of iron & steel. Hot dip galvanizations coating on structural steel. Method of testing weight, thickness and uniformity
2.0
11. IS:1573 Electroplated coating of zinc on iron and steel. 12. IS:6735 Spring washers. 13. IS:2016 Plain washers. 14. __ Indian Electricity Rules, 1956 --------------------- ----------------------------------------------------------------------------------------------Equipment meeting with the requirements of other authoritative National or International Standards, which ensure equal or better performance than the standards mentioned above, shall also be considered. When the equipment offered by the bidder conforms to other standards salient points of difference between standards adopted and the standards specified in this specification shall be clearly brought out in the relevant schedule. Four copies of such standards with authentic translation in English shall be furnished along with the offer. 3.0 SERVICE CONDITIONS: As per section -1 Vol -lI
-1-
3.1
AUXILIARY POWER SUPPLY: The equipment offered under this specification shall be suitable for the following auxiliary power supplies. a) Power Devices 415 V, 3 phase, 4 wire (like drive motors) 50 Hz, neutral grounded AC supply. b) AC control and protective 240 V, single phase, 2 wire devices, lighting 50 HZ, neutral grounded fixtures, space heaters. AC supply. c) DC alarm, control and 220 V, DC 2-wire protective devices Each of the foregoing supplies shall be made available by the HVPNL at the terminal point for each equipment for operation of accessories and auxiliary equipment. Bidder's scope shall include supply of interconnecting cables, terminal boxes, etc., The above supply voltages may vary as below and all devices shall be suitable for continuous operation over entire range of voltages. i) ii) AC supply - voltage + 10%& -15% frequency 5% DC supply - 15% to + 10%
4.0
PRINCIPAL PARAMETERS: The equipment covered in this specification shall meet the technical requirements listed below: ----------------------------------------------------------------------------------------------------------------Sl.No Technical Parameter 36kV 145 kV ---------------------------------------------------------------------------------------------------------------Rated Frequency (Hz) System Neutral Earthing No. of Phases (Poles) Temperature Rise Safe Duration of overload a) 150% of rated current b) 120% of rated current ---------- 5 minutes ----------------------- 30 minutes -------------33/36 132/145 ------------ 50 ----------------- Effectively Earthed --------------------- 3 ----------------------- As per relevant IS/IEC ---
1. 2. 3. 4. 5.
6.
Rated voltage /Highest system voltage (kV rms) Type of disconnect (AB) Rated normal current (Amp rms) Rated short time withstand current (kA rms) of MS & EB for 1 sec duration Rated dynamic withstand current (kA) Rated short circuit making current of EB (kA peak)
7. 8.
DB
DB
630 26.3
1600 31.5
9.
10.
65.75
78.75
11.
65.75
78.75
-2-
12.
Basic insulation level: i) 1.2/50 micro-sec lightning impulse withstand voltage (+ ve or - ve polarity) a) To earth (kVp) b)
170
650 750
Across isolating 195 distance One terminal subjected to lightning impulse (kVp) and opposite terminal subjected to power frequency (kV rms) voltage (as per IS) Rated 1 minute power frequency withstand voltage ( kV rms ) 100 70
ii)
a) Across isolating distance b) To earth and between poles 13. Min. creepage distance of support and rotating insulator (mm) Phase to Phase spacing for installation (mm)
315 275
900
3625
14. 15.
1220
3000
16.
17.
18. 19. 20. 21.
Minimum clearances: a) Phase to earth 320 1300 b) Phase to Phase 350 1600 (Across the same pole) ( Bidders offering lesser clearance must substantiate the same with adequate information on impulse withstand capability of the equipment, However the height of Post Insulator should not be les than 1500mm in case of 145kV and 508 mm in case of 36kV Isolator ) Height of center line of 2800 4000 terminal pad above ground level (mm) Rating of auxiliary 10 A at 220V DC with breaking capacity contacts of 2 A DC with time constant not less than 20 ms. Seismic acceleration .................... 0.3 g horizontal ................ Operating time ---------------- 12 sec or less --------------Rated mechanical As per relevant standards terminal load Rated magnetizing/ 0.7 0.7 capacitive current make/break (Amps/rms)
RIV at 1 MHz & 1.1 X rated phase to earth voltage (micro volts) ----------------------------------------------------------------------------------------------------------------------------------
22.
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5.0 5.1
5.2 5.3 5.3.1 5.4
5.5 5.5.1
5.5.2
5.5.3 5.5.4
GENERAL TECHNICAL REQUIREMENTS: The 145 kV and 36 kV Isolators with & with out earth blade shall be triple pole, single throw, double break , three post per phase, central pole rotating type. The blade shall open and close in a horizontal plane. Complete isolators with all the necessary items for successful operation shall be supplied including but not limited to the following: Isolators assembled with isolator blades (main and earth), complete base frame, linkages, operating mechanism complete etc. The three poles of the 145/36 kV Isolators covered by this specification will be gang operated with one central cabinet for the required electrical devices mounted therein. Material of earthing blades and contacts shall be same as those of main blades and contacts. Cross sectional area of Earthing blades and contacts shall not be less than 50% of cross sectional area of main blades and contacts. The Earthing blades shall have the same short time current rating (thermal and dynamic) as that of main blades. Support insulators for all types of isolators shall be of solid core type except for 33 kV Isolators where in post insulators shall be used. The insulator shall be made of homogeneous and vitreous porcelain of high mechanical and di-electric strength. It shall have sufficient mechanical strength to sustain electrical and mechanical loading on account of wind load, short circuit forces etc., Glazing of the porcelain shall be of uniform brown or dark brown colour with a smooth surface arranged to shed away rain water. The porcelain shall be free from lamination and other flaws or imperfections that might affect the mechanical or dielectric quality. It shall be thoroughly vitrified, tough and impervious to moisture. The porcelain and metal parts shall be assembled in such a manner and with such material that any thermal differential expansion between the metal and porcelain parts throughout the range of temperature specified in this specification shall not loosen the parts or create undue internal stresses which may affect the mechanical or electrical strength or rigidity. The assembly shall not have excessive concentration of electrical stresses in any section or across leakage surfaces. The cement used shall not give rise to chemical reaction with metal fittings. The insulator shall be suitable for water washing by rain or artificial means in service condition. Profile of the insulator shall also conform to IEC-815. Insulator shall have a minimum cantilever strength of 6 KN. Cap to be provided on top of the insulator shall be of high grade cast iron or malleable steel casting. It shall be machine faced and hot dip galvanized. The cap shall have four numbers of tapped holes spaced on a pitch circle diameter of 127 mm for 145 kV Isolators & Linecum-Earth Switches and 76 mm for 36 kV Isolators & Line-cum-Earth Switches. The holes shall be suitable for bolts with threads having anti corrosive protection. The effective depth of threads shall not be less than the nominal diameter of the bolt. The cap shall be so designed that it shall be free from visible corona. The casting shall be free from blow holes, cracks and such other defects. All the ferrous metal parts shall be hot dip galvanized smoothly as per IS: 3638 (as amended upto date), IS: 2633 or any other equivalent authoritative standard. The material shall be galvanised only after shop operations have been completed upon it. The metal parts before galvanising should be thoroughly cleaned of any paint, grease, rust, scales or alkali or any foreign deposit which are likely to come in the way of galvanising process. The coating on the metal parts shall withstand minimum four one minute dips in copper sulphate solution as per IEC-168. The insulator unit shall be assembled in a suitable jig to ensure correct positioning of the top and bottom metal fittings relative to one another. The faces of the metal fittings shall be parallel and at right angles to the axis of the insulator and the corresponding holes in the top and the bottom metal fittings shall be in a vertical plane containing the axis of the insulator. It shall be the sole responsibility of the Bidder to carry out thorough inspection and quality checks on the insulators at the insulator Bidder's works, before offering the insulators for HVPNL's inspection.
-4-
5.5.5
5.5.6
5.6 a)
b)
OPERATING MECHANISM: Each 145 kV & 36 kV isolators shall be remote controlled from the control room. Provision shall be made for local motor control also. Operating mechanism shall also be equipped with local manual operating device intended for emergency operation when motor operating mechanism becomes inoperative. Additional electromagnetic type interlock shall be provided so as to prevent the operation of isolator manually or electrically when the corresponding circuit breaker is ON. Manual operating mechanism through crank and reduction gear shall be provided for the earth switch which too will be gang operated. The operation of earth switch which too will be gang operated. The operation of earth switch shall also be electrically inter-locked by providing a 63.5V rated Bidder and 220 kV DC rated electro magnet. The Bidder will be fed from single phase (132 kV/3/110 kV/3) CVT/ PT provided at the entry of a transmission line in the sub-station. The normally closed contact of said contactor will form part of series chain with other contacts of line isolator/ earth switch to prevent closing of earth switch when the contactor is in picked up position (which means that when the concerned transmission line is live).
5.6.2 The operating mechanism shall provide quick, simple and effective operation. The motor operated type operating mechanism shall be suitable for remote operation of all three poles simultaneously as well as local manual operation through crank and reduction gear. The design of manual operation shall be such that one man shall be able to operate the isolator without undue effort with about 20 (twenty) revolutions of the crank. The operating mechanism shall be suitable to hold the dis-connector in CLOSE OR OPEN position and prevent operation by gravity, wind, short circuit forces, seismic forces, vibration, shock, accidental touching etc., 5.6.3 Limit switches for control shall be fitted on the isolator shaft within the cabinet to sense the open and close positions of the isolators and earth switches. 5.6.4 It shall not be possible, after final adjustment has been made, for any part of the mechanism to be displaced at any point in the travel sufficient enough to cause improper functioning of the isolator when the isolator is opened or closed at any speed. All holes in cranks, linkage etc., having moving pins, shall be drilled to fit accurately so as to maintain the minimum amount of slack and lost-motion in the entire mechanism. 5.6.5 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. The remote push buttons shall be arranged by the HVPNL. 5.6.6 Provision shall be made in the control cabinet to disconnect power supply to prevent local/remote power operation. 5.6.7 Each motor operated mechanism shall be subjected to blocked rotor test. 5.7 CONTROL CABINET: The control cabinet of the operating mechanism shall be made out of 12 SWG (2.64 mm thick) sheet steel duly hot dip galvanised or 10 mm thick aluminium plate or casting. Hinged door shall be provided with pad locking arrangement. Sloping rain hood shall be provided to cover all sides. 15 mm thick neoprene or better type of gaskets shall be provided to ensure degree of protection of at least IP:55 as per IS:2147. The cabinet shall be suitable for mounting on support structure with adjustment for vertical alignment. Details of these arrangements shall be furnished along with the tender. 5.8 MOTOR: The motor shall be suitable for three phase, 415 V, A.C. with variations as specified in this specification. It shall be totally enclosed type if mounted outside the control cabinet. The motor shall withstand without damage stalled torque for at least three times the duration of tripping device. The motor shall, in all other respects, conform to the requirement of IS-325. 5.9 GEAR: The disconnector may be required to operate occasionally, with considerably long idle intervals. Special care shall be taken for selection of material for gear and lubrication of gears to meet this requirement. The gears shall be made out of aluminium bronze or any other better material and lubricated for life with graphite or better quality non draining and
-5-
5.10
5.11
5.12
5.13
5.14
5.15
5.16
non hardening type grease. Wherever necessary automatic relieving mechanism shall be provided. Complete details of components, material, grade, self lubricating arrangement, grade of lubricants, details of jig, fixtures and devices used for quality check, shall be furnished by the Bidder in his offer. GLAND PLATE AND GLANDS: A removable gland plate with double compression type brass cable glands shall be provided with each operating mechanism for terminating all cables. Exact quantity of glands to be provided, shall be intimated to the Bidder. CONTROL CIRCUITS: Control device shall store OPEN and CLOSE command even if the corresponding switch is momentarily pressed until the command is fully executed and the components get deenergised after execution. Failure of auxiliary power supply or loose contact shall not cause faulty operation. SUPPORTING STRUCTURE: The Isolators and isolator - cum - earth switches shall be mounted rigidly in an upright position on their own supporting structure and not on the line or bus bar structure. The supporting structures will be arranged by the HVPNL. The isolator and isolator-cum-earth switch will be suitable for mounting on HVPNL's standard supporting structure HTD/ST-90R3 & HTD/ST-110 for 145 kV & 36 kV respectively. One print of detailed structure drawing is enclosed with the specification which may be perused & its suitability for the offered equipment be confirmed by the bidders. Any additional member of structure required for mounting the M O M box of isolators as well as line-cum-earth switch will be in scope of bidder's supply. LIMIT SWITCH: Limit switches shall be of reputed make. Auxiliary switch shall not be used as limit switch. Details of make, rating and type of limit switch shall be furnished in the offer. OVERLOAD AND SINGLE PHASING PREVENTER: Suitable relay/device shall be provided to prevent overloading of the motor. Single phase preventer shall be provided to operate on open circuiting of any phase and shall trip off the motor. Complete details of the devices shall be furnished in the offer. CONTACTOR: The Bidder shall be suitable for making and breaking stalled motor current. The Bidder coil shall be suitable for 220 V D.C. Two nos. of Bidders shall be provided for each motor for OPEN and CLOSE operation respectively. Make, type, rating and details of the Bidder shall be furnished in the offer. AUXILIARY SWITCH:
5.16.1 Each operating mechanism box shall be equipped with ten nos. of NC and ten nos. of NO auxiliary switches exclusively for HVPNL's use. In addition, two pairs of make-before-break NO/NC contacts shall be provided in the operating mechanism box. 3 pairs of NC and 3 pairs of NO contacts shall be provided in the auxiliary switch box for earth mechanism. 5.16.2 The auxiliary switches and auxiliary circuits shall be capable of carrying the current of atleast 10 Amps continuously 5.16.3 Auxiliary switches shall be capable of breaking atleast 2A in a 220 V D.C. circuit with a time constant of not less than 20 milli seconds. 5.16.4 Quick Make and Break (QMB) type auxiliary switch shall have snap action built-in within the switch. 5.16.5 The auxiliary switches shall be actuated by a cam or similar arrangement directly mounted on the isolator and shall be without any intermediate levels, linkages etc., to ensure fool proof operation. 5.17 SPACE HEATERS: Space heater, thermostatically controlled, suitable for single phase 240 V AC supply shall be provided for motor operated operating mechanism to prevent condensation. A switch and fuse/link shall be provided in the operating mechanism.
-6-
5.18
5.19 5.19.1
5.19.2
5.19.3
5.19.4 5.19.5 5.19.6
5.20
5.21
5.22
5.23 5.23.1 5.23.2
5.24
5.24.1
TERMINAL BLOCK AND WIRING: Each operating mechanism shall be provided with 1100 V grade stud type terminal block having washers, nuts & check nuts. All auxiliary switches, interlocks and other terminals shall be wired upto terminal block. The terminal block shall have at least 20% extra terminals. All wiring shall be carried out with 1100 V grade insulated 2.5 mm2 copper wires. DUTY REQUIREMENTS: 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. The earth switches, wherever provided, shall be constructionally interlocked so that the earth switch can be operated only when the isolator is open and not vice-versa. The constructional interlocks shall be built-in construction of isolator and shall be in addition to the electrical and mechanical interlocks provided in the operating mechanism. 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 be suitable for continuous operation from DC supply and within a variation range stipulated in this volume. The isolator shall be capable of making/breaking normal currents when no voltage occurs across the terminals of each pole of isolator on account of make/break operation. The isolator shall be capable of making/ breaking magnetising current of 0.7 A at 0.15 power factor and capacitive current of 0.7 A at 0.15 power factor. Isolator and earth switches shall be able to bear on the terminals the total forces including wind loading and electrodynamic forces on the attached conductor without impairing reliability or current carrying capacity. INTERIOR ILLUMINATION: A switch, HRC fuse and holder suitable for a 240 V lamp shall be provided in one of the motor operated mechanism box of isolator and manually operated mechanism box of earth switch. POWER SOCKET: A single phase 240 V 15A power socket and switch shall be provided in the motor operated operating mechanisms of the Isolators poles. CONTROL AND AUXILIARY SUPPLY: A three phase switch with HRC fuses for phases and link for neutral shall be provided for power supply and a 2 way switch with HRC fuses shall be provided for control supply in the motor operated mechanisms of the Isolators. ACCESSORIES: The accessories to be provided on the isolator shall include but not limited to the following: POSITION INDICATOR: A position indicator to show whether the isolator is in ON or OFF position. COUNTER BALANCE SPRINGS: Counter balance springs, cushions etc., shall be provided to prevent impact at the end of travel both on opening and closing of the isolator. The springs shall be made of durable and non-rusting type alloy. NAME PLATES: Isolator and Earthing switches and their operating devices shall be provided with a name plate. The name plate shall be weather proof and corrosion proof. It shall be mounted in such a position that it shall be visible in the position of normal service and installation. It shall carry the following information duly engraved or punched on it. Isolator Base: Name of utility (i.e. HVPNL) : Name of Manufacturer : P.O. No. : Type Designation :
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Manufacturer's serial number : Rated voltage : Rated normal current : Rated short time current (rms) : and duration : Rated short time peak current (kAp): Weight : 5.24.2 Earthing Switch: Name of utility (i.e. HVPNL) : Name of Manufacturer : P.O. No. : Type Designation : Manufacturer's serial number : Rated voltage : Rated short time current (rms) : and duration : Rated short time peak current (kAp) : Weight : 5.24.3 Operating Device: Name of utility (i.e. HVPNL) : Name of Manufacturer : P.O. No. : Type Designation : Reduction gear ratio : AC Motor : i) Rated auxiliary voltage : ii) Starting current : iii) Designation of AC motor as per per IS:4722 : iv) Starting torque at 80% of supply voltage : v) Over travel in degrees after cutting off supply : Total operating time in seconds : i) CLOSE operation - electrical : ii) OPEN Operation - electrical : -do- manual : Space Heater : Rated voltage and power Auxiliary contacts i) Rated current (Amps) : ii) Time constant (ms) : iii) No. of contacts used (NC & NO) : iv) No. of free contacts (NC & NO) : Terminal blocks and wiring i) Rated current : ii) Voltage grade and type : 5.25 PADLOCKING DEVICE: All Isolator and Earthing switches shall be provided with padlocking device to permit locking of the isolator and Earthing switch in both fully open and fully closed positions. Power driven isolator and Earthing switch shall be arranged to be interlocked electrically also. 5.26 SIGNALLING: 5.26.1 Signaling of the close position shall not take place unless the movable contact has set in a position in which the rated normal current, the peak withstand current and the short time withstand current can be carried safely.
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5.26.2
5.27 5.27.1
5.27.2
5.28 5.28.1
Signaling of the open position shall not take place unless the movable contact has reached the position such that the clearance between the moveable and fixed contacts is at least 80% of the isolating distance. EARTHING: Flexible copper connections shall be provided between rotating earth blades and the frame which shall have a cross-section of at least 50 mm2 and shall be tinned or suitably treated against corrosion. The frame of each disconnector and Earthing switch shall be provided with two reliable Earthing terminals for connection to the HVPNL's Earthing conductor/flat and also clamping screws suitable for carrying specified short time current. Flexible ground connections shall be provided for connecting operating handle to the Earthing flat. The diameter of clamping screw shall be atleast 12 mm. The connecting point shall be marked with earth symbol. DESIGN AND CONSTRUCTION: Full particulars of design, manufacture, jig template and quality control devices developed for manufacture of the equipment offered in respect of but not limited to the following, shall be furnished with drawings and descriptions alongwith the tender. i) Contacts, material, current density etc., ii) Design of contact pressure. iii) Contact support and fixing arrangement on isolators. iv) Turn and twist mechanism, clamps, locks etc., v) Bearings, housing of bearings, bushes etc., vi) Balancing of heights, vii) Coupling pipes, joints, connection adjustments. viii) Base plates. ix) Down pipe guides and joints. x) Brass bushes and bearings at various joints. xi) Operating mechanism, type of gear motor, limit switch, aux. switch, timers, size and thickness of box, degree of protection, gland plate, gland etc., xii) Nuts, bolts and fasteners. xiii) Interlocking devices. Offers without the above information or with incomplete information shall not be considered. FASTENERS: Nuts, bolts and washers of 5/8" and higher size shall be hot dip galvanised. The bolts used on tapped holes of insulator cap shall be galvanised by centrifuge process to avoid excess deposition of zinc on threads. Nuts, bolts and washers of less than 5/8" size shall be of stainless steel when used on live parts and nickel plated brass in other parts. CONTACTS: Contacts shall be made out of hard drawn electrolytic grade copper. Arcing contacts wherever provided shall close first and open last. The contacts surface shall be silver plated. Fabrication of contact shall be made with suitable jig to avoid deviations during production. Details of size and shape of contacts, springs, back plate, fixing arrangements design of contact pressure, life of contacts, limit of temperature rise etc., shall be furnished along with the tender. The moving contacts of tubular section shall be so dimensioned as to carry the rated current. MOUNTING OF CONTACTS: The contacts shall rest on a brass block and with initial tension. Suitable device shall be provided to prevent dashing. Fabrication, welding etc., shall be done in suitable jig to avoid deviations during production.
5.28.2
5.28.3
5.28.4
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5.28.5
5.28.6
5.28.7
5.28.8
5.28.9
5.28.10
5.29 5.29.1
5.29.2
5.29.3
TERMINAL PAD: The terminal pad shall be suitable for connection to aluminium terminal connector through bimetallic plate wherever necessary. It shall be made out of electrolytic copper heavily silver plated. Dimensions of the terminal pad shall be furnished with the tender. MOVING BLADE: Moving blade shall be made out of hard drawn Electrolytic grade copper. Contact surface of moving blade shall be heavily silver plated. The surface shall be wiped during closing and opening operations to remove any film, oxide coating etc., Wiping action shall not cause scouring or abrasion of surfaces. The rotating insulator shall be mounted on housing with bearing housing. The housing shall be made of gravity di-cast aluminium with smooth surfaces suitably machined for seating the bearings. Two nos. of bearings with adequate shaft diameter and distance between the bearings shall be provided to avoid wobbling during operations. The bearings shall be of atleast 50 mm shaft diameter. The bearings shall be of reputed make eg. SKF, HMT, NBC, TATA, and lubricated for life. All other friction locations shall be provided with bearings, bushes, joints, springs etc., shall be so designed that no lubrication shall be required during service. Complete details of bearings, bushes, housing, greasing etc., shall be furnished with the tender. The Earthing switch shaft shall also be provided with necessary bearings. Tandem pipes shall be of adequately dimensioned for the given duty and shall be class B. Base plate of insulators for connection of tandem pipe shall be made out of one piece 10 mm thick MS plate. Bolt and shackle device shall be used to connect tandem pipe to the base plate. The operating pipe too shall be of class B and adequately dimensioned for the given duty. The pipe shall be terminated into a suitable swivel or universal type joint between the insulator bottom bearing and the operating mechanism to take care of marginal angular misalignment at site. Each phase of isolator shall be provided with a rigid base fabricated from steel sections. The base shall be suitable for mounting on support structures. Fabrication, welding etc., shall be done by suitable jig, power press and templates to avoid deviations during production. Details of dimensions sections, jig templates and device used for production of the base shall be furnished with the tender. TERMINAL CONNECTORS: All Isolators shall be provided with universal type terminal connectors suitable for 0.4 Sq. inch ACSR conductor. The unit rate for types of terminal connector shall be quoted in the relevant schedule. The terminal connectors shall meet the following requirements: i) Terminal connectors shall be manufactured and tested as per IS: 5561. ii) All castings shall be free from blow holes, surface blisters, cracks and cavities. All sharp edges and corners shall be blurred and rounded off. iii) No part of a clamp shall be less than 10 mm thick. iv) All ferrous parts shall be hot dip galvanised conforming to IS:2629. v) For bimetallic connectors, copper alloy liner of minimum thickness of 2 mm shall be cast integral with aluminium body. vi) Flexible connectors shall be made from tinned copper / aluminium sheets. vii) All current carrying parts shall be designed and manufactured to have minimum contact resistance. viii) Connectors shall be designed to be corona free in accordance with the requirements stipulated in IS:5561. Wherever necessary bimetallic strip of standard quality shall be used to avoid galvanic corrosion.
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5.30
5.31
5.31.1 5.31.2 5.31.3
5.31.4 6.0 6.1
ASSEMBLY: The disconnector shall be fully assembled at the works of the Bidder and operations shall be carried out on it to ascertain that all parts fit correctly and function satisfactorily. PAINTING, GALVANISING AND CLIMATE PROOFING: All interiors and exteriors of enclosures, cabinets and other metal parts shall be thoroughly cleaned to remove all rust, scales, corrosion, grease and other adhering foreign matter and the surfaces treated by recognised phosphating (e.g. seven tank phosphating sequence). After such preparation of surfaces, two coats of zinc oxide primer shall be given by suitable staving and air drying before final painting. Colour of the final paints shall be of shade no. 631 of IS:5 i.e. epoxy light grey. The finally painted cubicle shall present aesthetically pleasing appearance free from any dent or uneven surface. Paint inside the metallic housing shall be of anti-condensation type and the paint on outside surfaces shall be suitable for outdoor installation. All components shall be given adequate treatment of climate proofing as per IS:3202 so as to withstand corrosive and severe service conditions. All metal parts not suitable for painting such as structural steel, pipes, rods, levers, linkages, nuts and bolts used in other than current path etc., shall be hot dip galvanised and shall be capable to prevent corrosion in view of the severe climatic conditions. Complete details of painting, galvanising and climate proofing of the equipment shall be furnished in the tender. TESTS: TYPE TESTS: The equipment should be offered type test. Test reports should not more then seven years old reckoned from date of bid opening in respect of all the tests carried out in accredited laboratories (based on ISO/IEC) by a reputed accreditatic body or witnessed by HVPN or another electric power utility and be submitted by the successful bidder to HVPNL for approval as schedule given in Bar Chart. i) Insulation level test ii) Temperature rise test iii) Rated peak withstand current and rated short time withstand current test iv) Short circuit making capacity test of earthing switch v) Operation and mechanical endurance test
6.2 63
ROUTINE TESTS: As per quality assurance program (QAP). ACCEPTANCE TESTS: The following acceptance tests as stipulated in the relevant IS:9921 (PART-IV) 1985 shall be carried out by the Supplier in presence of HVPNL representative, unless dispensed with in writing by the HVPNL. i) Power Frequency withstand voltage dry test of main circuit ii) Voltage test on control auxiliary circuits iii) Measurement of resistance of main circuit iv) Mechanical operating test
7.0
INSPECTION: i) The HVPNL shall have access at all times to the works and all other places of manufacture, where the dis-connectors, earth switches and associated equipment are being manufactured and the Bidder shall provide all facilities with out extra cost for unrestricted inspection of the works, raw materials
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8.0
manufacture of all the accessories and for conducting necessary tests as detailed herein. ii) The Bidder shall keep the HVPNL informed in advance of the time of starting and of the progress of manufacture of equipment in its various stages so that arrangements could be made for inspection iii) No material shall be despatched from its point of manufacture unless the material has been satisfactorily inspected and tested. iv) The acceptance of any quantity of the equipment shall in no way relieve the Bidder of his responsibility for meeting all the requirements of this specification and shall not prevent subsequent rejection if such equipment are later found to be defective. DOCUMENTATION: The successful bidder shall submit four sets of following drawings for HVPNL approval. LIST OF DRAWINGS AND DOCUMENTS: The Bidder shall furnish four sets of following drawings alongwith his offer: a) General outline and assembly drawings of the dis-connector operating mechanism, structure, insulator and terminal connector. b) Sectional views and descriptive details of items such as moving blades, contacts, arms contact pressure, contact support bearing housing of bearings, balancing of heights, phase coupling pipes, base plate, operating shaft, guides. c) Name plate. d) Schematic drawing along with detailed write-up. e) Wiring diagram All above drawings should be a minimum space (14x10cm) for stamping the approval of drawings by HVPNL. Instruction Manuals: Twenty copies of the erection, operation and maintenance manuals in English be supplied for each type of dis-connector one month prior to despatch of the equipment. The manual shall be bound volumes and shall contain all drawings and information required for erection, operation and maintenance of the dis-connector including but not limited to the following particulars: a) Marked erection prints identifying the component parts of the dis-connector as shipped with assembly drawings. b) Detailed dimensions and description of all auxiliaries. c) Detailed views of the insulator stacks, metallic, operating mechanism, structure, interlocks, spare parts etc.,
NOTE: 8.5
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ANNEXURE-I (Isolators) LIST OF SPECIAL TESTS TO BE CARRIED OUT --------------------------------------------------------------------------------------------------------Sl. Name of the Test Standard to which it No. Conforms ---------------------------------------------------------------------------------------------------------1. Tests on insulators IS:2544 IEC:168 IS:5561 IS:2633
2. 3.
Tests on terminal connectors Tests on galvanised components
-------------------------------------------------------------------------------------------------------
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SECTION 4, CHAPTER 3 TECHNICAL SPECIFICATION FOR SURGE ARRESTORS (LIGHTNING ARRESTORS) 1.0 1.1 SCOPE: This specification provides for the design, engineering, manufacture, assembly, stage testing, inspection and testing before dispatch, packing, forwarding and delivery at site of Metal Oxide (gapless) 120 kV, 30 kV & 9 kV Surge Arrestors complete with discharge counter, insulating base and other accessories for all rating arresters except 9 kV & 30 kV surge arrester as specified hereunder. It is not the intent to specify completely herein all the details of design and construction of Surge Arrestors. However, Surge Arrestors shall conform in all respects to the high Standard of design and workmanship and be capable of performing in continuous commercial operation up to Bidder's guarantee in a manner acceptable to HVPNL. The Arrestors offered shall be complete with all parts, necessary for their effective and trouble free operation. Such components shall be deemed to be within the scope of supply, irrespective of whether they are specifically brought out in the commercial order or not. STANDARDS: The Surge Arrestors shall conform to the latest editions and amendments available at the time of supply, of the standards listed hereunder. Sl. Standard Title No. Ref. No. 1. IEC:99-4 Specification Part-4 for Surge Arrestors without gap for AC system. 2. IS:3070 Specification for Lightning Arrestors for alternating current system (Part-III) 3. IS: 2629 Recommended practice for hot dip galvanizing of iron and steel. 4. IS: 2633 Method for testing uniformity of coating on zinc coated articles. 5. IS:5621 Specification for large hollow porcelain for use in electrical installation. 6. IS:2147 Degree of protection provided by enclosures for low voltage switchgear and control. 7. Indian Electricity Rules, 1956. For the purpose of this specification all technical terms used hereinafter shall have the meaning as per IEC/ISS specification. For the parameters of the Arrestor which are not specified in IEC specification for Surge Arrestors, the provisions of IS: 3070 (Part-I) shall be applicable. Surge Arrestors meeting with the requirements of other authoritative standards, which ensure equal or better quality than the standards mentioned above shall also be acceptable. Where the equipment offered by the Bidder conforms to other standards, salient points of difference between the standards adopted and the specified standards shall be clearly brought out in the offer. Four (4) copies of the reference standards in English language shall be furnished along with the offer. SERVICE CONDITIONS: As per section-1 Vol-II AUXILIARY POWER SUPPLY: The equipment offered under this specification shall be suitable for the following auxiliary power supplies. Power Devices (like drive motors) 415V, 3 Phase, 4 wire 50 Hz, neutral grounded AC supply AC Control and protective devices, lighting 240V, single space, 2 wire 50 Hz, fixtures, space heaters neutral grounded AC supply DC alarm, control and protective devices 220V, DC 2-Wire Each of the foregoing supplies shall be made available by the HVPNL at the terminal point for each equipment for operation of accessories and auxiliary equipment. Bidders scope
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1.2
2.0 2.1
Note: i.) ii.) 2.2
3.0 3.1
a) b) c)
i.) ii.) 4.0
5.0 5.1 5.2 5.3
5.4 5.5
5.6 5.6.1
5.6.2
5.6.3
shall include supply of interconnecting cables, terminal boxes, etc., The above supply voltages may vary as below and all devices shall be suitable for continuous operation over entire range of voltages. AC Supply-voltage+10%&-15% frequency + 5% DC Supply-15% to +10% SYSTEM PARAMETERS: The Surge Arrestors offered under this specification shall conform to the parameters given below: Sl. Particulars System Voltage (KV rms) No. 132 33 11 1. Nominal system voltage (kV rms) 132 33 11 2. Highest system voltage (kV rms) 145 36 12 3. 1.2/50 microsecond impulse voltage withstand level a) Transformers and Reactors (kVp) 550 170 75 b) Other equipment and lines (kVp) 650 170 75 4. Minimum prospective symmetrical 31.5 26.3 18.4 fault current for 1 second at Arrestor location (kA rms) 5. Anticipated levels of Temporary over voltage and its duration a) Voltage (p.u.) 1.5/1.2 1.5/1.2 1.5/1.2 b) Duration (Seconds) 1/10 1/10 1/10 6. System frequency(Hz) --------------------- 50 2.5 C/S ---------------------7. Neutral Grounding E.E* E.E* E.E* 8. Number of Phases ----------------------- Three -------------------*E/E = Effectively earth GENERAL TECHNICAL REQUIREMENTS: The Surge Arrestors shall conform to the technical requirements as per Annexure-II. The energy handling capability of each rating of Arrestor offered, supported by calculations, shall be furnished in the offer. The Surge Arrestors shall be fitted with pressure relief devices and arc diverting ports and shall be tested as per the requirements of IEC specification for minimum prospective symmetrical fault current as specified in Clause 4.0 (4). The grading ring on each complete Arrestor for proper stress distribution shall be provided if required for attaining all the relevant technical parameters. PROTECTIVE LEVELS: The basic insulation levels and switching impulse withstand levels of the lines and equipment to be protected, have been specified in clause 4.0, "Principal Parameters". The protective characteristics of the Arrestors offered shall be clearly specified in the schedule of guaranteed technical particulars. GENERAL REQUIREMENTS: The materials and components not specifically stated in this specification but which are necessary for satisfactory operation of the equipment are deemed to be included in the scope of supply unless specifically excluded. Unless otherwise brought out separately by the Bidder in the schedule of deviations the Surge Arrestors offered shall conform to the specification scrupulously. All deviations from the specification shall be brought out in the schedule of deviations. The discrepancies between the specification and the catalogues or literature submitted as part of the offer shall not be considered as valid deviations unless specifically brought out in the schedule of deviations. Any deviation which has not been specifically brought out in the schedule of deviations of the Bid Proposal Sheets, shall not be given effect to. The deviations brought out in the schedule shall be supported by authentic documents, standards and other references.
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5.6.4
5.6.5 5.6.6 5.7 5.7.1 5.7.2 5.7.3
5.7.4 5.7.5 5.8 5.8.1 5.8.2 5.8.3 5.8.4
5.8.5 5.9 5.9.1
5.9.2 5.9.3 5.10 5.10.1
5.10.2 5.10.3
5.11
5.11.1
Each individual unit of Surge Arrestor shall be hermetically sealed and fully protected against ingress of moisture. The hermetic seal shall be effective for the entire life time of the Arrestor and under the service conditions as specified. The Bidder shall furnish sectional view of the Arrestor, showing details of sealing employed. The Bidder shall furnish in the offer, a sectional view of pressure relief device employed in the Surge Arrestors offered. The Surge Arrestors shall be suitable for hot line washing. CONSTRUCTION: All the units of Arrestors of same rating shall be inter changeable without adversely affecting the performance. The Surge Arrestors shall be suitable for pedestal type mounting. All the necessary flanges, bolts, nuts, clamps etc., required for assembly of complete Arrestor with accessories and mounting on support structure to be supplied by the HVPNL, shall be included in Bidder's scope of supply. The drilling details for mounting the Arrestor on HVPNL's support shall be supplied by the Contractor. The minimum permissible separation between the Surge Arrestor and any earthed object shall be indicated by the Bidder in his offer. PORCELAIN HOUSING: All porcelain housings shall be free from lamination cavities or other flaws affecting the maximum level of mechanical and electrical strengths. The porcelain shall be well vitrified and nonporous. The Creepage distance of the Arrestor housing shall be as per Annexure-I. The porcelain petticoat shall be preferably of self-cleaning type (Aerofoil design). The details of the porcelain housing such as height, angle of inclination, shape of petticoats, gap between the petticoats, diameter (ID and OD) etc., shall be indicated by the Bidder in his offer in the form of a detailed drawing. The Arrestor housing shall conform to the requirements of IEC/ISS specification. GALVANISATION, NICKEL PLATING ETC.: All ferrous parts exposed to atmosphere shall be hot dip galvanised as per IS:2629 as amended from time to time., Tinned copper/brass lugs shall be used for internal wiring of discharge counter. Screws used for electrical connections shall be either made of brass or nickel plated. Ground terminal pads and name plate brackets shall be hot dip galvanised. The material shall be galvanised only after completing all shop operations. ACCESSORIES AND FITTINGS: Discharge counters shall be provided for the Arrestors except for 9 kV and 30 kV Arresters. The discharge counter shall be provided with milli-ammeter for measuring the leakage current and shall not require any DC or AC Aux. supply. It shall be suitable for outdoor use. The installation of discharge counter shall not adversely affect the Arrestor performance. The discharge counter shall register operation whenever lightning or any other type of surge strikes the Surge Arrestor. All necessary accessories and Earthing connection leads between the bottom of the Arrestor and the discharge counter shall be in the Bidder's scope of supply. The connecting lead between discharge counter and Surge Arrestor shall be of copper flexible tape of size 25x4 mm and minimum of 1.5 meter length. The discharge counter shall be so designed that the readings of discharges recorded by the counter and the readings of milli ammeter shall be clearly visible through an inspection window to a person standing on ground. The minimum height of HVPNL's support shall be 2.5 Meters. Terminal connector conforming to IS: 5561 shall be supplied along with the arrester. Each Surge Counter shall have terminals of robust construction for connection to Earthing lead and these shall be suitably arranged so as to enable the incoming and outgoing connections to be made with minimum bends. Suitable grounding terminal shall be provided for earthing of surge arrestors up to water
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level. Proper functioning of the Surge counter with Surge Arrestor shall be ensured by the Bidder. 5.12 NAME PLATE: The arrestor shall be provided with non-corrosive legible name plate indelibly marked with the following information: 1. Haryana Vidyut Prasaran Nigam Ltd. 2. Order No. 3. Manufacturer's name or trade mark and identification of the Arrestor being supplied. 4. Rated voltage. 5. Maximum continuous operating voltage. 6. Type. 7. Rated Frequency. 8. Nominal discharge current. 9. Long duration discharge class. 10. Pressure relief current in kA rms. 11. Year of manufacture. 6.0 TESTS: 6.1 TYPE TESTS: The equipment should be offered type test. Test reports should not more then seven years old reckoned from date of bid opening in respect of all the tests carried out in accredited laboratories (based on ISO/IEC) by a reputed accredited body or witnessed by HVPN or another electric power utility and be submitted by the successful bidder to HVPNL for approval as schedule given in Bar Chart. i.) Insulation withstand test. ii.) Residual voltage test. iii.) Long duration current impulse withstand test. iv.) Operating duty test. v.) Pressure relief test. vi.) Test of arrestor dis-connector. vii.) Artificial pollution test on porcelain housed arrestors. viii.) Temperature cycle test on porcelain housed arrestors. ix.) Porosity test on porcelain house arrestors. x.) Galvanising test on exposed ferrous metal parts. 6.2 ROUTINE TESTS: As per quality assurance program (QAP). 6.3 ACCEPTANCE TESTS: The following acceptance tests as stipulated in the relevant IS:3070 (PART-III) 1993 shall be carried out by the Supplier in presence of HVPNL representative, unless dispensed with in writing by the HVPNL. i.) Measurement of power frequency reference voltage. ii.) Lightening impulse residual voltage test. iii.) Partial discharge test. 6.4 SURGE MONITOR The following routine test shall be performed in the presence of HVPNLs representative: i.) Tests for satisfactory operation of surge counter while discharging surges. ii.) Test for correctness of leakage current meter before and after the passage of surges. iii.) Visual examination tests. 7.0 INSPECTION: The inspection may be carried out by the HVPNL at any stage of manufacture. The 7.1 successful Bidder shall grant free access to the HVPNL's representative at all times to the works and all other places of manufacture, where equipment are being manufactured and the Contractor shall provide all facilities without extra charges, for unrestricted inspection of the Contractor's works, raw materials, manufacture of the equipment., all the accessories and for conducting necessary test as detailed herein.
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The Contractor shall keep the HVPNL informed in advance, about the manufacturing program so that arrangement can be made for inspection. No material shall be dispatched from its point of manufacture unless the material has been 7.3 satisfactorily inspected and tested. The HVPNL reserves the right to insist for witnessing the acceptance/routine testing of the 7.4 bought out items. The Contractor shall submit their internal inspection report containing manufacturer's test 7.5 certificates before offering the material for inspection. 7.6 The acceptance of any quantity of equipment shall in no way relieve the Contractor of his responsibility for meeting all the requirements of this specification and shall not prevent subsequent rejection if such equipment are later found to be defective. 8.0 DOCUMENTATION: 8.1 The successful bidder shall submit four sets of following drawings for HVPNL approval. List of drawings:i.) General outline drawings of the complete Arrestors with technical parameters. ii.) Drawing showing clearance from grounded and other live objects and between adjacent poles of Surge Arrestors, required at various heights of Surge Arrestors. iii.) Drawings showing details of pressure relief devices. iv.) Detailed drawing of discharge counters along with the wiring and schematic drawing of discharge counter and meter. v.) Outline drawing of insulating base. vi.) Details of grading rings, if used. vii.) Mounting details of Surge Arrestors. viii.) Details of line terminal and ground terminals. ix.) Volt-time characteristics of Surge Arrestors. x.) Details of galvanising being provided on different ferrous parts. xi.) The detailed dimensional drawing of porcelain housing such as ID, OD, thickness and insulator details such height, profile of petticoats, angle of inclination and gap between successive petticoats, total Creepage distance etc., NOTE: All above drawings should bear a minimum space (14x10cm) for stamping the approval of drawings by HVPNL. 7.2
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ANNEXURE - I (Surge Arrestors) TECHNICAL REQUIREMENTS FOR METAL OXIDE (GAPLESS) SURGE ARRESTORS System voltage wise requirement of parameters(kV) Particulars 132 33 11 Rated Arrestor Voltage 120 30 9 M.C.O.V. (kV rms) 104 25 7 Installation ----------------------- Outdoor ----------------------Class -------------------- Station Class ------------------Type of construction for 10 kA --------- Single Column, Single Phase---------rated Arrestor. Nominal discharge current 10KA 10KA 10KA corresponding to 8/20 microsec wave shape (kA rms) Min. discharge capability. 5 KJ/kV (Referred to rated arrester voltage corresponding to Min. discharge characteristics) Type of mounting ----------------------- Pedestal ---------------------Connection P/E P/E P/E (Between phase to earth P/E) (Between phase to phase P/P) Long duration discharge class 3 2 1 Max. Switching Surge kV(P) 280 70 21 Protective level voltage at 1000 Amp. Max. residual voltage kV(P) for 340 85 25 nominal discharge current 10 KA with 8/20 micro second wave Max.residual voltage kV(P) steep 372 93 28 fronted current impulse of 10 KA. Minimum pros-symmetrical fault 31.5 26.3 18.4 current for pressure relief test (kA rms) a) Terminal Connector suitable for ---------------Single Tarantula--------------------AAC conductor size b) Take off Vertical Vertical Vertical Voltage (kV rms) (corona Rated voltage of the Arrestor extinction) Maximum radio Interference ------------------------ 500 -------------------------voltage (Microvolt) when energized at MCOV Yes Yes Whether insulating base and Yes discharge counter with milli-ammeter are required. Minimum creepage distance of 3625 900 300 Arrestor housing (mm)
Sl. No. 1. 2. 3. 4. 5. 6.
7. 8. 9.
10. 11.
12.
13. 14.
15.
16. 17.
18.
19.
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SECTION-4 CHAPTER-4 TECHNICAL SPECIFICATION FOR 36 kV VACUUM CIRCUIT BREAKER (630A) 1. 1.1 Scope: This specification covers the design, manufacture, inspection and testing before dispatch, packing & delivery at site of 36 kV Vacuum Circuit Breaker complete with all accessories including terminal connectors & supporting structure required for satisfactory operation in various sub-stations in the state. It is not the intent to specify completely herein all the details of design and construction of 36kV Vacuum Circuit Breaker. However, 36kV V.C.B. shall conform in all respect to the high standard of design and workmanship and be capable of performing in continuous commercial operation up to Bidder's guarantee in a manner acceptable to HVPNL, who will interpret the meanings of drawings and specifications and shall have the power to reject any work or material which in his judgment are not in accordance there with. The circuit breaker offered shall be complete with all parts, necessary for their effective and trouble free operation. Such components shall be deemed to be within the scope of supply, irrespective of whether they are specifically brought out in the commercial order or not. Standards: The 36kV Vacuum Circuit Breaker shall conform to the latest editions and amendments available at the time of supply of the standards listed here under: Sr. Standard Ref. Title IEC No. ISS No. 1. 2. 3. 4. 5. 6. 7. 8. 2.1 ISS 13118 ISS 2071 (Part-I) ISS 3716 ISS 2099 ISS 4759 ISS 2633 ISS 2147 -Specification for High Voltage Alternating Current Circuit Breaker. Method of High voltage testing General definitions and test Equipment. Application guide to insulation Co-ordination. Bushing for alternating voltage 1000 volts. Hot dip zinc coating on structural steel and other allied products Method for testing uniformity of coating on zinc coated articles. Degree of Protection provided by enclosures for low voltage switch gear and control. Indian Electricity Rules, 1956 IEC-56 IEC-601 IEC-71-2 IEC-137
1.2
2.
--
Equipment meeting with the requirement of other authoritative standards which ensure equal or better quality then the standards mentioned above shall also be acceptable. Where the equipment offered by the Bidder Conforms to other standards, salient points of difference between the standards adopted and the specified standards shall be clearly brought out in the offer. Four copies of reference standards in English language shall be furnished alongwith the offer. Climatic Conditions: The 36 kV Vacuum Circuit Breakers shall be suitable for continuos satisfactory operation under climatic conditions listed below: Location In the State of Haryana Pradesh Max. Ambient Air-temperature 500C Min. Ambient Air-temperature -2.50 C Average daily Ambient temp. 320 C Max. Relative humidty 100%C Annual rainfall 900 mm
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3.
1. 2. 3. 4. 5. 6.
7. Max. Wind pressure 8. Isoceraunic level (days/year) 9. Altitude above mean Sea-level less than 10. Seismic level (Horizontal Acceleration) 4. I) Principal Parameters Nominal system voltage
195 Kg/meter2 45 1000 meter 0.3 g
33kV(RMS) 36kV(RMS) 3 502.5 Hz 1650 MVA 170 kV (P) 0.3min-co-3min-co 3 cycles max.(60 ms) i) ii) 220 volts DC 10% to 15% 240 volts +10% to - 15% for single phase AC supply 415 volts 10% to - 15% for 3 phase AC supply 630 Amp.
ii) Highest system voltage iii) No. Of poles iv) Frequency v) Interrupting Capacity vi) Basic Insulation level vii) Operating duty viii) Total break time for any current upto the rated breaking current. ix) Control circuit voltage
iii)
Continuous current rating at ambient temperature of 50oC xi) Short Circuit breaking 26.3 KA for 1 second current. xii) Creepage distance 900 mm or more 5. General Technical Requirements 5.1.1 The circuit breaker shall consist of 3 phase vacuum circuit breaker consist of porcelain clad for each phase mounted on common clad and mechanically connected for gang operation. The unit shall be capable of with-standing pressure resulting from any specified performance of the breaker. 5.1.2 5.1.3 Material used in construction of circuit breakers shall be acceptable of withstanding the degree of vacuum without distortion or failure of any part. The circuit breaker shall be supplied complete in all respect with necessary lifting tools, foundation bolts and other accessories considered necessary by Bidders for the satisfactory operation. The vacuum interrupter bottles shall be completely maintenance free. Tips of main contacts shall be heavily silver plated. All equipment accessories and wiring shall have tropical protection, involving special treatment of metal and insulation against fungus, insects and corrosion. The safety clearances of all live parts of the equipment shall be as per relevant standards. Electrical as well as mechanical indicator shall be provided to show open and close positions of breaker. It shall be located in a position where it will be visible to a man standing on the ground with mechanism housing closed. And operation counter shall also be provided with each breaker.
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x)
5.1.4 5.1.5 5.1.6 5.1.7 5.1.8
5.2
Mounting: The circuit breakers shall be suitable for mounting on steel structures. The prices of necessary frames for mounting & including connecting material of the circuit breakers shall be quoted for separately. Bushing & Insulator: The basic insulation level of the bushings and support insulator shall be as per clause 4(vi) and the circuit breakers shall be suitable for installation in heavily polluted atmosphere. The porcelain used shall be homogenous and free from cavities or other flaws. These shall be designed to have adequate insulation, mechanical strength and rigidity for satisfactory operation under conditions specified above. All the bushings of identical ratings shall be interchangeable. The puncture voltage shall be entirely free from disturbances, when operating at voltage up to a voltage 10% above rated voltage and shall also be free from external and internal corona. Metal parts and hardware shall be hot dip galvanized as per ISS-2633 latest edition. Operating Mechanism: The circuit breaker shall be designed for remote control from the control room and in addition there shall be provision for manual operation of circuit breaker during maintenance and for local electrical tripping and closing. The circuit breaker shall have a mechanical 'open' and 'closed' indicators in addition to facilities for remote electrical indications The operating mechanism shall be electrical motor operated spring closing mechanism type. The motor shall operate at 240 volts Single phase or 415 volts three phase AC supply with a voltage variation +10% to - 15% in Clause 4 (ix). The mechanism shall be trip free electrically and mechanically. All working parts in the mechanism shall be of corrosion resistant material and all bearings which require greasing shall be equipped with pressure grease fittings. The mechanism shall be strong and quick action and shall be removable without disturbing the other parts of circuit breakers. The mechanism of the breaker shall be such that failure of any spring will not prevent tripping and will not cause tripping or closing The operating mechanism along with its accessories shall be mounted in the weather proof sheet steel cabinet of 2 mm CRCA or 2.64 mm thick M.S sheet with hinged doors of 3 mm thick M.S sheet & lock device located near the circuit breaker. The local control switch and the breaker position indicator shall be provided in this cabinet. The circuit breaker shall also be provided with means for manual operation for maintenance purpose. The control circuit shall be designed to operate on 220 volt DC and it shall be possible to adapting it to work on other voltage by simply changing the operating coils. The closing coil shall be designed to operate satisfactorily at control voltage from 85% to 110% of the normal voltage. It shall also be ensured that the trip coil can operate from 70% to 110% of the normal DC voltage as provided in IS: 13118/91. An AC heater shall be provided in the cabinet to prevent moisture condensation. Necessary cable glands for the cables of the operating mechanism shall also be provided. The Bidder will use the terminal block of moulded dielectric having brass studs for termination of HVPNL's control cables to be laid for remote control of the circuit breaker including its automatic tripping under fault condition. The entire small wiring to be carried out by the manufacturer at the time of constructing the circuit breaker shall be terminated at the terminal block with the help of lugs duly crimped on to the cable cores. The Bidder will supply sufficient number of cable glands & lugs for the HVPNL's use at the time of erection of equipment.
5.3
5.4 5.4.1
5.4.2 5.4.3
5.4.4
5.4.5
5.4.6
5.4.7 Thermostat controlled space heater, internal illumination lamp and 3 pin 5 Amp. socket with individual ON/OFF switches shall be provided in the cabinet.
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5.5
TERMINAL CONNECTOR: Each circuit breaker shall be provided with requisite number of clamp type bimetallic terminal connectors suitable for single/twin/triple 0.4/0.5 Sq. inch ACSR Zebra/Moose Conductor. Two nos. terminal earth connectors for earthling connection shall also be supplied. Interlocking: Provision shall be made to enable electrical interlocking with the opening or closing of the isolator when breaker is closed etc. Provision should also be made for light indication arrangement on control & relay panel when the electrical motor is in operation for charging spring, so that breaker is not operated from remote during the charging cycle. All electrical & mechanical interlock which are necessary for safe & satisfactory operation shall be furnished. AUXILIARY SWITCHES: At least eight pairs of auxiliary contacts each of the normally open and normally closed type shall be provided in circuit breaker for customer's use for the remote indication and control scheme of the circuit breaker and for providing safety interlocking with associated equipment by the HVPNL. Contact shall be provided with trip coil for pre close and post close supervision of trip circuit. Temperature rise limit: The temperature rise on any part of equipment shall not exceed the max. temperature rise limit specified in ISS-13118 over an ambient temperature of 500C. Erection Tools: Special tools and standard accessories required for assembly and for maintenance of the breakers should also form a part of the supply. Necessary list should be supplied with the tender. Rating Plate: Circuit breaker and its operating device shall be provided with a rating plate marked with but not limited to following data. 1. Manufacturer's name, Type of breaker. 2. 3. 4. 5. 6. 7. 8. Serial Number. Rated voltage. Rated normal continuous current. Rated insulation level. Rated frequency. Rated short time breaking current with rated duration. Total weight of breaker. TESTS Type Tests: The equipment should be offered type test. Test reports should not more then seven years old reckoned from date of bid opening in respect of all the tests carried out in accredited laboratories (based on ISO/IEC) by a reputed accreditatic body or witnessed by HVPN or another electric power utility and be submitted by the successful bidder to HVPNL for approval as schedule given in Bar Chart. i) Impulse withstand voltage test ii) Power frequency voltage withstand dry test on main circuit iii) Short circuit withstand capability test iv) Mechanical endurance test v) Temperature rise test
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5.6
5.7
5.8
5.9
5.10
6.0 6.1
vi) Radio interference voltage (RIV) vii) Measurement of the resistance of main circuit viii) Short time withstand current and peak withstand current test 6.2 6.3 Routine Tests: As per quality assurance program (QAP). Acceptance Tests: The following acceptance tests as stipulated in the relevant ISS-13118 shall be carried out by the Supplier in presence of HVPNL representative, unless dispensed with in writing by the HVPNL. i) Power frequency voltage withstand dry test on main circuit ii) Voltage withstand test on control and auxiliary circuits iii) Measurement of resistance of the main circuit iv) Mechanical operating test v) Design and visual test Inspection: The inspection may be carried out by the HVPNL at any stage of manufacture. The successful Bidder shall grant free access to the HVPNL's representative at a reasonable time when the work is in progress. Inspection and acceptance of any equipments under this specification by the HVPNL shall not relieve the Bidder of his obligation of furnishing equipment in accordance with the specification and shall not prevent subsequent rejection if the equipment is found to be defective. The Bidder shall keep the HVPNL informed in advance about the manufacturing programme so that arrangement can be made for inspection. 7.2 7.3 8.0 8.1 The HVPNL reserves the right to insist for witnessing the acceptance/routine testing of the bought out items. No material shall be despatched from the point of manufacture unless the material has been satisfactorily inspected tested and further despatch authorised by HVPNL. DOCUMENTAION: The successful bidder shall submit four sets of following drawings for HVPNL approval. List of Drawings and documents: The Bidder shall furnish four sets or relevant descriptive and illustrative published literature pamphlets and the following drawings for preliminary study alongwith the offer. a) General outline drawings showing dimensions and shipping weights, quantity of insulating media etc. b) Sectional views showing the general constructional features of the circuit breaker including operating mechanism, arcing chambers, contacts with lifting dimensions for maintenance. c) Schematic ideograms of breaker offered for control supervision and re-closing. d) Structural drawing, design calculations and loading data for support structures. e) Foundation drilling plan and loading data for foundation design. NOTE: All above drawings should be a minimum space (14x10cm) for stamping the approval of drawings by HVPNL. 8.2 TEST REPORTS: i Four copies of type test reports shall be furnished to the HVPNL within one month of conducting the tests. One copy will be returned duly certified by the HVPNL to the bidder within three weeks thereafter and on receipt of the same, bidder shall commence with the commercial production of the concerned material. ii Four copies of acceptance test reports shall be furnished to the HVPNL. One copy will be returned, duly certified by the HVPNL and only there afterwards the material shall be despatched.
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7.0 7.1
iii All records of routine test report shall be maintained by the Bidder at his works for periodic inspection by the HVPNL. iv All test reports of tests conducted during manufacture shall be maintained by the Bidder. These shall be produced for verification as and when requested for by the HVPNL. 8.3 GUARANTEES: i) The Bidder shall guarantee that the material, workmanship and performance of the plant and accessories shall meet the requirement of this specification. ii) Should the Bidder wish to depart from the provision of the specifications either on account of manufacturing practice or any other reasons he shall draw attention to the proposed points of departure in his bid and submit such full information, drawings and specification so that merit or his such proposal may be full under-stood. This specification shall be held binding unless the departures have been fully recorded as required above.
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SECTION-4 CHAPTER-5 TECHNICAL SPECIFICATION FOR 11 kV SWITCHGEAR PANELS VACUUM TYPE (1250A)
1.0 1.1 SCOPE: This specification covers the design, engineering, manufacture, assembly, stage testing, inspection and testing before supply, packing forwarding and delivery at site FOR destination of 11 kV switch gear vacuum type 12 panel boards, having 1250 Amp normal current rating all accessories and auxiliary equipments and mandatory spares and maintenance equipment specified here-in required for their satisfactory operation in various Sub-Station of the state as specified here-in. It is not the intent to specify completely herein all details of the design and construction of the circuit breakers. However, the breakers shall conform in all respects to high standards of engineering, design and workmanship and shall be capable of performing in continuous commercial operation upto the Bidder's guarantee acceptable to the Purchaser. The circuit breakers offered shall be complete with all components necessary for its effective and trouble free operation. Such components shall be deemed to be within the scope of bidder irrespective of whether they are specifically brought out in this specification and/or commercially ordered or not. STANDARDS: The circuit breakers shall conform to the latest revisions with amendments available at the time of testing of relevant standards, rules and codes, some of which are listed herein for ready reference. Sr. No. 1 2 3 4 5 6 2.2 STANDARD IEC-56 IS-5578 & 11333 IS- 2147 IS- 13118 IS- 3427 IS-2099 TITLE Specification for alternating current circuit breakers Making and arrangement for switch gear bus-bar main connection and auxiliary wiring. Degree of protection provide for enclosures for low voltage switch gear. Specification for circuit breakers. Disconnectors of circuit breaker & their interlocking. High voltage porcelain bushings.
1.2
2.0 2.1
3.0 3.1 a. b
Equipment meeting with the requirement of any other authoritative standards, which ensure equal or better quality than the standard mentioned above shall also be acceptable. if the equipment offered by the bidders conforms to any other standards , salient points of difference between the standards adopted and the specific standards shall be clearly brought out in relevant schedule . Four copies of such standards with authentic English Translations shall be furnished along with the offer. SERVICE CONDITIONS : As per Section-1 Vol-II. AUXILIARY POWER SUPPLY : Auxiliary electrical equipment shall be suitable for operation on the following supply system. Power devices 415 V, 3 phase 4 wire 50 Hz, neutral (like drive motors ) grounded AC supply . DC alarm, control and protective devices i) 220 V DC, underground 2 wire for 220 kV 132 kV &66 kV Sub-Station. lighting 240 V, single phase ,50 Hz AC supply.
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4.0
Each of the foregoing supplies shall be made available by the purchaser at the terminal point for each circuit breaker for operation of accessories and auxiliary equipment . Bidders scope include supply of interconnecting cables, terminal boxes etc. The above supply voltage may vary as below and all devices shall be suitable for continuous operation over the entire range of voltages. i) AC Supply voltage + 10% & -15 %, frequency 5% ii) DC Supply 10% TYPE & RATING: The panels 11 kV switchgear panels shall comprise of 11 kV Vacuum Type circuit breakers, instrument panels and instrument transformers etc. suitable for indoor use. The equipment shall be totally enclosed in a metal clad cubicle, dust and vermin proof with necessary isolation arrangement. Each panel shall be easily extensible on either side and should be complete with necessary internal copper connections, small wiring, L.T. fuses and supporting frame work with bolts to secure it to the floor. The maximum permissible width of each panel should not be greater than 710mm. The Circuit Breakers shall be draw out type in horizontal position and horizontal isolation. Principal parameters The breakers shall have the following ratings : 4.1 Type Vacuum 4.2 No of poles 3 4.3 Nominal system voltage 11 kV 4.4 Highest system voltage 12 kV 4.5 Rated frequency 50 +/- 1.5 Hz 4.6 Rated continuous current 1250 Amp for incoming & 400 Amp rating at an ambient for outgoing feeders. temp. as specified in IS : 13118-1991 (Latest edition) 4.7 Symmetrical breaking 350 MVA capacity 4.8 Impulse withstand test 75 kV (Peak) voltage 4.9 One minute power 28 kV (rms) frequency withstand test voltage 4.10 Short time current Not less than 18.4 kA current rating corresponding to 350 MVA for 1 sec. 4.11 System neutral Solidly earthed. 5.0 GENERAL DESIGN OF SWITCHGEAR PANELS: 5.1 OPERATING MECHANISM: The vacuum type circuit breaker shall be draw out type & trip free. The VCBs shall be suitable for operation from 220 V DC auxiliary supply. The operating mechanism shall be motor operated spring charged type. There shall be provision(s) for manual charging of closing spring and emergency hand trip. The motor used for the purpose will be suitable for 240 V AC as well as for 220 V DC . The operating mechanism shall work satisfactorily at 85 % - 110 % of rated supply voltage. The VCB shall have 2 normally open & 2 normally-closed auxiliary contacts over & above the ones required for various control & supervision circuits. 5.2 INSTRUMENT PANELS : Each unit shall have its own instrument panel provided at the top & complete with small wiring connections from relays, instrument transformers, metering instruments, indicating instruments, selector switches & circuit breaker control switch. All wiring shall be carried out by using stranded single annealed copper conductor insulated with poly vinyl chloride insulation suitable for 650 V service and in accordance
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with IS:732-1963. CT/PT circuit shall use wire of not less than 4.0 mm2 cross-sectional area whereas control/alarm/supervision circuit shall use wire of not less than 2.5 mm2 cross-sectional area. All wires will be continuous from one terminal to the other and, also will have no Tee-junction enroute. The connections shall be securely made with the help of connecting lugs duly crimped on to the copper conductor. The meters and relays shall be mounted in a convenient position so as to be readily accessible for inspection or repair. The terminal board provided in the instrument panel of VCBs will be made of moulded dielectric having brass studs, washers, holding nuts & locking nuts. All holding nuts shall be secured by locking nuts. The connection studs shall project 6 mm from the lock nut surface. NO OTHER TYPE OF TERMINAL BOARD IS ACCEPTABLE. The panels shall have a degree of protection of IP-4x. The leads from metering CTs shall be directly terminated at TTB & there from at the KWH meter/SEM with a provision to seal TTB and KWH meter/SEM. The said CT leads will be concealed to prevent their tempering enroute. Similarly PT leads from secondary box of the PT to TTB & there from to energy meter including inter panel PT leads will also be concealed to prevent their tempering. The mode & extent of concealing the metering leads of CTs & PTs to prevent their tempering (by unscrupulous operating personnel) will be discussed & mutually agreed upon with the successful bidder(s). TTB used on the instrument panel should be suitable for front connections. Earthing of current free metallic parts or metallic bodies of the relays/switches mounted on the instrument panel and metal enclosed switchgear shall be done by a suitably sized copper conductor. Earth bus made of 25x3 mm bare copper flat will be extended through entire length of 11 kV switch-board with suitable provision to connect it to the sub-station earth at the extremities. The earthing arrangement will meet with the requirements laid down in IS : 3427 read with its latest amendment. 5.3 VACUUM INTERRUPTER: The Vacuum Interrupter of 12 kV minimum 25 kA short time current rating, 2000Amp. Normal current rating capable of withstanding minimum 100 full short circuit operations as per test duty 1 to 5 of IEC-56. Vacuum Interrupters for incomers as well as outgoing shall be same type. These vacuum interrupters shall be of approved make only. 5.4 INSTRUMENT TRANSFORMER : The secondary voltage & current rating of the instrument transformers shall match with the metering or protective equipment. The CTs shall have ratio & accuracy class as mentioned in the schedule of requirement. The CTs shall be wound/ring type in accordance with their ratings. The terminal boards associated with differential CTs, REF CTs & over current / earth fault protection CTs will be of disconnecting type having short circuiting facility & thus facilitate secondary testing of concerned protective relay without disturbing the associated small wiring. Inter- changeability of housing of CTs from one panel to another must be ensured. A resin cast potential transformers shall be provided on the Incoming side of each panel set & shall be star/star connected as per attached Schedule of Requirement Annexure-I. The neutral point of star connected secondary windings of instrument transformers shall be earthed to the main earth bus referred to in the concluding paragraph of clause 5.2. Multiple earthing of any instrument transformers shall be avoided. 5.5 BUS - BARS: All the panels shall be provided with one set of 3 phase 1250 Amps. heat shrunk PVC sleeves insulated Main electrolytic copper bus bars for all switchboards and shall be connected in a separate moisture and vermin proof sheet metal chamber. The cross sectional area of bus bar should however not be less than 1200 mm2 per phase. The bus-bars connections & insulator supports shall be mechanically strung & rigidly supported so as to withstand the stresses generated by vibrations, variations in temperature and due to severe short circuits.
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The bus bars shall be heat shrunk PVC sleeves insulated type and supported on insulators at short intervals keeping adequate clearance as per IE rules between bus bars and earth. However the minimum clearance between phases and phase to earth should not be less than 95mm. The bus bar chamber shall be provided with inspection covers with gaskets & bus bar shutters. Provision shall be made for future extension of bus bar & switch board. 5.6 LIMIT OF TEMPERATURE RISE: The temperature rise of the current carrying parts shall not exceed the permissible limits above the ambient temperature as per relevant standards (latest edition). However, the reference maximum ambient temperature may be taken as 500C. 5.7 BUSHING INSULATORS: These shall comply with the latest issue of IS : 2099 in all respects. 5.8 DISCONNECTORS OF CIRCUIT BREAKER & THEIR INTERLOCKS All disconnectors (isolators) of the 11 kV VCBs & interlocks between different pieces of apparatus provided for reasons of safety & for convenience of operation of switchgear shall meet with the requirement of IS : 3427-1969 read with its latest amendment. Efficient mechanical interlocking shall be provided to meet the following conditions i) It shall be possible to insert/withdraw the breaker only after circuit breaker has been opened. ii) It shall be possible to insert/withdraw the breaker only when it is fully open position as well as it is in Isolated/test position. iii) It shall not be possible to remove the breaker until the moveable plug unit having secondary connections has been withdrawn. iv) It shall not be possible to replace in position moveable plug unit unless the circuit breaker has been racked in. v) Provision of shutters or locks shall be made to prevent access to bus bar chambers and receptacles when the circuit breaker is withdrawn. vi) Provision shall be made for locking the circuit breaker closing mechanism in open position. 5.9 CABLE BOXES: Each 11 kV incoming VCB shall be provided with cable termination arrangement suitable for receiving 2 sets of cable each comprising 3 nos 630 mm2, 11 kV single core XLPE, outer PVC sheathed cables. However cable boxes complete with jointing kits & sealing material suitable for receiving 2 sets of cable each comprising 3 nos 630 mm2, 11 kV single core XLPE, outer PVC sheathed cables shall be supplied for each incomer. The 11 kV capacitor controlling VCB shall be provided with cable boxes suitable to receive 2 sets of 3 core, 11 kV XLPE PVC Sheathed cables of size of 185 mm2 for 3000KVAR Capacitor bank and 300mm2 for 6000KVAR Capacitor Bank (panel with CT ratio 300-150-75/5 A). The 11 kV station transformer VCB shall be provided with cable boxes suitable to receive 3 core, 11 kV, XLPE cables of size upto 50 mm2 (panel with CT ratio 60-30/5 A). Each cable box shall have vertical entry from below. These cable boxes shall be complete in all respects including cable glands of requisite size. The cable boxes should only be either heat shrinkable or push on type. The cable boxes for outgoing panels are not in the scope of this specifications. 5.9A Earthing Truck One no. earthing trolley should be provided for each incomer panel. Earthing trolley must be full fault make type device which is capable of making fault at 46.2 KA(peak) and carry 18.4 KA for one second. The earthing truck for incoming panel must be so designed that it is impossible to earth a live circuit. However manufacturers offering this a standard inbuilt feature of Breaker Trolley is also acceptable 5.10 SUPERVISION SCHEME : 5.10.1 Instrument panels on each of the 11 kV VCB covered by this specification shall be provided with the following indicating lamps/relay:-
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Circuit breaker òpen' Green Circuit breaker `close' Red Auto trip White Circuit breaker spring charged Blue For monitoring of trip circuit both in pre-close and post- close position of the circuit breaker, 1 no. automatic trip circuit supervision relay will be provided on each of the 11 kV (incoming) instrument panel. In case of trip circuit becoming faulty, the operation of this relay shall be accompanied by visual and audio annunciation in accordance with clause 5.10.1 of the specification. However, the trip circuit of each of the 11 kV outgoing / capacitor / Stn. VCB will be monitored òn demand' with the help of an indicating lamp & a push button both when the VCB is òpen & closed'. The lamp will be àmber' coloured. Circuit breaker `close' & òpen' lamps will be wired so as to be on 240 V AC under `normal' condition. These lamps will be switched over to 220 V DC automatically in the event of failure of 240 V AC supply. Each of 11 kV (incoming) instrument panel will be equipped with a suitable relay for the purpose. 5.11 ALARM SCHEME: 5.11.1 NON TRIP ALARM SCHEME: Each of 11 kV (incoming) panel will be provided with a non-trip alarm scheme comprising suitable auxiliary relay (rated for 220 V DC), accept push button, reset push button & a buzzer. It will cater to non-trip condition such as trip circuit faulty & PT secondary fuses blow òff'. The non-trip alarm scheme will meet with the following requirements:i) The closing of an initiating contact shall actuate a buzzer and will be accompanied by a flag indication on the concerned auxiliary relay. ii) The closing of an initiating contact shall glow a lamp which will not reset until the fault has cleared. iii) It shall be possible to silence the buzzer by pressing àccept' push button. If after cancelling the alarm but before resetting the visual signal, the same fault persists the buzzer shall be suppressed. iv) If after canceling the alarm but before resetting visual signal some other fault takes place, the alarm accompanied by flag indication on appropriate auxiliary relay shall take place. v) If after canceling the alarm and after resetting the visual signal, the same fault appears or some other fault take place, the alarm, flag indication and non-trip lamp indication shall reappear as usual. vi) The non-trip alarm acceptance shall be by means of a push button and resetting of visual signal may also preferably be done through a push button. vii) Means shall be provided for test checking the lamp and alarm circuit at frequent intervals. viii) The equipment shall be suitable for 220 Volts DC operation. 5.11.2.TRIP ALARM SCHEME: Trip commands due to operation of protective relay on any of 11 kV VCB constituting the switchboard will trip the concerned VCB. Its auxiliary contact will actuate a bell (provided in each of the 11 kV incoming VCB) & will be cancelled by the associated circuit breaker control handle. Auto trip lamp will glow on the concerned 11 kV VCB & there will be flag indication on the concerned protective relay. 5.12 PT FUSE FAIL ALARM SCHEME: Each of the 11 kV (incoming) instrument panel is to be provided with a relay to monitor the fuses on the secondary side of 11 kV metering PT. The failure of any of secondary fuse on the 11 kV PT will be accompanied by visual & audio indication in accordance with clause 5.10.1 of the specification. None of the 11 kV outgoing/capacitor/Stn. VCB will be provided with fuses & inter-circuit PT leads may run from one bus wire board to the other.
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5.13. METERING SCHEME : 5.13.1 Each of the 11 kV VCB will be provided with a suitably sealed ammeter (additional dials, if any, required to cover all the taps of the CTs shall be included at the time of bidding) with a selector switch facilitating measurement of phase currents as well as unbalance current. The coil of ammeter shall be rated for 5 Amp. The instrument shall be of moving iron spring controlled type of industrial grade À' classification having accuracy class 1.0 & shall conform to IS:1248(1968). 5.13.2 Each of the 11 kV (incoming) VCB will be provided with a suitably sealed voltmeter with a selector switch. The selector switch shall facilitate the measurement of phase to phase & phase to neutral voltage of all the three phases one by one. The coil of the voltmeter shall be rated for 110 V (phase to phase). The instrument shall be of moving iron spring controlled type of industrial grade À' classification with accuracy class 1.0 & shall conform to IS:1248(1968). 5.13.3 Each of the 11 kV VCB except the 11 kV capacitor VCB & incomer VCBs will be equipped with a three-phase four-wire Electronic KWH meter/SEM. The KWH meter shall be rated for 5 A CT secondary and 110 V/3 (phase to neutral) available from 11 kV PT mounted on each of the incoming VCB. The instrument shall be having accuracy class 1.0 and digital LED display only. 5.13.4 Each of the 11 kV (incoming) VCB will be provided with a power factor meter. The PF meter having a range of 0.5Lag - one - 0.5lead shall be of 2 element type suitable for use on three phase three wire unbalanced system. It shall be rated for 5 A CT secondary & 110 V (phase to phase) available from 11 kV PT mounted on each of the 11 kV incoming VCB. The instrument shall be iron-cored dynamometer type having accuracy class 1.0. N.B. Routine test certificates of all the indicating & integrating instruments will be submitted alongwith the routine test certificates of 11 kV switchgear. 5.14 CONTROL SCHEME : 5.14.1 The instrument panel of each of the 11 kV VCB will be equipped with a circuit breaker control handle of pistol grip type with spring return to neutral position and having bell alarm cancellation contacts. The control handle shall be so designed that after being operated to `close' a VCB the operation can not be repeated until the control handle has been turned to `trip' position making it impossible to perform two closing operation consecutively. 5.14 .2 The rating of the control handle shall be suitable for the duty imposed by the closing and opening mechanism of VCB. The moving and fixed contacts shall be of such a shape & material to ensure good contact and long life under service operating duty. All contacts shall be readily renewable. 5.14.3 The number of contacts in the control handle will be decided by the bidder keeping in view the requirements of this specification. Two pairs of contacts shall be kept spare. The total number of contacts proposed to be provided shall be stated in the bid. 5.14.4 Safety against inadvertent operation due to light touch on the control handle shall be ensured. 5.15 PROTECTION SCHEME : 5.15.1 FOR INCOMING PANELS: The back up protection shall be in the form of a combined over current and earth fault relay (two over current and one earth fault). The relay shall be housed in draw out flush mounting case. This shall be triple pole having Inverse Definite Minimum Time (IDMT) characteristics with a 3/10 time current curve i.e. the relay operating time shall be 3 second at 10 times the plug setting at TMS 1. The outer element of the relay shall be arranged for over current protection and shall have a setting range of 50-200 % of 5 A (The relay for station transformer shall have a setting range of 20-80 % of 5 A) and adjustable in suitable equal steps by means of a plug board. The central element shall be used for earth fault protection with a setting range of 20-80 % of 5 A adjustable in suitable equal steps by means of a plug board (for station transformer panels, the setting range
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shall be 10-40% of 5 A ) Each of the three elements shall be fitted with shunt reinforcing unit with hand reset operation indicator. 5.15.2 FOR OUTGOING FEEDERS PANELS: Each outgoing feeder panel shall be provided with a triple pole IDMTL type combined over current and earth fault relay (two over current and one earth fault element) conforming to the technical specification stated in the clause: 5.15.1 above and one set of triple pole instantaneous relay (high set element) in the form of two over current and one earth fault element. The outer element of the relay shall be arranged for over current protection and shall have a setting range of 500-2000 % of 5 A (The relay for station transformer shall have a setting range of 200-800 % of 5 A) and adjustable in suitable steps. The central element shall be used for earth fault protection with a setting range of 200-800 % of 5 A (The relay for station transformer shall have setting range of 100-400 % of 5 A) adjustable in suitable steps. The relay shall have low transient over reach with a high pick-up/ drop of ratio. The relay will be connected in series with the triple pole combined over-current and earth fault relay referred to above and shall be so wired so as to take this (instantaneous) out, if so desired by the purchaser at any time during operation of the equipment. 5.15.3 FOR CAPACITOR PANEL: Each capacitor panel shall be provided with the following relays for protection of capacitor banks:Triple pole non-directional IDMTL type combined over current & earth fault relay (two over current & one earth fault element) conforming to the technical specification stated in clause 5.15.1 above. ii) 1 no. inverse time over voltage relay with setting range 100 % to 130 % of 110 V available from 11 kV PT mounted in the 11 kV (incoming) VCB along with auxiliary transformers(for external mounting) of ratio 110/103.5 to 116.5 V ( in steps of one volt) to be used for compensating the error of over voltage relay. iii) 1 no. inverse time under voltage relay with setting range of 50 % to 90 % of 110 V (phase to phase connections). iv) 2 no. neutral displacement rely with settings 5.4, 7.5, 12.5 & 20 volts and to be fed from open delta winding of three phase (11000//3/(110//3) Volts. Residual voltage transformer (Residual voltage transformer is not a part of this specification). The bidders offering relays with different settings than above shall technically justify their offer. v) 5 minute timer to ensure that the capacitor bank is fully discharged once it has been switched "OFF" before it can be switched "ON" again. 5.15.4 COMMUNICATION COMPATIBILTY OF RELAYS 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. 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 contractors scope of supply. All main protective relays (viz over current and earth fault, Restricted Earth Fault, Over voltage and neutral displacement) shall be 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. 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 personal computer installed in the substation. However, the supply of PC is not covered under this clause. b) The relay shall have suitable communication facility for future connectivity to SCADA. The relay shall be capable of supporting IEC 61850 protocol (with optical port).
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i)
N.B.
5.16
6.0
6.1
The relay shall be suitable for 220 V DC auxiliary supply. The relay cover & case shall be dust proof, water proof & vermin proof. Operating indicators shall be provided on all protective relays/ on their immediate auxiliary units to indicate the type of fault & phase / phases involved. It shall be possible to reset the operation indication without opening the relay case. The routine test certificates of all protective & auxiliary relays will be submitted along with routine test certificates of 11 kV switchgear covered by the specification. D.C. FAIL ALARM SCHEME: A suitable relay for monitoring the DC supply to the 11 kV switchboard shall be mounted on each of the 11 kV incoming instrument panel. The operation of DC fail scheme shall be accompanied by visual (indicating lamp on the instrument panel) & audio (ringing of hooter) annunciation. It shall be possible to silence the hooter by pressing the àccept' push button while the lamp shall continue to glow till the fault has been attended to & DC supply restored. A DC fail `Test' push button may be provided to test the lamp circuit of the scheme. TEST All routine tests shall be carried out in accordance with IS : 13118-1991 (latest edition thereof). TYPE TESTS The equipment offered should be type tested. Type test report should not be more than seven years old, reckoned from the date of bid opening, in respect of the following tests, carried out in accordance with ISS-13118/IEC-56, from Govt./ Govt. approved test house, shall be submitted along with bid: i) Impulse with-stand voltage tests. ii) Power frequency voltage dry & wet tests on main circuits. iii) Short circuit with stand capability tests. iv) Mechanical endurance tests. v) Temperature rise test. However Mechanical endurance tests and Temperature rise test conducted at Firms works in the presence of representative of any of the SEBs/State Power Utilities shall also be acceptable. The remaining type test report as per clause 6.0 of ISS-13118/IEC-56 shall be submitted by the successful bidder with in three month from the date of placement of Purchase Order. These type test reports will also be from Govt./ Govt. approved test house & shall not be more than seven years old reckoned from the date of placement of order. Voltage transformers & current transformers shall comply with the type tests as stipulated in the latest version of IS : 3156 & IS: 2705 respectively. The reports of all type tests conducted shall be supplied. The 11 kV VCB & associated CTs & PTs shall be subjected to routine tests as specified in the latest version of the relevant ISS in the presence of purchaser's representative, if so desired by the purchaser. The routine test certificates of bought out components such as relays, switches, indicating instruments, KWH Meter & SEM will also be presented to HVPNL's inspecting officer who will forward them to the purchaser alongwith his inspection report for the main equipment. All test reports should be got approved from the purchaser before despatch of equipment. DRAWINGS: In addition to any other drawing which the tenderer may like to furnish to explain the merits of his proposal, following drawings shall be submitted with the tender in quadruplicate : i Principal dimensional details of 11 kV Switchgear. ii General arrangement of 12/14 Panel 11kV switchboard including its foundation details.
7.0
-8-
8.0
9.0
10.0 11.0
Schematic drawings of control, metering & protection circuits in respect of 11kV incoming VCB, 11kV outgoing VCB including station transformer VCB & 11 kV capacitor VCB alongwith detailed write-up. iv Drawing showing height of 11 kV bus bars & arrangement of bus bars v Vacuum interrupter drawing. Four copies of the descriptive literature in respect of 11 kV switchgear, relays, KWH meters, SEM, voltmeters, ammeters, selector switches etc. proposed to be used shall also be supplied. The successful bidder shall submit within four weeks the above drawings in quadruplicate on A-3 size paper to the CE/MM, Shakti Bhawan, Sector-6, HVPNL, Panchkula for approval. The purchaser shall communicate his comments/approval on/to the drawings to the successful bidder within a period of four weeks. The supplier shall, if necessary, modify the drawings & resubmit four copies of the modified drawings for purchaser's approval within two weeks from the date of receipt of purchaser's comments. The modified drawings will be approved within 15 days of their receipt by the purchaser. After receipt of purchaser's approval to drawings, a set of reproducibles of approved drawings & five sets of all the approved drawings and operating manuals containing, erection, operation & maintenance instructions per 11 kV switchboard shall be supplied to CE/MM, Shakti Bhawan, Sector-6, HVPNL, Panchkula for use by various agencies of the purchaser. However, one set of drawings and operating manual will be despatched alongwith each 11 kV switch board. The 11 kV switchgear will not be fabricated without getting the drawings approved from the purchaser. In order to ensure timely receipt of all the drawings, literature & reproducibles etc., the purchase section of D&P organisation will issue despatch instruction for despatch of 11 kV switchgear. SPECIAL TOOLS: The tenderer shall separately quote for a set of special tools, if so required, for erection and maintenance of the switchgear panels. DEVIATION FROM SPECIFICATION: Should the tenderer wish to deviate from the provisions of the specification either on account of manufacturing practice, or any other reasons, he shall draw attention to the proposed point of deviation in the tender and submit such full information drawing and specification so that merits of his proposal may be fully understood. The specification shall be held binding unless the deviation have been fully recorded as required above. TRAINING FACILITIES :VOID GUARANTEED AND OTHER TECHNICAL PARTICULARS: These particulars shall be furnished strictly as per Annexure-A. Any deviation from this specification shall be clearly brought out separately.
iii
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ANNEXURE -'I' SCHEDULE OF REQUIREMENT 1. VACUUM TYPE 12 PANELS, 11 kV SWITCH BOARDS AND EACH SWITCH BOARD COMPRISING OF THE FOLLOWING:1 NO. INCOMING PANEL EQUIPPED AS BELOW: Triple pole 350 MVA, 11 kV 1250A draw out type vacuum circuit breaker fitted with arc control device, interlocks, auxiliary switches isolating contacts, emergency hand trip device, mechanical ÒN' & Òff' indicator and motor operated spring charged mechanism. Bus bars 3 phase 1250A. Cable termination arrangement located at the rear of the unit for receiving 2 set of power cables each comprising 3 no. single core 630 mm2 11 kV XLPE PVC sheathed cables & complete in all respect. Cable boxes with jointing kits etc. as per clause 5.9 of the specification. CTs of ratio 1200-900/0.577-5 A with first core for differential protection having a minimum knee point voltage equal to 40 RCT (neglecting lead resistance) and the 2nd core for REF protection having a minimum knee point voltage of 92(RCT)V on 1200 A tap where RCT secondary winding resistance. These CTs shall conform to accuracy class PS of ISS:2705 (Part-IV) and shall have magnetising current as low as possible but in no case exceeding the value corresponding to class 5 P of IS:2705 (Part-III). CTs of 1200-900/5 A of 15 VA output and 5P10 accuracy for over current and earth fault protection & Ampere meter etc. CTs of 1200-900/1 A of 15 VA output, accuracy class 0.2S and ISF less than 5 for SEM.CT secondary terminals shall be brought out in weather proof sealable terminal box & shall be connected to SEM through TTB. Both TTBs and SEM shall be sealable type. 3 phase star/star connected resin cast voltage transformer as per IS: 3156 (Part-II)1965 complete with HT & LT fuses, isolating plugs and sockets for HT & LT copper connectors, current limiting resistances as per following specifications:Sr.No. Core Ratio VA Burden Accuracy 1. Core-I 11000/3/110/3 100VA 1/3p 2. Core-II 11000/3/110/3 10VA 0.2 CT Secondary terminal of metering core i.e. Core-II shall be brought out in whether proof terminal box and shall be connected to SEM through TTB. Both TTBs and SEM shall be sealable type. Vermin and dust proof fitments. INSTRUMENT PANEL MOUNTED ON TOP AND EQUIPPED AS BELOW: Ammeter with selector switch as per clause: 5.13.1 of the specification. Voltmeter with selector switch as per clause: 5.13.2 of the specification. PF meter with TTB as per clause: 5.13.4 of the specification. Triple pole combined over current and earth fault IDMTL relay as per clause: 5.15.1 of the specification. Over voltage relay for incomer panels only. Tripping relay with hand reset contacts suitable for 220 V DC auxiliary supply. Indicating lamps with fittings to indicate breaker òpen', `close', àuto trip' & spring charged as per clause 5.10 of the specification. Automatic trip circuit supervision scheme as per clause 5.10 of the specification. PT fuse alarm scheme as per clause 5.12 of the specification. DC fail alarm scheme as per clause 5.16 of the specification. Circuit breaker control handle as per clause 5.14 of the specification.
1.01.
-1 No.
-1 Set
-3 No.
-3 No. -3 No.
-1 No.
-1 set -1 NO. -1 No. -1 No. -1 No. -1 Set -1 Set -1 No. -4 No. -1 No. -1 No. -1 No. -1 No.
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Alarm equipment for non-trip & trip fault annunciation as per clause 5.11.1 & 5.11.2 of the specification. -1 No. Cubicle illumination lamp with door operated ON/OFF switch. -1 No. 15 A power socket with switch. -1 No. Anti-condensation tubular space heater suitable for connection to 240 V AC supply with a thermostat & a miniature circuit breaker. - 1 No. Special Energy Meter as per Section-5 Chapter- 6. 1.02 8 N0. OUTGOING FEEDER PANELS EACH COMPRISING OF: -1 No. Triple pole 400 A, 350 MVA 11 kV circuit breaker fitted with Arc control devices, interlock arrangement, auxiliary switches, isolating contacts, emergency hand trip device, mechanical ON & OFF indicator & motor operated spring charged mechanism operate at 220 V DC. -1 Set Bus bars 3 phase 1250 A. -3 No. CTs of ratio 300-150/5-5 A with first core of 15 VA output & 5P10 accuracy for O/C & E/F protection & second core 15 VA output & accuracy class 1.0 for metering. -1 No. Anti-condensation tubular space heater for connection to 240 V AC supply with a thermostat & a miniature circuit breaker. -1 Set Vermin proof & dust proof fitments. -1 No. Instrument panel mounted on top & equipped as below:-1 No. Ammeter with selector switch as per clause: 5.13.1 of specification. -1 No. KWH meter with TTB as per clause: 5.13.3 & 5.2 of the specification. -1 set Triple pole combined 2 O/C & 1 E/F IDMTL relay supplemented with triple pole instantaneous relay (high set element) in the form of 2 O/C & 1 E/F as per clause : 5.14.2 of the specification. -1 No. Tripping relay with hand reset contacts suitable for 220 V DC auxiliary supply. -4 No. Indicating lamps with fittings to indicate breaker òpen', `close', àuto-trip' & 'spring charged' as per clause 5.10 of the specification. -1 No. Indicating lamp with fittings & push button switch to indicate trip circuit healthy in pre-close & post-close conditions as per clause: 5.10 of the specification. -1 No. Circuit breaker control handle as per clause: 5.14 of the specification. -1 No. Cubicle illumination lamp with door operated ON/OFF switch. -1 No. 15 A power socket with switch. -1 No. Anti-condensation tubular heater suitable for connection to 240 V AC supply with a thermostat & a miniature circuit breaker. 1.03 1 NO. PANEL FOR CAPACITOR BANK: The capacitor controlling breaker should be suitable to meet all conditions required for capacitor operation & should be suitable for controlling capacitive current upto 400 A at 11 kV which is equivalent to 7.5 MVAR approx. & equipped similar to item No. 1.02 except KWH meter but with the following changes/additions: -2 No. Trifurcating main cable box for receiving 3 core XLPE, PVC sheathed cable upto 185 mm2 & 300 mm2 size and complete with cable glands and jointing kits etc. as per clause: 5.9 of the specification. -3 No. CTs of ratio 300-150-75/5 A output & 5P10 accuracy for over current & earth fault protection. Protection scheme including closing circuit interlock timer shall be as per clause: 5.15.3 of the specification. 1.04 1 NO. STATION TRANSFORMER FEEDER PANEL: Similar to item No. 1.02 but with the following cable box & CTs:-1 No. Trifurcating main cable box for receiving 3 core XLPE cable upto 50 mm2 size & complete in all respect as per clause: 5.9 of the specification. -3 No. CTs of ratio 60-30/5-5 A with first core of 15 VA output & class 5P10 accuracy for O/C & E/F protection & second core of 15 VA output & accuracy class 1.0 for metering.
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-1 No.
1.05
1 No. INCOMING PANEL EQUIPPED EXACTLY IDENTICAL TO ITEM 1.01 DETAILED ABOVE NOTE : The two incoming panels at Sr. No. 1.01 & 1.05 shall be placed at the two extreme ends of the switch board. Provision shall be made to split the 12 panels boards into two parts each having an incoming panel at its end with complete non-trip alarm, trip alarm & protection schemes. VACUUM TYPE 8 PANELS, 11 KV SWITCH BOARD AND EACH SWITCH BOARD COMPRISING OF THE FOLLOWING:2.01 2 No. INCOMING PANELS EQUIPPED EXACTLY IDENTICAL TO ITEM 1.01 & shall be placed at the two extreme ends of the switch board. 2.02 5 No. OUTGOING FEEDER PANELS EQUIPPED EXACTLY IDENTICAL TO ITEM 1.02. 2.03 1 No. PANEL FOR CAPACITOR BANK EQUIPPED EXACTLY IDENTICAL TO ITEM 1.03.
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SECTION-5 CHAPTER-1
TECHNICAL SPECIFICATION FOR 145kV & 36kV CTs & NCTs & 12kV NCTs
C:\Documents and Settings\XENWB\Desktop\G-11 Website\Final Technical G-11- Pkg B 06.09.11\SECTION-5\Ch-1 CT.doc
CT-1
CONTENTS CLAUSE NO.

1.0 2.0 3.0 4.0 5.0 6.0
TITLE
SCOPE STANDARDS PRINCIPAL PARAMETERS GENERAL TECHNICAL REQUIREMENTS TESTS DOCUMENTATION 4
PAGE NO.
3 3 5 8 8
ANNEXURES I.
A-(i) A-(ii) A-(iii) B-(i) B-(ii) B-(iii) B-(iv) C-(i)
COREWISE DETAILS FOR

145kV TRANSFORMER CTs (150-100-75/0.577-1-1A) 145kV LINE cum B/C CTs (600-300-150/1-1-1A) 145kV NCTs (150-100-75/1A) 36 kV T/F I/C CTs FOR 132/33KV T/F WITH 26.3KA STC (600-400-300/0.577-5-5-1A) 36kV LINE CTs WITH 26.3KA STC (300-150/5A) 36kV CAPACITOR CTs (300-150/5A) FOR 132/33KV T/F WITH 26.3KA STC 36kV T/F I/C NCTs (600-400-300/5A) FOR 132/33KV T/F WITH 26.3KA STC 12kV NCTs (1200-900/5A) FOR 16/20 MVA 9 9 10 10 11 11 11 12
CT-2
1.0 1.1
SCOPE This specification provides for design, engineering, manufacture, stage testing inspection and testing before despatch, packing, forwarding and delivery at site for 145kV & 36kV CTs and 145kV, 36kV & 11kV NCTs complete with all fittings. It is not the intent to specify complete herein all details of the design and construction of equipments. However the equipment shall conform in all respects to high standards of engineering design and workmanship and shall be acceptable of performing in continuous commercial operation up-to the bidders guarantee acceptable to the purchaser. The equipment offered shall be complete with all components necessary for its effective and trouble free operation. Such components shall deemed to be within the scope of supply irrespective of whether those are specially brought out in this specification and or the commercial order or not. All similar parts shall be interchangeable. STANDARDS Unless otherwise specified elsewhere in this specification the rating as well as performance and testing of the instrument transformers shall conform but not limited to the latest revisions and amendments available at the time of placement of order of all the relevant standards as listed hereunder.
1.2
2.0
2.1
INSTRUMENT TRANSFORMERS : Sr. No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. Standard No. IS:2165 IS:2705 (I to IV) IS:2099 IS:3347 IS:2071 IS:335 IS:2147 IS:2633 IS:4800 IS:5561 IS:11065 IEC 44-1 IEC-270 (or IS:11322) IEC-44(4) IEC-171 IEC-60 IEC-8263 IS:5621 Title Insulation Co-ordination for equipment of 100kV and above. Current Transformers. Bushings for alternating voltages above 1000Volts. Dimensions of porcelain transformer bushings. Method of High Voltage Testing. Insulating oil for transformers Switchgears. Degree of protection provided by enclosures for low voltage switchgear and control. Method of testing hot dipped galvanized articles. Enameled round winding wires. Terminal connectors. Drawings. Current Transformers. Partial Discharge Measurement Instrument Transformer measurement of PDs. Insulation co-ordination. High voltage testing techniques. Method for RIV test on high voltage insulators. Indian Electricity Rules 1956. Hollow porcelain insulators.
2.2
Equipment meeting with the requirements of other authoritative standards, which ensure equal or better performance than the standards mentioned above, shall also be considered. When the equipment offered by the supplier conforms to other standards salient points of difference between standards adopted and the standards specified in this specification shall
CT-3
be clearly brought out in the relevant schedule. Four copies of such standards with authentic translation in English shall be furnished alongwith the offer. 3.0 PRINCIPAL PARAMETERS: The current transformers covered in this specification shall meet the technical requirements listed hereunder. Sr. No.
1.
PRINCIPAL TECHNICAL PARAMETERS: Item

Type of C.T./ installation.
145kV
36kV
12kV
Single phase, oil filled, Hermetically sealed, outdoor type.
2. 3. 4. 5. 6. a. b. c. d. e. f. 7. 8. 9. 10.
Type of Mounting Suitable for system Frequency Highest system Voltage (KV rms) Minimum Neutral CT Insulating Voltage Current Ratio A/A Line CT Transformer CT Transformer Incomer CT Capacitor CT NCT
145 15
600-300-150/ 1-1-1 150-100-75/ 0.577-1-1 -
Steel Structures 50 Hz 36 15
300-150/5 600-400-300 /0.577-5-5-1 300-150/5A (For 10.864MVAR &
5.432MVAR)
12 8.66
-
150-100-75/1
1200-900/5 -
600-400-300/5
11. 12. a. b. 13. a. b. 14.
600-300-150/ 1-1-1 Bus Coupler CT Method of Earthing the System Solidly Earthed Rated Continuous Thermal current 125% for all taps Ratio taps The tapings shall be only on secondary winding. Acceptable limit of temperature rise As per IS:2705 or equivalent IEC above the specified ambient temperature for continuous operation at rated current. Acceptance partial discharge level at As per IS:11322-1985 or equivalent IEC 1.1 times the rated voltage. 1.2/50 microsecond lightning impulse withstand voltage (kVp) 650 CTs 95 NCTs 1 minute dry & wet power frequency withstand Voltage primary (kV rms) 275 CTs 38 NCTs 3 Power frequency over voltage withstand requirement for secondary winding (kV rms) (for 1 minute) Min. creepage distance of porcelain housing (mm) 3625 CTs 440 NCTs 31.5 Rated short time withstand current (kArms) for 1 Second. 78.75 Rated Dynamic withstand current (kAp) 4.0 Maximum Creepage Factor 170 95 70 38
75 28
15. a. b. 16. 17. 18.
900 440
26.3
65.75
250 18.4 46
CT-4
4.0 4.1
GENERAL TECHNICAL REQUIREMENTS : The insulation of the instrument transformer shall be so designed that the internal insulation shall have higher electrical withstand capability than the external insulation. The designed dielectrics withstand values of external and internal insulation's shall be clearly brought out in the guaranteed technical particulars. The dielectric withstand values specified in this specification are meant for fully assembled instrument transformers. PORCELAIN HOUSING: The details of location and type of joint, if provided on the porcelain, shall be furnished by the Supplier alongwith the offer. The housing shall be made of homogeneous, vitreous porcelain of high mechanical and dielectric strength, glazing of porcelain shall be uniform brown or dark brown colour with a smooth surface arranged to shed away rain water or condensed water particles (fog). Details of attachment of metallic flanges to the porcelain shall be brought out in the offer. The metal tanks shall have bare minimum number of welded joints so as to minimize possible locations of oil leakage. The metal tanks shall be made out of mild steel/stainless steel/aluminum alloy, depending on the requirement. Welding in horizontal plane is to be avoided as welding at this location may give way due to vibrations during transport resulting in oil leakage. Supplier has to obtain specific approval from purchaser for any horizontal welding used in the bottom tank. SURFACE FINISH : The ferrous parts exposed to atmosphere shall be hot dip galvanized or shall be coated with atleast two coats of Zinc Rich Epoxy painting. All nuts, Bolts and washers shall be of stainless steel. INSULATING OIL: Insulating oil required for first filling of the instrument transformer shall be covered in Supplier's scope of supply. The oil shall meet the requirements of latest edition IS:335 or equivalent IEC. PREVENTION OF OIL LEAKAGE & ENTRY OF MOISTURE: The supplier shall ensure that the sealing of instrument transformer is properly achieved. In this connection the arrangement provided by the Supplier at various locations including the following ones shall be described, supported by sectional drawings. i) Locations of emergence of primary and secondary terminals. ii) Interface between porcelain housing and metal tank/s. iii) Cover of the secondary terminal box. Nuts and bolts or screws used for fixation of the interfacing porcelain bushings for taking out terminals shall be provided on flanges cemented to the bushings and not on the porcelain. For gasketed joints, wherever used nitrile butyl rubber gaskets shall be used. The gasket shall be fitted in properly machined groove with adequate space for accommodating the gasket under compression. OIL LEVEL INDICATORS: Instrument transformers shall be provided with oil sight window (Prismatic Type) at suitable location so that the oil level is clearly visible with naked eye to an observer standing at ground level. EARTHING: Metal tank of instrument transformer shall be provided with two separate earthing terminals for bolted connection to 50x8mm MS flat to be provided by the Purchaser for connection to station earth mat. Instrument transformer shall be provided with suitable lifting arrangement to lift the entire unit. The lifting arrangement shall be clearly shown in the general arrangement drawing. Lifting arrangement (lifting eye) shall be positioned in such a way as to avoid any damage to the porcelain housing or the tanks during lifting for installation/transport. Necessary string guides, if required shall be offered which shall be removable type.
4.2 4.2.1.
4.2.2 4.3
4.4
4.5
4.6 4.6.1
4.6.2 4.6.3
4.7
4.8
4.9
CT-5
4.10
i) ii) iii) iv)
NAME PLATE: The instrument transformer shall be provided with non-corrosive, legible name plate with the information specified in relevant standards, duly engraved/punched on it. In addition to these the following specific points shall also be marked on the name plate. P.O. No. with date and (item No, if any) Connection diagram. Rated continuous thermal current. General knee point voltage formula. The size of nameplate and its location on the equipment should be such that it is clearly readable with naked eyes while standing on ground. Suitable terminal connectors for connecting conductor shall be supplied. Suitable terminal earth connectors for earthing connections shall also be provided.
4.11 4.11.1. 1) 2) 3) 4) 5) 6) 7) 8) 4.12
4.13
The terminal connectors shall meet the following requirements: Terminal connectors shall be manufactured and tested as per IS:5561 or equivalent IEC. All castings shall be free from blowholes, surface blisters, cracks and cavities. All sharp edges and corners shall be blurred and rounded off. No part of a clamp shall be less than 10mm thick. All ferrous parts shall be hot dip galvanized conforming to IS:2633 or equivalent IEC. For bimetallic connectors, copper alloy liner of minimum 2mm thickness shall be cast integral with aluminium body. Flexible connectors shall be made from tinned copper/ aluminium sheets. All current carrying parts shall be designed and manufactured to have minimum contact resistance. Connectors shall be designed to be corona free in accordance with the requirements stipulated in IS:5561 or equivalent IEC. Enamel, if used for conductor insulation, shall be polyvinyl acetate type and shall meet the requirements of IS:4800 or equivalent IEC. Polyester enamel shall not be used. Double cotton cover, if used, shall be suitably covered to ensure that it does not come in contact with oil. The temperature rise on any part of equipment shall not exceed maximum temperature rise specified in IS:2705 or equivalent IEC. However, the permissible temperature rise is for a maximum ambient temperature of 50o C. The CT/NCT shall be so constructed that it can be easily transported to site within the allowable transport limitation and in horizontal position, if the transport limitations so demand. Suitable arrangement shall be made for compensation of variation in the oil volume due to ambient variation and to take care of internal abnormal pressures. The pressure variation shall be kept within limits, which do not impair the tightness of the instrument transformer. A pressure relief device capable of releasing abnormal internal pressure shall be provided. The CT secondary terminals except for 145kV Line CT (Annexure I A-(ii)), 33kV T/F I/C CT (Annexure I B-(i)) shall be brought out in a weather proof terminal box. The terminal box shall be provided with removable gland plate. In case of 145kV Line CT & 33 kV T/F I/C CT, CT secondary terminals shall be brought out in two separate weatherproof terminal boxes. In the first box, the terminals of Core Nos.1& 2 (Ref. Annexure I A-(ii)) of 145kV Line CT & Core Nos.1, 2 & 3 (Ref. Annexure I B-(i) of 33kV T/F I/C CT shall be brought out. The terminal box shall be provided with removable gland plate. The terminal of Core No.3 (Ref. Annexure I A-(ii)) of 145kV Line CT & Core No. 4 (Ref. Annexure I-B (i)) of 33kV T/F I/C CT shall be brought out in the second terminal box. This shall also be provided with a removable gland plate. This terminal box shall be provided with proper sealing facility.
4.14 4.15
4.16
CT-6
The terminal box/boxes shall be dust and vermin proof. The dimensions of the terminal box/boxes and its/their openings shall be adequate to enable easy access and working space with use of normal tools. 4.17 4.18 Polarity shall be indelibly marked on each primary and secondary terminal. Facility shall be provided for short-circuiting and grounding of the secondary terminals inside the terminal box. The instrument transformers shall be vacuum filled with oil after processing and thereafter hermetically sealed to eliminate breathing and to prevent air and moisture from entering the tanks. Sealing type oil filling and/or oil sampling cocks shall be provided with facility to reseal the same. The method adopted for hermetic sealing shall be described in the offer. The castings of base, collar etc. shall be die-cast and tested before assembly to detect cracks and voids if any. The instrument security factor of metering core shall be low enough and less than 5. This shall be demonstrated on all the ratios of the metering core, in accordance with procedure specified in IS:2705 or equivalent IEC. In case the instrument security factor of less than 5 is not possible to be achieved on higher ratios, auxiliary CTs of ratio 1/1 and accuracy class 1.0 shall be deemed to be included in the supplier's scope of supply. This shall also be specifically brought out by the supplier in his offer. The provision of auxiliary CT is not acceptable in case of 145kV Line CT (Annexure I A-(ii)) & 33 kV T/F I/C CT (Annexure I-B (i)) as these CT are to be used for commercial metering purpose. PRIMARY WINDING: The design density for short circuit current as well as conductivity of the metal used for primary winding shall meet the requirement of IS:2705 or equivalent IEC. The supplier shall in his offer furnish detailed calculations for selection of winding cross-sections. 4.22 SECONDARY WINDING: Suitably insulated wire of electrolytic grade shall be used for secondary windings. Type of insulation used shall be described in the offer. For multi ratio design, suitable tapping shall be provided on secondary winding only. Ratio tap selection through primary side shall not be acceptable. 4.23 The exciting current of the CT shall be as low as possible. The supplier shall furnish alongwith his offer the magnetization curve/s for all the core/s. The cores shall be of high grade, non-ageing electrical silicon laminated steel of low hysterisis loss and high permeability to ensure high accuracy at both normal and over current. PRIMARY TERMINALS: The primary terminal shall be made out of rods of not less than 30mm dia. copper or equivalent as per IS/IEC. 4.25 Any deviation from the specification shall be clearly brought out separately. In the absence of any specific mention, it shall be implied that the equipment offered is entirely according to this specification. The 72.5 kV and above voltage level instrument transformers shall be provided with suitable test tap for measurement of tests such as partial discharges etc. in factory as well as at site. Provision shall be made of a screw on cap for solid and secured earthing of the test tap connection, when not in use. A suitable caution plate shall be provided duly fixed on the cover of the secondary terminal box indicating the purpose of the test tap and necessity of its solid earthing as per prescribed method before energising the equipment.
4.19 4.20
4.21
4.24
4.26.
CT-7
NOTE:5.0 5.1
The Overall Tolerance for dimensions, Quantity of Oil, Weight, etc should be +5% max. The General Tolerance should be as per ISS. Tolerance for Mounting Dimension should be +5mm. TESTS : TYPE TESTS The equipment offered should be type tested. Test reports should not more then seven years old reckoned from date of bid opening in respect of all the tests carried out in accredited laboratories (based on ISO/IEC) by a reputed accreditation body or witnessed by HVPN or another electric power utility and be submitted by the successful bidder to HVPNL for approval as schedule given in Bar Chart. Temperature-rise Test. Short time current tests. Lighting impulse test. High voltage power frequency wet withstand voltage test. Determination of errors or other characteristic according to the requirement so of the appropriate designation or accuracy class. ROUTINE TESTS : As per quality assurance program (QAP). ACCEPTANCE TESTS: The following acceptance tests as stipulated in the relevant ISS-2705 shall be carried out by the Supplier in presence of HVPNL representative, unless dispensed with in writing by the HVPNL. Verification of terminal marking and polarity. High voltage power frequency dry withstand voltage test for primary winding. High voltage power frequency dry withstand voltage test for secondary winding. Over voltage inter-turn test. Partial discharge tests Determination of errors or other characteristic according to the requirement so of the appropriate designation or accuracy class. DOCUMENTATION: The successful bidder shall submit four sets of following drawings except 6.1(b) below (actual of which shall be supplied at the time of inspection) for HVPNL approval.
i) ii) iii) iv) v) 5.2 5.3
i) ii) iii) iv) v) vi) 6.0 6.1 6.2 a) b) c) i) ii) iii) iv) v) d) e) f) g) h)
List of drawings: General outline and assembly drawings of the equipment. Graphs showing the performance of equipment's in regard to magnetisation characteristics; ratio & phase angle curves, ratio correction factor curves. Sectional views showing: General Constructional Features. Materials/Gaskets/Sealing used. The insulation & the winding arrangements, method of connection of the primary / secondary winding to the primary/ secondary terminals etc. No. of Turns, Cross-Sectional Area, Current density of Primary and secondary windings. Porcelain used and its dimensions. Arrangement of terminals and details of connection studs provided. Name plate. Schematic drawing. Detailed drawing of pressure release device with detailed literature. Terminal connector drawing.
CT-8
NOTE:-
All above drawings should bear a minimum space (14X10cm) for stamping the approval of drawings by the purchaser.
ANNEXURE I-A(i) COREWISE DETAILS OF 145kV TRANSFORMER CT (150-100-75/.577-1-1A) No. OF CORES = 3

Core No. Application Current Ratio (A) Output burden (VA) Accuracy class as per IEC 185
5 PS PS 5P
Formula for minimum knee-point voltage At CT Secondary resistance at 750C at 75A tap (Volt)
6 40 (RCT+1) 20 (RCT+1) -
Maximum Exciting Current (mA)

7 30AT Vk/4 30AT Vk/2 -
A.L.F.
1 1. 2. 3.
2 DIFFERENTIAL PROTECTION REF PROTECTION OVER CURRENT PROTECTION
3 150-10075/0.577 150-10075/1 150-10075/1
4 25
8 10
ANNEXURE I-A(ii) COREWISE DETAILS OF 145kV LINE/BUS COUPLER CT (600-300-150/1-1-1A) No. OF CORES = 3
Core Application No. Current Ratio (A) Output Accurac burden y class (VA) as per IEC 185 4
25 5P
1
1 2
2
DISTANCE PROTECTION OVER-CURRENT & EARTH FAULT PROTECTION METERING
3
600-300-150/1 600-300-150/1
5
PS
Formula for minimum knee-point voltage At CT Secondary resistance at 750C at 300Atap (Volt) 6
120 (RCT+4.5) -
Maximum Exciting Current (mA) 7

80AT VKP -
A.L.F./ I.S.F.
8
ALF 10
600-300-150/1
25
0.2S
ISF<5 for ratio 150/1, ISF<10 for ratio 300/1, ISF<20 for ratio 600/1
CT-9
ANNEXURE I-A(iii) COREWISE DETAILS OF 145kV NEUTRAL CT (150-100-75/1A) No. OF CORE= 1

Core No. Application Current Ratio (A) Output burden (VA) Accuracy class as per IEC 185 5
PS
1
1
2
REF PROTECTION
3
150-100-75/1
4
-
Formula for minimum knee-point voltage At CT Secondary resistance at 750C at 75A tap (Volt) 6
20 (RCT+1)

30AT VK/2
Minimum Insulation Voltage (kV) 8

15
ANNEXURE I-B(i) COREWISE DETAILS OF 36kV TRANSFORMER INCOMER CT FOR 132/33KV WITH 26.3KA STC (600-400-300/.577-5-5-1) No. OF CORES = 4
Core No. Application Current Ratio (A) Output Accuracy burden class as (VA) Per IEC 185 4
20
1
1 2 3
2
DIFFERENTIAL PROTECTION REF PROTECTION OVER CURRENT & EARTH FAULT PROTECTION MAIN METERING
3
600-400-300/0.577 600-400-300/5 600-400-300/5
5
PS PS 5P
Formula for minimum knee point voltage At CT Secondary resistance at 750C at 300A tap (Volt) 6
40 (RCT+1) 100(RCT+1) -
Maximum A.L.F./ Exciting I.S.F. Current (ma) 7

30AT VK/4 75AT VK/2 -
10
600-400-300/1
10
0.2S
<5forratio 300/1 <10forratio 400/1 <20forratio 600/1 -do-
CT-10
ANNEXURE I-B(ii) COREWISE DETAILS OF 36kV LINE CT WITH 26.3KA STC (300-150/5) No. OF CORES = 1
Core No. Application Current Ratio (A) (VA) Output Burden Accuracy Class as per IEC 185 5.
5P
A.L.F.
1.
1.
2.
OVER CURRENT & EARTH FAULT PROTECTION
3.
300-150/5
4.
20
6.
10
ANNEXURE-I-B(iii) COREWISE DETAILS OF 36kV CAPACITOR CT for 5.436 & 10.872 MVAR FOR 132/33KV WITH 26.3KA STC (300-150/5) No. OF CORES = 1
Core No. Application Current Ratio (A) Output Burden (VA) 4.
20
1.
1.
2.
OVER CURRENT & EARTH FAULT PROTECTION
3.
300-150/5
Accuracy Class as per IEC 185 5.

5P
A.L.F.
6.
10
ANNEXURE I-B(iv)
COREWISE DETAILS OF 36kV TRANSFORMER INCOMER NCT FOR 132/33KV WITH 26.3KA STC
(600-400-300/5) No. OF CORES = 1

Core No. Application Current Ratio (A) Output burden (VA) Accuracy class as Per IEC 185 5
PS
1
1
2
REF PROTECTION
3
600-400-300/5
4
-
Formula for minimum knee point voltage At CT Secondary resistance at 750C at 300A tap (Volt) 6
100 (RCT+1)

75AT VK/2

15
CT-11
ANNEXURE I-C(i) COREWISE DETAILS OF 12kV NEUTRAL CT FOR 16/20 MVA T/F (1200-900/5) No. OF CORE = 1
Core Application No. Current Ratio (A) Accuracy class as per IEC 185 4
PS
1
1
2
REF PROTECTION
3
1200-900/5
Formula for minimum knee-point voltage At CT Secondary resistance at 750C at 1200A tap (Volt) 5
95 (RCT+1)

75AT VK/2

8.66
CT-12
SECTION -5 CHAPTER-2
TECHNICAL SPECIFICATION FOR 145kV CAPACITIVE VOLTAGE TRANSFORMERS (CVTs) AND 36kV POTENTIAL TRANSFORMERS (PTs)
C:\Documents and Settings\XENWB\Desktop\G-11 Website\Final Technical G-11- Pkg B 06.09.11\SECTION-5\Ch-2 CVT, PT.doc
CONTENTS
CLAUSE NO. TITLE PAGE NO. -----------------------------------------------------------------------------------------------------------1.0 SCOPE 3 2.0 3.0 4.0 5.0 6.0 STANDARDS PRINCIPAL PARAMETERS GENERAL TECHNICAL REQUIREMENTS TESTS DOCUMENTATION 3 4 4 9 10
ANNEXURES
I. A-(i) B-(i) COREWISE DETAILS FOR 145kV CVTs 36kV PTs 11 12
-----------------------------------------------------------------------
1.0 1.1
SCOPE : This specification provides for design, engineering, manufacture, stage testing, inspection and testing before dispatch, packing, forwarding and delivery at site of 145kV CVTs and 36kV PTs complete with all fittings. It is not the intent to specify completely herein all details of the design and construction of equipments. However the equipment shall conform in all respects to high standards of engineering design and workmanship and shall be capable of performing in continuous commercial operation upto the bidders guarantee acceptable to the purchaser. The equipment offered shall be complete in all components necessary for its effective and trouble free operation. Such components shall be deemed to be within the scope of supply irrespective of whether those are specially brought out in this specification and or the commercial order or not. All similar parts particularly movable ones shall be interchangeable. STANDARDS: Sl.No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 2.2 Standard No. IS : 3156 (Part-I to Part-III) IS : 3156 (Part-IV) IS : 2099 IS : 3347 IS : 2071 IS : 335 IS : 2165 IS : 2147 IEC- 186 IEC - 186A IEC - 270 IS - 5561 IS -4800 IEC- 44 (4) IEC-171 IEC - 358 IEC-60 IEC-8263 IS: 9348 IS: 2633 IS: 11065 IS: 5621 Title. Voltage transformer Capacitor Voltage Transformer High Voltage porcelain bushing. Dimensions of porcelain transformer bushings Method of High Voltage Testing Insulating oil for transformers and switchgears Insulation Co-ordination for equipments of 100 kV and above. Degree of protection provided by enclosures for low voltage switchgear and control. Voltage Transformers First supplement to IEC publication 186 Partial discharge Measurement Terminal Connectors Enameled round winding wires Instrument Transformer measurement of PDs Insulation Co-Ordination Coupling capacitor divider. High Voltage testing techniques. Method for RIV test on high voltage insulators. Coupling capacitors and capacitor dividers Methods of testing hot dipped galvanized articles Drawings. Indian Electricity Rules 1956 Hollow porcelain insulators.
1.2
2.0
Equipment meeting with the requirements of other authoritative standards, which ensure equal or better performance than the standards mentioned above, shall also be considered. When the equipment offered by the supplier conforms to other standards
salient points of difference between standards adopted and the standards specified in this specification shall be clearly brought out in the relevant schedule. Four copies of such standards with authentic translation in English shall be furnished alongwith the offer. 3.0 PRINCIPAL PARAMETERS : The capacitor voltage transformers and potential transformers covered in this specification shall meet the technical requirements listed hereunder. PRINCIPAL TECHNICAL PARAMETERS
Sl. No. Item Type/Installation Type of mounting Highest system voltage (kV rms) Suitable for system frequency Rated primary voltage (kV rms No. of Secondary Cores & Secondary Voltage (Volts) PT CVT Specification 145kV 36kV Single Phase, Oil filled, Self cooled, Hermetically sealed, Outdoor type -----Steel structure---------145 36 50 Hz 132/3 33/3
1. 2. 3. 4. 5.
6. i) ii) 7. 8. 9. 10. 11. 12. 13. 14.
15. 16.
Method of earthing the system 1.2/50 microsecond lightning impulse withstand voltage (kVp) 1 Minute dry & wet power frequency withstand 275 70 voltage primary (kV rms) Min. creepage distance of porcelain housing 3625 900 (mm) Creepage factor (max.) 4.0 Rated voltage factor 1.2 continuous and 1.5 for 30 seconds Equivalent capacitance at power frequency for 8800+10% N.A carrier coupling for CVT (PF) -5% Resultant high frequency capacitance for CVT 8800 in carrier frequency range of 40 KHz N.A to (PF) 500 KHz with variation in capacitance as contained in IEC-358 (i.e- 20% & +50%) One minute power frequency withstand 3.0 voltage for secondary winding (kV rms) Max. temperature rise over ambient of 50C As per IS:3156 or equivalent IEC
Core I,II, III 110/3 Solidly earthed 650 170
Core I,II, III 110/3 -
4.0 4.1 4.1.1
GENERAL TECHNICAL REQUIREMENTS: Common for all CVTs & PTs The insulation of the instrument transformers shall be so designed that the internal insulation shall have higher electrical withstand capability than the external insulation. The designed dielectric withstand values of external and internal insulations shall be clearly withstand values specified in this guaranteed
technical particulars. The dielectric withstand values specified in this specification are meant for fully assembled instrument transformers. Porcelain Housing : The details of location and type of joint, if provided on the porcelain, shall be furnished by the supplier alongwith the offer. The housing shall be made of homogeneous, vitreous porcelain of high mechanical and dielectric strength, glazing of porcelain shall be of uniform brown or dark brown colour with a smooth surface arranged to shed away rain water or condensed water particles (fog). 4.1.2.2 Details of attachment of metallic flanges to the porcelain shall be brought out in the offer. 4.1.2.3 The metal tanks shall have bare minimum number of welded joints so as to minimise possible locations of oil leakage. The metal tanks shall be made out of mild steel/Stainless steel/aluminium alloy, depending on the requirement. Welding in horizontal plane is to be avoided as welding at ths location may give way due to vibratins during transport resulting in oil leakage. Supplier has to obtain specific approval from purchaser for any horizontal welding used in the bottom tank. 4.1.3 Surface Finish: The ferrous parts exposed to atmosphere shall be hot dip galvanised or shall be coated with atleast two coats of zinc rich epoxy painting. All nuts, bolts and washers shall be made out of stainless steel. Insulating Oil: Insulating oil required for first filling of the instrument transformer shall be covered in supplier's scope of supply. The oil shall meet the requirements of latest edition IS:335 or equivalent IEC. 4.1.2 4.1.2.1
4.1.4
4.1.5 Prevention of Oil leakages and Entry of Moisture: 4.1.5.1 The supplier shall ensure that the sealing of instrument transformer is properly achieved. In this connection the arrangement provided by the supplier at various locations including the following ones shall be described, supported by sectional drawings. i) Locations of emergence of primary and secondary terminals. ii) Interface between porcelain housing and metal tanks. iii) Cover of the secondary terminal box. 4.1.5.2 Nuts and bolts or screws used for fixation of the interfacing porcelain bushings for taking out terminals, shall be provided on flanges cemented to the bushings and not on the porcelain. 4.1.5.3 For gasketed joints, wherever used nitrile butyl rubber gaskets shall be used. The gasket shall be fitted in properly machined groove with adequate space for accommodating the gasket under compression. 4.1.6 Oil level indicators: Instrument transformers shall be provided with oil sight window (Prismatic Type) at suitable location so that the oil level is clearly visible with naked eye to an observer standing at ground level. Earthing: Metal tank of the instrument transformer shall be provided with two separate earthing terminals for bolted connection to 50X8mm MS flat to be provided by the Purchaser for
4.1.7
4.1.8
connection to station earth-mate. Instrument transformer shall be provided with suitable lifting arrangement, to lift the entire unit. The lifting arrangement shall be clearly shown in the general arrangement drawings. Lifting arrangement (lifting eye) shall be positioned in such a way so as to avoid any damage to the porcelain housing or the tanks during lifting for installation/transport. If necessary, string guides shall be offered which shall be of removable type. NAME PLATE: The instrument transformer shall be provided with non-corrosive, legible name plate with the information specified in relevant standards, duly engraved/punched on it. In addition to these P.O. NO.& Connection diagram shall also be marked in rating plate. Suitable terminal connectors for connecting suitable conductor for shall be supplied. Suitable terminal earth connectors for earthing connections shall also be provided. The terminal connectors shall meet the following requirements: Terminal connectors shall be manufactured and tested as per IS:5561 or equivalent IEC. All castings shall be free from blow holes, surface blisters, cracks and cavities. All sharp edges and corners shall be blurred and rounded off. No part of a clamp shall be less than 10mm thick. All ferrous parts shall be hot dip galvanized conforming to IS:2633 or equivalent IEC. For bimetallic connectors, copper alloy liner of minimum 2mm thickness shall be cast integral with aluminium body. Flexible connectors shall be made from tinned copper/aluminium sheets. All currents carrying parts shall be designed and manufactured to have minimum contact resistance. Connectors shall be designed to be corona free in accordance with the requirements stipulated in IS: 5561 or equivalent IEC. Enamel, if used for conductor insulation, shall be polyvinyl acetate type or amide emide type and shall meet the requirements of IS:4800 or equivalent IEC. Polyester enamel shall not be used. Double cotton cover, if used, shall be suitably covered to ensure that it does not come in contact with oil. The temperature rise on any part of equipment shall not exceed maximum temperature rise specified in IS:3156 or equivalent IEC. However, the permissible temperature rise indicated is for a maximum ambient temperature of 50C. The instrument transformers shall be so constructed that it can be easily transported to site within the allowable transport limitation and in horizontal position, if the transport limitations so demand. The instrument transformers shall be vacuum filled with oil after processing and thereafter hermetically sealed to eliminate breathing and to prevent air and moisture from entering the tanks, sealing type oil filling and/or oil sampling cocks shall be provided with facility to reseal the same. The method adopted for hermetic sealing shall be described in the offer. Suitable arrangement shall be made to accommodate the expansion and contraction of oil due to temperature variation. The pressure variation shall be kept within limits which do not impair the tightness of the instrument transformer. A pressure relief device capable of releasing abnormal internal pressure shall be provided. CAPACITOR VOLTAGE TRANSFORMER (CVT): The CVTs comprising of a capacitor divider unit and electromagnetic unit shall be single
4.1.9
4.1.10 4.1.10.1 1) 2) 3) 4) 5) 6) 7) 8) 4.1.11
4.1.12
4.1.13
4.1.14
4.1.15
4.2 4.2.1
4.2.2
4.2.3
4.2.4
4.2.5 4.2.6 4.2.7
4.2.8
4.2.9 4.2.10
4.2.11
phase, oil filled hermetically sealed, self cooled, outdoor type and suitable for direct line connection without any fuse and isolating switches, These CVTs are required to be used on interlinking substations in Haryana power system for the purpose of protection, synchronising, interlocking, carrier coupling and metering. CVTs shall be suitable for connecting the carrier terminals to single circuit and double circuit transmission lines for phase to phase coupling for power line carrier, voice communication, telemetering & teleprinting services. The secondary terminals of potential unit, high frequency coupling terminal and the earthing terminals shall be brought out separately and housed in a water proof cabinet outside the main steel chamber. The capacitor voltage transformer shall be suitable for simultaneous use as measuring unit, for feeding voltage supply to protective relays and as coupling capacitor for carrier transmission i.e. for voice communication, carrier protective relays, telemetering, teleprinting services over one or more carrier channels in the frequency range of 40 to 500KHz. The capacitors shall be designed for wide frequency band and low dielectric loss. Their natural frequency shall be considerably higher than the carrier frequency range of 40 KHz to 500 KHz. The unit capacitors shall be so designed that no damage to internal elements or change in electrostatic capacitance is resulted by the application of impulse voltage. Each CVT including its emvt unit shall be filled with insulating oil conforming to IS:335 or equivalent IEC. And shall be hermetically sealed against moisture and dust. The electromagnetic voltage transformer unit of CVT intended for out-door installation whose primary is to be fed by the inter-mediate tapping of capacitor divider shall be of oil immersed, self cooled design and shall be suitable for metering, relaying & synchronising services. The core of this transformer shall be of high accuracy at normal & high voltages. The primary winding shall be connected through a compensating reactor to compensate the voltage increase at inter-mediate tapping, whatever is the load within range of rated burden. The design shall be free from corona effect to keep noise level of carrier frequency link very low. Use may be made of grading rings or Electrostatic screen for this purpose if required. The design shall be suitable for rapid reclosing of the circuit and shall be capable of accurate and proportionate transmission of sudden variation in the primary voltage. Each CVT shall be provided with a suitable damping device so that ferro resonance oscillation due to saturation of iron core of transformer or any inductance connected in parallel with it and initiated by either over voltages on the net work side or by opening of the short circuited primary or secondaries, shall be practically zero. Oscillations of the secondary voltages which may arise as a result of breakdown of primary voltages due to short circuits shall not affect the proper working of protective relays. This shall confirm to provisions of clause:42 of IEC recommendations 186-A. Design of the potential units of the CVT shall be based on the following requirements in connection with protective relaying. i) They must transmit accurately sudden drops of primary voltage. ii) The CVTs must not enter into sub-harmonic resonance and transient oscillations during energisation. They must be damped out with sufficient rapidness. iii) They must have sufficiently low short circuit impedance as seen from secondary.
4.2.12 A device shall be incorporated in a capacitor voltage transformer for the purpose of limiting over
voltages which may appear across one or more of its components and/or to prevent sustained ferro resonance. The device may include a spark gap and may be located in several different ways according to its nature. (Clause 2.12 of IS:3156 (Part-IV)-1978 or IEC-186A Clause 37.12) 4.2.13 Suitable terminal boxes with removable gland plate for facilitating the entry of H.F. Cable & VT control cables shall be provided at an accessible position. 4.2.14 The secondary terminals of 145kV CVTs shall be brought out in two separate weather proof terminal boxes and it shall be provided with a removable gland plates. In case of 145kV CVTs, in the first box, secondary terminals of Core-I & II (i.e. Protection and measurement cores) shall be brought out. In the second box the secondary terminals of 3rd core (i.e metering Core) of 145kV CVTs. The Metering secondary terminal box shall be provided with proper sealing facility. 4.3 4.3.1 Voltage Transformer (PT): The voltage transformers shall be oil immersed, sealed type and self cooled, suitable for the services indicated & conforming to the modern practices of designs and construction. The core shall be of high grade, non ageing, electrical silicon laminated steel of low hysteresis loss and high permeability to ensure high accuracy at both normal and over voltages. The primary winding of voltage transformers will be connected phase to ground. All the fuses and the links shall be provided at the V.T terminal boxes. i) ii) 4.3.5 The design of PT shall be based on following requirements. They must transmit sudden drops of primary voltages. They must have sufficiently low short circuit impedance as seen from secondary. The secondary terminals of the PTs except 36kV PTs (Having two cores) shall be brought out in a weather proof terminal box and it shall be provided with a removable gland plate. In case of 36kV PTs (Having two cores) two separate weather proof terminal boxes shall be provided. In the first box terminals of Core-I of 36kV PT (i.e. metering core) shall be brought out. The terminal box shall be provided with a removable gland plate and with proper sealing facility. In the second box the terminals of 2nd core of 36kV PT shall be brought out. The terminal box shall be provided with a removable gland plate. TESTS : TYPE TEST TYPE TESTS OF POTENTIAL TRANSFORMERS (PT's) The equipment offered should be type tested. Test reports should not more then seven years old reckoned from date of bid opening in respect of all the tests carried out in accredited laboratories (based on ISO/IEC) by a reputed accreditation body or witnessed by HVPN or another electric power utility and be submitted by the successful bidder to HVPNL for approval as schedule given in Bar Chart. Temperature-rise Test. Lightning impulse test. High voltage power frequency wet withstand voltage test.
4.3.2 4.3.3 4.3.4
5.0 5.1 5.1.1
i) ii) iii)
iv) 5.1.2
Determination of errors or other characteristics according to the requirement of the appropriate designation or accuracy class. TYPE TESTS OF CAPACITIVE VOLTAGE TRANSFORMERS (CVT's) The equipment offered should be type tested. Test reports should not more then seven years old reckoned from date of bid opening in respect of all the tests carried out in accredited laboratories (based on ISO/IEC) by a reputed accreditation body or witnessed by HVPN or another electric power utility and be submitted by the successful bidder to HVPNL for approval as schedule given in Bar Chart. Temperature Rise Test. Impulse test. Ferro-resonance test. Transient response test. High voltage power frequency wet withstand voltage test. Determination of errors or other characteristics according to the requirements of the appropriate designation or accuracy class. Capacitance measurement before voltage test. Voltage test between terminals. Measurement of capacitance and tangent of the loss angle after voltage test. Voltage test between the low-voltage terminal and the earth terminal. Oil leakage test. High frequency test. Determination of temperature co-efficient.
ROUTINE TESTS :
i) ii) iii) iv) v) vi) vii) viii) ix) x) xi) xii) xiii) 5.2 5.3
As per quality assurance program (QAP). ACCEPTANCE TESTS: The following acceptance tests as stipulated in the relevant ISS-3156 shall be carried out by the Supplier in presence of HVPNL representative, unless dispensed with in writing by the HVPNL. Verification of terminal marking and polarity. High voltage power frequency dry withstand voltage test for Primary winding. High voltage power frequency dry withstand voltage test for Secondary winding. Partial discharge tests Determination of errors or other characteristics according to the requirements the appropriate designation or accuracy class. DOCUMENTATION: The successful bidder shall submit four sets of following drawings except 6.1(b) below (actual of which shall be supplied at the time of inspection) for HVPNL approval. List of drawings: General outline and assembly drawings of the equipment. Graphs showing the performance of equipment's in regard to magnetisation characteristics; ratio & phase angle curves, ratio correction factor curves. Sectional views showing:
i) ii) iii) iv) v)
6.0 6.1
a) b) c)
i) ii) iii) iv) d) e) f) g) h)

NOTE:-
General Constructional Features. Materials/Gaskets/Sealing used. The insulation & the winding arrangements, method of connection of the primary / secondary winding to the primary/ secondary terminals etc. Porcelain used and its dimensions. Arrangement of terminals and details of connection studs provided. Name plate. Schematic drawing. Detailed drawing of pressure release device with detailed literature. Terminal connector drawing. All above drawings should bear a minimum space (14X10cm) for stamping the approval of drawings by the purchaser.
ANNEXURE- IA(i)
COREWISE DETAILS OF 145kV CAPACITOR VOLTAGE TRANSFORMER (CVT). Sl. No. 1. 2. 3. 4. 5. 6. Requirement Rated Primary voltage Type No. of Secondaries Rated voltage factor Capacitance (minimum) Rated voltage (volts) Particulars 1323kV Single phase 3 1.2 continuous & 1.5 for 30 seconds 8800 (+10%, -5%) pico farads Secondary-I 110/3 7. Application Protection & Measurement 8. 9. 10. Accuracy Output burden (VA) Percentage voltage error & phase displacement (minutes) for respective specified 1/3P 50 3P 25 As per ISS/IEC 0.2S 10 Secondary-II 110/3 Protection Secondary-III 110/3 Metering
accuracy classes. Note:Each winding shall fulfil its respective specified accuracy requirement within its specified output range whilst at the same time the other winding has an output of any value form zero to 100% of the output range specified for the other winding in line with clause 6.2.1 of IS 3156 (Part-2 & Part-3) 1992 or its equivalent IEC.
ANNEXURE- IB(i)
COREWISE DETAILS OF 36kV POTENTIAL TRANSFORMER (PT) OF 2 CORES. Sl. Requirement No 1. Rated Primary voltage 2. 3. 4. 5. Type No. of Secondaries Rated voltage factor Rated voltage (volts) Particulars 36/3kV Single phase 2 1.2 continuous & 1.5 for 30 seconds Secondary-I 110/3 6. 7. 8. 9. Application Accuracy Output burden (VA) Percentage voltage error & phase displacement (minutes) for respective specified Main metering 0.2S 10 As per ISS/IEC Secondary-II 110/3 Metering & Protection 1/3P 50
accuracy classes. Note:Each winding shall fulfil its respective specified accuracy requirement within its specified output range whilst at the same time the other winding has an output of any value form zero to 100% of the output range specified for the other winding in line with clause 6.2.1 of IS 3156 (Part-2 & Part-3) 1992 or its equivalent IEC.
Section-5 Chapter-3A
TECHNICAL SPECIFICATION FOR 132kV CONTROL AND RELAY PANEL BOARDS FOR SUBSTATIONS WITHOUT SUBSTATION AUTOMATION SYSTEM
C:\Documents and Settings\XENWB\Desktop\G-11 Website\Final Technical G-11- Pkg B 06.09.11\SECTION-5\Ch-3A C&R Panel (without automation).doc
CONTENTS -------------------------------------------------------------------------------CLAUSE NO.

1.0 2.0 3.0 4.0 5.0 6.0 7.0
TITLE
PAGE NO.
3 3 4 4 5 14 15
--------------------------------------------------------------------------------SCOPE STANDARDS SERVICE CONDITION PRINCIPAL PARAMETERS GENERAL TECHNICAL REQUIREMENTS TESTS DOCUMENTATION
ANNEXURES
A. B. C. D. E. F. TRANSMISSION LINE DATA SCHEDULE OF DEVIATIONS FROM THE SPECIFICATION LINE PARAMETERS ANNUNCIATION DETAILS DETAILS OF CARRIER EQUIPMENTS PANELS MOUNTING DETAILS 16 17 18 19 20 21
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1.0 1.1
1.2
1.3
SCOPE: This specification covers the design, engineering, manufacture, inspection & testing at manufacturers work before despatch, packing, forwarding and delivery at site of 132kV control & relay panels for S/Stns. without substation automation system. Unless specifically excluded from the offer, all fittings and accessories, not specifically stated in this specification but which are necessary for satisfactory operation of the scheme or to complete the work in a good workman like manner shall be deemed to have been included in the scope of supply of the Bidder. CO-ORDINATION : Circuit Breakers, CT's, PT's/CVT's & Isolating Switches etc. are being purchased against separate specification. The Contractor of control & relay panels shall be responsible for preparing complete wiring diagram of 132 kV C&R panel boards and shall also undertake to mount & wire any equipment received from other supplier. The schematic of breakers & isolators are required to be incorporated in the panel schematic. EXPERIENCE: For 132kV C&R Panels: The supplier of C&R panels shall be manufacturer of relays and all the main relays on the C&R panels shall be of his make only. The suppliers own make relay includes the relays manufactured by their Principals/Associates and they have their service centre with them.
1.4 1.4.1
2.0 2.1
2.2
2.3 2.4
2.5 2.6
STANDARDS: The equipment offered shall conform to latest relevant Indian Standards listed hereunder or equivalent IEC: Sr. No. Standard Title 1. IS: 5 Colour for ready mix paints. Marking & arrangements for switchgear, bus bars, main 2. IS: 375 connections & auxiliary wiring. PVC insulated cable for working voltage upto and including 3. IS: 694 1100 V. 4. IS: 722 AC Electricity meters. IS: 1248 Direct acting indicating analogue electrical measuring 5. Part-I& IV instruments & their accessories. Dimensions for panel mounted indicating & recording 6. IS: 2419 electrical instruments. 7. IS :3231 Electrical relays for power system protection. 8. IS :8686 Static protective relays. Degree of protection provided by enclosures for low voltage 9. IS :2147 switchgear & control gear. The works covered by the specification shall be designed, engineered, manufactured, built, tested and commissioned in accordance with the Acts, Rules, Laws and Regulations of India. The equipment to be furnished under this specification shall conform to latest issue with all amendments of standard specified above. In addition to meeting the specific requirement called for in the Technical Specification, the equipment shall also conform to the general requirement of the relevant standards and shall form an integral part of Specification. The Bidder shall note that standards mentioned in the specification are not mutually exclusive or complete in themselves, but intended to compliment each other. The Contractor shall also note that list of standards presented in this specification is not complete. Whenever necessary the list of standards shall be considered in conjunction with specific IS/IEC.
2.7
2.8 2.9
2.10
When the specific requirements stipulated in the specification exceed or differ than those required by the applicable standards, the stipulation of the specification shall take precedence. Other internationally accepted standards which ensure equivalent or better performance than that specified in the standard referred shall also be accepted. In case governing standards for the equipment is different from IS or IEC, the salient points of difference shall be clearly brought out alongwith English language version of standard or relevant extract of the same. The equipment conforming to standards other than IS/IEC shall be subject to Employer's approval. The bidder shall clearly indicate in his bid the specific standards in accordance with which the works will be conformed.
3.0 3.1
SERVICE CONDITIONS: Equipment to be supplied against this specification shall be suitable for satisfactory continuous operation under the following tropical conditions:i) Location IN THE STATE OF HARYANA ii) Max. ambient air temp (C) 50 iii) Min. ambient air temp (C) -2.5 iv) Maximum Relative humidity (%) 100 v) Minimum Relative humidity (%) 26 vi) Average annual rainfall (mm) 900 vii) Max. wind pressure (kg/sq. m.) 195 viii) Max. altitude above mean sea level (meters). 1000 ix) Isoceraunic level (days/Year) 50 x) Seismic level (horizontal acceleration) 0.3 g xi) Average number of dust storm 35 (days per annum) Note:-i)Moderately hot and humid tropical climate conducive to rust and fungus growth. The climatic conditions are also prone to wide variations in ambient conditions. ii)Air conditioning or any special arrangement for making the control room dust proof shall not be provided in any of the S/Stn. All control wiring, equipment & accessories shall be protected against fungus growth, condensation, vermin & other harmful effects due to tropical environments.
3.2
3.3 AUX. POWER SUPPLY : i) A.C. Supply Voltage variation Frequency variation ii) D C Supply
415/240 Volts, 3-phase, 4-wire, 50 Hz 10% 3% 220 Volts, 2 wire available from S/Stn. battery(insulated) Variation : 10%. 3.4.1.1 132 kV voltages will be three phase having normal frequency of 50 Hz subject to a variation of 3%. Neutrals of the Power Transformers at the S/Stn. covered in this specification are solidly earthed. 4.0 PRINCIPAL PARAMETERS: 4.1 The panel shall have the principal dimensions as detailed below:i). Depth of panels = 610 mm ii). a) Height of switchboard above base frame = 2210 mm b) Height of base frame = 102 mm iii). Width of corridor in case of duplex panels = 762 mm iv). TYPE OF PANEL : a) Simplex control & relay panels for all 132 kV circuits. Note:- The offer of the bidder not conforming to above requirement shall be out rightly rejected.
: : : :
4.2.1
MIMIC DISPOSITION: The mimic disposition on control panel should be matching to our standard drawings; the details of which will be supplied to successful Bidders.
4.2.2
MIMIC SCHEME: Suitably painted mimic diagram will be reproduced on the panels/boards covered by the specification. Automatic semaphores for indicating 'open' and 'close' position of circuit breakers, isolators & earth switches shall be suitable incorporated in the mimic diagram. The colour scheme for all the S/Stn. specified herein shall, however, be as under;--------------------------------------------------------------------------------------------------------------------------------Voltage Level Colour Shade No. (according to IS:5 or Equivalent IEC) --------------------------------------------------------------------------------------------------------------------------------132 kV Black --------------------------------------------------------------------------------------------------------------------------------4.3 ARRANGEMENT OF PANELS: The panels shall be fabricated so that even if the serial of panels is changed no difficulty will be faced in the placement of panels and cabling etc. The sequence of various panels in a panel board at a S/Stn. shall be supplied to successful bidder. GENERAL TECHNICAL REQUIREMENTS: MATERIAL & WORKMANSHIP: All material used in the construction of the panels/relays shall be of the best quality obtainable of their respective kind and whole of the work shall be of the highest class, well finished and of approved design and make. Castings shall be free from blow-holes, flaws, cracks or other defects and shall be smooth grained and of true dimensions and forms. The draw out mechanism in respect of draw out relays should be smooth and convenient so as to give adequate service during their use. DEPARTURE FROM THE SPECIFICATION: Should the tenderer wish to depart from the provisions of this specification either on account of manufacturing practice or for any other reasons, he will draw specific attention to the proposed points of departure on the prescribed Performa (enclosed) at annexure-B in his tender and submit such full information, drawings and specifications as will enable the merit of his proposal to be appreciated. In the event of contractor drawings, specification and tables etc. disagreeing with this specification during the execution of the contract this specification shall be held binding unless the departures have been fully recorded as required above. PAINTING: All unfinished surfaces of steel panels and frame works shall be sand blasted to remove rust scale, foreign adhering matter & grease. A suitable rust resistance primer shall be applied on the interior & exterior of steel which will be followed by application of an under coat suitable to serve as base for finishing coat. The finishing coat shall be as under: Exterior Stove enameled light grey as per shade No.631 of IS: 5. Interior stove enameled white. Base frame Stove enameled glossy black. 5.4. TESTING EQUIPMENT AND TESTING FACILITIES ON THE RELAYS: The tenderer shall recommend suitable testing equipment (alongwith quantity) required for field testing of protective schemes and other relays offered against this specification. The actual quantity to be ordered shall be determined by the Purchaser. Also adequate testing facilities should be provided on the relay so as to test them without the necessity of their removal or making any extra connections. The Bidder will clearly indicate the testing procedure to be followed in respect of relays offered.
5.0 5.1
5.2
5.3
5.5
The transmission lines shall be either in form of overhead conductor or combination of overhead conductor & underground cable. The tentative transmission line data in respect of 132kV lines covered in this specification is given at Annexure-A. The standard chart providing the details of per unit values of Z1, Z2 & Z0 on 100 MVA base per 100 km of line for calculating these values for full lengths of lines are enclosed at Annexure-C. The tentative details of carrier equipment are enclosed at Annexure-E. The suitability of distance scheme offered with reference to the above parameters may be seen. Guaranteed test sheets shall be submitted by the tenderer. Relevant literature shall be supplied along with the bid for proper appreciation of the offered equipment. SUPERVISORY SERVICES: VOID TRANINING OF PERSONNEL: as per Clause 12 of Section I General.
5.6 5.7
5.8 GENERAL DESCRIPTION: 5.8.1 SIMPLEX C&R PANEL BOARDS: The panel board for the substations mentioned at Cl. No. 4.1(iv) (a) above shall be of `simplex' type & consisting of separate cubicles (for each circuit complete with side covers) made of sheet steel of thickness not less than 10 SWG for the base frame, door frame and front portions of the cubicles and not less than 14 SWG for door, side, top & bottom portion having provision for extension at both ends with internal wiring, illumination with door operated off & on switch. The cubicle shall be suitable for floor mounting with its bottom open. Each cubicle shall be fitted with flush mounted steel hinged door & lock at the back & all the equipments will be mounted in front. The supply shall include suitable grouting bolts and nuts etc. All holes and extension windows shall be blanked and access doors shall be provided with compressible liners at the edges. These simplex panels offered may, therefore, match in following respects:i) Height-wise and depth-wise matching. ii) Size & disposition of mimic diagram matching. The control & relay boards shall be completely dust & vermin proof. The enclosure shall provide degree of protection not less than IP-31 in accordance with IS: 2147 and shall be suitable for tropical use. NOTE:- For testing purpose a small opening with a cap to close the same is required to be provided to extend the testing leads on front side of the relay panel. 5.9 5.9.1 SUPERVISION SCHEME: INDICATING LAMPS:
5.9.1.1. 132kV control panels covered by this specification shall be fitted with the following supervision lamps:Circuit breaker Òpen' : Green. Circuit breaker `Close' : Red. Auto trip : White. Spring charge lamp : Blue 5.9.1.2 All indicating lamps shall be of LED type having low wattage. 5.9.1.3 Indicating lamp shall be wired on 220 V DC. 5.9.1.4 Glass/Plastic lens of appropriate color shall be screwed into the front of the lamp body. The design of indication lamps shall be such as to facilitate replacement of fused lamps. 5.9.1.5 An engraved label indicating the purpose of the lamp shall also be provided with each lamp.
5.9.2
SEMAPHORE INDICATORS: Automatic semaphore relays of the under-mentioned types shall be provided to mimic the position of circuit breakers, isolators and earth switches in the mimic diagram painted on the control and relay boards.
5.9.2.1. The control & relay panels of all the S/Stns. covered by this specification shall be provided with supply failure type semaphores to show on/off position of the circuit breakers/isolators/earth switches. When the supply failure to the semaphore occurs the pointer shall take up an intermediate position to indicate the supply failure. For distinction purposes, the disc diameter of the semaphore relays used to mimic the circuit breaker position will be bigger than those for isolator/earth switch. 5.9.2.2. The operating coil of the semaphore relays shall be continuously rated & shall be suitable for use with 220 V DC. The semaphore relays shall work satisfactorily between 80% 120% of rated DC voltage. 5.9.3 ANNUNCIATOR:
5.9.3.1. Each of the control and relay panels shall have independent annunciation scheme. The scheme shall generally conform to the followings: The closing of an initiating contact shall sound a hooter and light an annunciator indicating lamp. It shall be possible to silence the hooter by pressing àccept' push button. ii) By pressing the `reset' push button the individual indicating lamp shall be extinguished provided that the troubled contact has opened. The resetting shall be possible only after the alarm is accepted. iii) Lighting of an annunciator lamp shall not interfere with or cause false operation of any other annunciator lamp whether lighted simultaneously or in sequence. Operation of `reset' push button shall not cause the alarm to sound whether or not the trouble contact is closed. iv) With the help of `lamp test' push button it shall be possible to test all the lamps in the group. v) The lamps for visual annunciation system shall have separate compartments behind inscribed translucent windows. These shall be so arranged that illumination from one compartment shall not light adjacent windows. vi) The equipment shall operate on 220 V DC and shall be complete with àlarm accepts', àlarm reset' and `lamp test' push buttons. vii) Only static facia alarm scheme is acceptable. 5.9.3.2. The annunciation ways for various 132 kV C&R panels shall be provided as under:Description Annunciation Ways (Nos.) Feeder panel 12 i)
132 kV
The detail of annunciations on all these panels is attached at Annexure D. All the 132kV panels have trip as well as non trip annunciations, as such the facia must have two buses; one for trip alarm and another for non trip alarm. All trip facia shall have red colour and all non trip facia shall have white colour. 5.9.4 5.9.4.1 ALARMS: Alarm scheme for trip alarms: Trip commands due to operation of protective relays will trip the breaker and light the relevant annunciation window. Auxiliary contact of circuit breaker and trip bus of annunciator will actuate bell (common to a panel board at a S/Stn.) & will be cancelled by the circuit breaker control handle & Accept button of annunciator in case of all the panels against this specification. Auto trip lamp will glow on the concerned panel & there will be flag indication on the concerned protective relays/auxiliary relay of the panel.
5.9.4.2 Alarm scheme for non-trip alarms: Non-trip commands will light the relevant annunciation window. Non- trip bus of annunciator will actuate hooter (common to a panel board at a S/Stn.) & will be cancelled by the Accept button of annunciator in case of all the panels against this specification. 5.10 METERING SCHEME : 5.10.1. All indicating and integrating instruments shall be of switch-board type back connected suitable for flush mounting and provided with dust and vermin proof cases and finished in egg shell bright black colour and shall be calibrated to read directly the primary quantities. All fixing screws, nuts and threaded parts shall be designed to relevant Indian Standards. All the instruments (i.e. Voltmeters, frequency meters & Wattmeters) shall be in square pattern case and shall conform to the provisions of the latest edition of IS: 1248 & IS: 2419 or relevant I.E.C. standards. The nominal sizes of these indicating instruments shall be 144 mm2. Energy meters shall conform to provisions of IS: 13779 amended up-to date or relevant I.E.C. standards. 5.10.2 AMMETERS: Ammeter shall be suitably scaled (additional dials, if any, required to cover all the taps of the CT's shall be included at the time of tendering) and provided with a selector switch facilitating the measurements of phase currents as well as the unbalance current. The coil of the ammeter shall be rated for 1 Amp. for 132kV levels . The instruments shall be of digital type of industrial grade À' classification with accuracy class 1.0 or better. 5.10.3 VOLTMETERS : Voltmeter shall be suitably scaled and provided with selector switch (wherever asked for) to facilitate the measurement of phase-to-phase and phase- to-neutral voltage of all the three phases one by one. The coil of the voltmeter shall be rated for 110 volts (phase-tophase) wherever asked with selector switch and 110/3 volts if asked without selector switch. The instrument shall be digital type of industrial grade À' classification with accuracy class of 1.0 or better. 5.10.4 DIGITAL BUS VOLTAGE AND FREQUENCY METERS : Digital bus voltage and frequency meters shall be of class 0.5 and shall have digital display of four & a half (4) and four (4) digits respectively, with display size not less than 25 mm (height). 5.10.5 KILO WATT HOUR METERS : All the 132kV feeder C & R panels against this specification shall be provided with Kilo Watt hour meter. The Kilo Watt hour meter shall be of 3 element type suitable for use on three phase four wire unbalanced system. Calibration shall correspond to CT ratio 300/1A for all the 132kV feeder panels. For other C.T. ratios, multiplying factors shall be used which may be inscribed on the dial plate. The current coil of the instrument shall be suitable for 1 Amp. CT secondary and voltage coil shall be suitable for 110 Volts (phase to phase).The instrument shall be digital type. The accuracy class should be 1.0 or better. 5.10.6 MEGAWATT METERS & MEGAVAR METERS: The 220kV feeder C&R panels against this specification shall be provided with export/import type megawatt-meter & mega VAR-meter. The instrument shall be of two element type suitable for use on three phase & three wire unbalanced system and shall be scaled with Zero center MW and zero center MVAR (i.e. suitable for indicating flow of active & reactive power in both the directions) corresponding to line CT particulars. The current coil of these instruments shall be suitable for 1 Amp. CT secondary & voltage coil shall be rated 110 volts (phase to phase). The instruments shall be digital type and calibrated corresponding to a CT ratio, spare dials shall be provided for remaining ratios of CT's. Accuracy class should be 1.0 or better. 5.10.7 FREQUENCY METERS:
Frequency meter shall have a range of 45 to 55 Hz. The instrument shall be of digital type of Industrial grade 'A' classification. Accuracy class should be 1.0 or better. 5.11 CONTROL SCHEME: 5.11.1 CONTROL SWITCH FOR CIRCUIT BREAKER : 5.11.1.1 It shall be possible to close various circuit breakers from the control room. For this purpose control switches having pistol grip type and of the spring return to neutral position type non lockable handles with alarm cancellation contacts shall be provided for ÒP' of ckt. breakers. These shall be so designed that after being operated to `close' a circuit breaker, the operation cannot be repeated until the switch has been turned to a `trip' position making it impossible to perform two `closing' operations consecutively. 5.11.1.2 The rating of the control switch contacts shall be suitable for the duty imposed by the closing & opening mechanism of circuit breakers and shall conform to the recommendations which may be made by the suppliers of circuit breakers. The moving & fixed contacts shall be of such a form & material as will ensure good contact and long service under severe operation duty. All contacts shall be readily renewable. 5.11.1.3 The number of contacts in the control switches shall be decided by the tenderer in view of various requirements of this specification. Two pairs of contacts one normally open and one normally closed shall be kept spare. The total number of contacts proposed to be provided shall be stated in the tender. 5.11.1.4 Safety against inadvertent operation due to light touch in the control switches shall be ensured. 5.11.2 CONTROL SWITCH FOR ISOLATOR: It shall be possible to close the 220 kV Isolators from the control room. For this purpose control switches with pistol grip handles & having no provision for locks shall be mounted on the 220 kV C&R panels specified herein. The size/colour of the control switch handle meant for isolator will be different so as to be easily distinguishable from those meant for circuit breaker controls. GENERAL REQUIREMENTS OF RELAYS: 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. 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 contractors scope of supply. All main protective relays shall be 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. 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 personal computer installed in the substation. However, the supply of PC is not covered under this clause. b) The relay shall have suitable communication facility for future connectivity to SCADA. The relay shall be capable of supporting IEC 61850 protocol (with fibre optical port). c) Numerical relays should have clock (Real Time Clock) with inbuilt battery back up having life span of about 10 years. d) Numerical relays shall have adequate no. of output contacts and LEDs to meet the specification / Scheme requirement. All numerical relays shall be supplied pre-configured as per specification / scheme requirements / approved drgs.
5.12
5.13
TRIP CIRCUIT SUPERVISION RELAY: The relay shall be capable of monitoring the healthiness of each trip coil and associated circuit of circuit breaker during "on & off" conditions. The relay shall have time delay on drop-off of min. 200 milli seconds and shall be provided with operation indicator.
For monitoring of entire trip circuit (from control & relay panel terminal to the trip coil of circuit breaker) both in òpen' & `close' position of the circuit, 2 No. automatic trip circuit supervision relays are proposed for 132kV panels. 5.14 D.C. FAIL ALARM RELAY: A suitable relay for monitoring the Trip Circuit D.C. wiring of the control and relay panels shall be provided. The relay shall have time delay on drop-off of min. 100 milli seconds and shall be provided with operation indicator. VOLTAGE SELECTION SCHEME: The 132kV bus PTs exist on all the phases of both the 132kV buses at substations having double bus arrangement. Proper voltage selection scheme shall be provided on panels. PROTECTION SCHEME:
5.15
5.16
5.16.1 PROTECTION SCHEME FOR LINES: A) NON-SWITCHED DISTANCE PROTECTION SCHEME [FOR 132kV LINES]: The main protection scheme for these lines will be distance scheme working on definite distance measuring principle both for phase & earth faults. The scheme shall:i) be numerical & modular in construction. Relay shall have continuous self monitoring & diagnostic feature. ii) have high speed non-switched distance relays for three phase systems to clear all type of line faults within the set reach of the relay. iii) It should cover at least line sections completely with 20% in hand margin. iv) measure all type of faults without the need to switch the measuring elements to the faulty phase or phases. Zone switching to extend the reach of the measuring elements is not allowed. The reach of each zone shall be independently & individually adjustable and shall have setting in steps of 1%. Memory circuits with defined characteristics shall be provided in all three phases to ensure correct operation during close-up 3 phase faults and other adverse conditions. v) have a max. operating time up-to trip impulse to circuit breaker (complete protection time including trip relay time) under source to line impedance ratios (SIR) :0.01-4 as 50ms under all possible combinations of fault at 50% of zone-1 reach. vi) have stepped time-distance characteristics and shall have at least four independently variable time graded distance protection zones to cover two adjacent line sections out of which Zone-1, 2 & 3 should be selectable in forward direction and Zone-4 should be selectable in reverse direction. vii) The relay shall have mho or quadrilateral or other suitably shaped characteristics for zone-1, 2, 3 & 4. The relay shall have an adjustable characteristics angle setting range of 30 - 85 degree or shall have independent resistance(R) & reactance(X) setting. viii) ensure that this long coverage is consistent with limitations imposed by heavy loading and sound phase component of fault current. If the characteristics of starting relays are such that it cannot pick-up because of very low in-feed, under-voltage relays may also be used as supplementary relays. ix) have two independent continuously variable time setting range of 0-3 seconds for zone-2 and 0-5 seconds for zone-3 & 4. x) have a maximum resetting time of less than 55milli-seconds (including the resetting time of trip relays). xi) have facilities for offset features with adjustable 10-20% of Zone-3 setting. xii) For correct measurement of earth faults necessary equipment for residual compensation shall be included. It shall have residual compensation variable from 30-150%. xiii) operate instantaneously when circuit breaker is closed to zero-volt 3 phase fault. xiv) be suitable for three phase tripping. xv) 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
xvi) xvii)
xviii) a1) a2) a3) a4) a5) xix) a1) a2) a3) a4) xx)
capable of carrying a high short time current of 80 times rated current without damage for a period of 1 sec. have adequate contacts to meet the complete scheme requirements & if required incorporate separate high speed self reset trip relays. have suitable number of potential free contacts. Multiplication relays, if required, shall be provided for Event Logger, Disturbance recorder & Data acquisition system. include power swing blocking protection which shall be of triple pole type have suitable setting range to encircle the distance protection described above. have a continuously adjustable time delay on pick up of setting range 0-2seconds. block tripping during power swing conditions. be of numerical type include fuse failure protection which shall monitor all the three fuses of PTs/CVTs and associated cable against open circuit. inhibit trip circuits on operation and initiate annunciation. remain inoperative for system earth faults. be of numerical type. be suitable for 1 Amp. rated CT secondary, 110V (phase to phase ) VT supply and 220 V DC supply. Mode of conversation of DC supply from 220 V DC to the voltage level required for their scheme may be mentioned in detail. Requirement of CTs & VTs for the satisfactory working of the scheme may also be indicated in the tender. The Scheme shall have in-built features of broken conductor detection, distance to fault locator, disturbance recorder and event logger. THREE OVER CURRENT+ ONE EARTH FAULT PROTECTION: The 3 O/C & 1 E/F elements shall be either independent or composite units. It shall include VT fuse failure relays for alarm purposes. DIRECTIONAL OVER CURRENT RELAY : The relay shall have IDMTL characteristic with a definite minimum time of 3.0 seconds at 10 times setting. have a variable setting range of 50-200% of 1 Amp. have a characteristic angle of 45 degree lead. include operatio indicator. be suitable for 110V VT secondary. be numerical type. DIRECTIONAL EARTH FAULT RELAY: The relay shall be numerical type. have IDMTL characteristic with a definite minimum time of 3.0 seconds at 10 times setting. have a variable setting range of 20-80% of 1 Amp. have a characteristic angle of 45 degree lag. include operation indicator. be suitable for connection across open delta formed by 110/3 volt rated secondary of VT.
xxi) D)
i) ii) iii) iv) v) vi)
i) ii) iii) iv) v) vi) E)
FEEDER OVER LOAD ALARM RELAY: It is proposed to provide a single pole over current relay for the purpose of monitoring the load flow on feeders to sound an alarm whenever load flow in the line exceeds the setting for a given period of time to draw the operator's attention. The relay shall have
CONTINUOUS VARIABLE setting range of 50-200% of 1 Amp. and shall be supplemented by a continuously variable timer of 1 to 10 seconds. Note:- The Feeder over Load Alarm Relay in-built with numerical distance protection relay or Over current & Earth Fault Protection Relay is acceptable provided it meets the above specification. 5.17 TRIPPING RELAY: High speed tripping relay shall i) be instantaneous ( operating time not to exceed 10milli-seconds.) ii) reset within 20milli-seconds. iii) Be 220 Volt DC operated. iv) have adequate contacts to meet the scheme requirement v) Be provided with operation indicators for each element/coil. 5.18 RELAY SETTINGS : The successful bidder will be responsible for calculating the relay setting of the protection schemes included in the bid and obtain HVPN's M&P wing clearance before their adoption. Any data\ information in regard to the power system required by the supplier for this purpose shall be supplied by HVPN. SMALL WIRING : a) All wiring shall be of switch board type consisting of stranded /single annealed copper conductor insulated with polyvinyl chloride insulation suitable for 650 volts service and in accordance with IS : 694. b) The wiring of the following circuits shall not be less than the size specified below: CTs, PTs & CVTs circuits : 2.5 mm2 Control, alarm & supervision circuits etc. : 1.5 mm2 c) All wires will be continuous from one terminal to the other and also will have no tee - junction en-route. The connections shall be securely made with the help of connecting lugs to ensure non-oxidation of the bare copper conductor. At the terminal connections, washers shall be interposed between stud type terminals and holding nuts. All holding nuts shall be secured by locking nuts. The connection studs shall project at least 6 mm from the lock nut surface. d) Bus wires shall be fully insulated and run separately. MCBs shall be provided to enable all the circuits in a panel to be isolated from the bus wire. Wherever practicable, all circuits in which the voltage exceeds 125 volts shall be kept physically separated from the remaining wiring. The function of each circuit shall be marked on the associated terminal boards. e) All wiring diagrams for the control and relay boards shall be drawn as viewed from the back of the cubicle and shall be in accordance with IS:375 or equivalent IEC. Multi core cable tails shall be so bound to its cable that each wire may be traced without difficulty. f) All potential bus wiring, non-trip and trip alarm bus wiring, AC & DC control supply, panel lighting bus wires and such other wiring which runs from panel to panel within a C&R panel board shall be laid out in gutters and shall be suitably screened. In case of `simplex' type C&R boards these common wires will run through bus wire holes. TERMINAL BOARDS, TEST BLOCKS & SPARE CONTACTS: a) Terminal block connectors built from cells of moulded dielectric and brass stud inserts shall be provided for terminating the outgoing ends of the panel wiring and the corresponding tail ends of control cables. Insulating barriers shall be provided between adjacent connections. The height of the barriers and the spacing between terminals shall be such as to give adequate protection while allowing easy access to terminals. Provision shall be made on each pillar for holding 10% extra connectors. b) The terminal blocks shall be suitable for 650 Volts service and for connection with both copper and aluminum wires.
5.19
5.20.
c)
d)
e)
f) 5.21.
Terminal boards shall be mounted in such a manner as to afford easy access to terminations and to enable ferrule numbers to be read without difficulty. Wire ends shall be so connected at the terminals that no wire terminal gets marked due to succeeding connections. Terminal board rows shall be adequately spaced and shall not be less than 100 mm apart so as to permit convenient access to wires and terminations. Labels in the form of engraved plastic plates shall be provided on the fixed portion of terminal boards. No live metal parts shall be exposed at the back of terminal boards. Switch board type back connected test block with contacts shall be provided with links or other devices for shorting terminals of CT leads before interrupting the normal circuit for injection from an external source or for inserting testing instruments in the circuit without causing open circuit of the CT. The potential testing studs shall preferably be housed in narrow recesses of the block, wherever required, shall be placed as close to the equipments as possible. Test blocks shall be of flush mounting pattern and the number of test blocks being provided on each control and relay panel shall be stated in the tender. The purpose of all the relays (including the auxiliary relays) switches, lamps & push buttons etc. is required to be indicated just below the respective equipment through engraving or painting. Spare contacts of relays are required to be brought on T.B's and shall be indicated on the drawings.
BUS WIRES: The VT, DC, AC, trip alarm , non-trip alarm & DC fail etc. inter panel bus wire terminals shall be brought on Bus T.B's as well as on T.B's so that any panel specified herein can be used separately at the Substation specified in this specification. The said bus wires for the panels specified in case of existing substations shall be matched with the bus wires of the C&R panels already available at site, the drawing for matching purposes for which shall be supplied to the successful bidder. The bus wire terminals shall be indicated on the panel schematic drawings as well. The bus wire diagram shall also be supplied alongwith the schematic drawings for each panel. FERRULES : Wire No. shall be indicated on panel schematic and wiring diagrams and accordingly engraved ferrules with the same numbers and letters as indicated in the said diagrams shall be provided on the terminal ends of all wires for easy identification of circuits for inspection and maintenance. Ferrules shall be of strong & flexible insulating material with glossy finish to prevent adhesion. These shall be engraved and marked clearly and shall not be affected by dampness. Ferrule numbering shall be in accordance with IS: 375. The same ferrule number shall not be used on wires in different circuits on a panel. At those points of interconnection between the wiring carried for equipments of different suppliers where a change of number cannot be avoided double ferrules shall be provided on each wire with the appropriate connection diagram of the equipment. SPACE HEATERS: Tubular space heaters suitable for connection to the single phase 220 Volts AC supply complete with switches located at convenient positions shall be provided at the bottom of each control and relay panel to prevent condensation of moisture. The watt loss per unit surface of heater shall be low enough to keep surface temperature well below visible heat. ILLUMINATION: The C&R panel shall be provided with 220/240 Volts AC interior lighting. The lamp shall be free from hand shadows. A door operated button switch shall be provided in each simplex panel. Each simplex panel shall be provided with one no. illumination lamp with door switch. POWER SOCKET :
5.22.
5.23.
5.24.
5.25
Single phase 240 volt AC, 5-Pin, 5/15A power socket with power on/off switch shall be provided in each simplex panel. 5.26 SAFETY EARTHING: Earthing of current free metallic parts or metallic bodies of the equipment mounted on the switch boards shall be done with bare copper conductor. Copper bus of size 25 mm x 6 mm extending through entire length of a control and relay board shall be provided. The earthing conductor shall be connected by Rose Courtney terminals and clamp junctions. The neutral point of star connected secondary windings of instrument transformers and one corner of the open delta connected LV side of potential transformer, if used shall be similarly earthed with the main earth bar of the switch board earthing system. Multiple earthing of any instrument transformer shall be avoided. An electrostatic discharge point shall be provided in each panel connected to earth bus via 1 Mega Ohm resistor. 5.27 NAME PLATE: An easily accessible engraved or painted panel name plate shall be provided inside each panel. It must include G.A. drawing No., purchase order No., Contractor's reference No., name of S/Stn. as per purchase order and name of circuit. In addition to this, an engraved plate indicating the purchase order no. alongwith name of S/Stn. is required to be affixed on the panel at appropriate height so that it is readable while standing in front of the panel. These are required to be indicated on the G.A. drawings also. An engraved label indicating the purpose of all the relays & switches shall also be provided. 5.28 PANEL MOUNTING DETAILS: The mountings on various 132 kV C&R panels against various Substations specified herein shall be as per Annexure F. The tenderers shall give the details of the various panel mountings in the same serial as specified herein for the convenience of checking of the same w.r.t. the provision in the specification. Any trip relay, auxiliary relay, timers, contact multiplication relay, ICT, IVT,& test block etc. required for the completeness of the scheme shall be added by the Bidder as per scheme requirements, no addition on these accounts shall be considered at a later date. 6.0 6.1 TESTS: TYPE TESTS: The equipment offered should be type tested. Test reports should not more than seven years old reckoned from date of bid opening in respect of all the tests carried out in accredited laboratories (based on ISO/IEC) by a reputed accreditation body or witnessed by HVPN or another electric power utility and be submitted by the successful bidder to HVPNL for approval as schedule given in Bar Chart. a) Insulation tests as per IEC 60255-5 b) High frequency disturbance test as per IEC 60255-4 (Appendix -E) -Class III (not applicable for electromechanical relays) c) Fast transient test as per IEC 1000-4, Level III(not applicable for electromechanical relays) d) Relay characteristics, performance and accuracy test as per IEC 60255. 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 h) Conformance tests as per IEC 61850 ROUTINE TESTS: As per quality assurance program (QAP). ACCEPTANCE TESTS: Following tests shall be carried out at the manufacturers works after complete assembly in presence of HVPNL representative, unless dispensed with in writing by the HVPNL:Checking wiring of circuits and their continuity.
6.2 6.3
i)
ii) iii) iv) 7.0 7.1 a) b)
One minute high voltage test. Insulation resistance of complete wiring, circuit by circuit with all equipment mounted on panel. Checking the operation of protection schemes. DOCUMENTATION: The successful bidder shall submit four sets of G.A. and schematic drawings for HVPNLs approval incorporating following details also. Schematic drawings of breakers are to be incorporated in the panel schematic drawings. Trip details of transformer are to be incorporated in the panel schematic drawings. After receipt of HVPNLs approval, the bidder shall submit final drawings for each circuit of the following drawings:i) Boardwise arrangement drawing (applicable for the panel board at a Substation having more than one panel). ii) G.A.drawing alongwith G.A. legend and foundation details. iii) Schematic drawings alongwith legend & internal wiring details of main relays like transformer differential relay, REF relay, local breaker back up schemes, distance protection scheme, bus-bar protection scheme, voltage selection scheme etc. iv) Equipment-wise & wire-wise wiring diagrams. Each set of drawings shall be bound separately. The bidder shall furnish specified no. of nicely printed and bound volumes of the instruction manuals in English language of the equipment. The instruction manual shall contain step by step instructions for all operational & maintenance requirements for all the protective and aux. relays, switches, instruments etc. mounted on the panel and shall include the following aspects. i) Storage for prolonged duration. ii) Unpacking. iii) Erection. iv) Handling at site. v) Pre commissioning tests. vi) Operating procedures. vii) Maintenance procedure. viii) Precautions to be taken during operation & maintenance work. ix) Catalogue numbers of all the components liable to be replaced during the life of the panels. x) Internal wiring diagrams of all the relays. Each set of instruction manuals shall be bound separately.
7.2
NOTE:-One master set for all the Circuits/Items shall be supplied with in a week of placement of order to the Design Directorate to facilitate the checking and approval of drawings.
ANNEXURE-A TRANSMISSION LINE DATA (TENTATIVE) -----------------------------------------------------------------------------------------------------------------------------------Sr. Name of Circuit Line Conductor size No. length Sq. inch ACSR in KM. Copper equivalent ---------------------------------------------------------------------------------------------------------------------------------
--------------------------------------------------------------------------------------------------------------------------------* The line lengths and conductor size shall be supplied to successful Bidder.
ANNEXURE-B
SCHEDULE OF DEVIATIONS FROM THE SPECIFICATION: In the table the Bidder shall set out all deviations clause by clause from the specification of the equipment offered. The bid shall be deemed to conform to Purchaser's specification in all respects unless specifically mentioned in this table. Sr.No. -----Clause No. ---------Detailed deviations with justification. --------------------------------------
ANNEXURE-C LINE PARAMETERS (per UNIT)/100 MVA BASE/100 km WITH CONDUCTOR SIZE & POWER CAPACITY
Volt age (kV) 132 132
No.of Ckt.
Conduc tor size (inch2) 0.20 0.20
Resistan ce R
Reactan ce X
Suscepta nce Y 0.0970 0.0485
Resistan ce R0 0.15648 0.19776
Reactanc e X0
Line Capacity (MW )
D/C S/C
0.0445 0.0890
0.1167 0.2335
0.64289 0.76814
112 56
Remarks: 1. Size of Earth wire for:132 kV = 7/2.5 mm
2. Resistance of conductor at 20 C. 3. Resistivity of Earth Assumed = 100.
ANNEXURE-D (C&R PANELS) ANNUNCIATION DETAILS I. 132 kV FEEDER C&R PANELS. DESCRIPTION Sr. No. 1. TRIP CIRCUIT- 1 Faulty 2. TRIP CIRCUIT- 2 Faulty 3. CB Low SF-6 Gas Pressure alarm 4. CB low SF-6 Gas Pressure lockout. 5. CB DC fail alarm 6. CB motor single phasing/overload alarm 7. Spare for CB. 8. Spare for CB. 9. VT fuse fail. 10. Distance Protection operated. 11. SOTF Trip. 12. Spare.
-1 -1 -1 -1 -1 -1 -1 -1 -1 -1 -1 -1
ANNEXURE-E DETAILS OF CARRIER EQUIPMENT The carrier terminals available in carrier equipment for feeders are as under:-
CARRIER BOOST
CARRIER SEND (MAIN-I)
+ VE
CARRIER SEND (MAIN-II)
+ VE - VE
DIRECT TRIP (SEND)
+ VE - VE
CARRIER HEALTHY (MAIN-I) CARRIER HEALTHY (MAIN-II)
CARRIER SIGNAL RECEIVE (MAIN-I)
CARRIER SIGNAL RECEIVE (MAIN-II)
DIRECT TRIP (RECEIVE)
ANNEXURE-F MOUNTING DETAILS OF C&R PANELS. 132 kV FEEDER C&R PANEL FOR 132 kV LINE : The panel shall be equipped with the followings : On the front :1. Black PVC circuit label. 2. Mimic diagram section. 3. Indicating lamps for CB open/close and auto trip indications. 4. Spring charge indication lamp. 5. Semaphore indicators for isolator position indication for double bus arrangements respectively. 6. Semaphore indicator for earth switch position indication. 7. Semaphore indicator for CB position indication 8. Ammeter suitably scaled. 9. Ammeter selector switch. 10. Voltmeter suitably scaled. 11. Voltmeter selector switch. 12. 3 phase, 4 wire, 3 element KWH meter. 13. 3 phase, 4 wire T.T.B. 14. Spring return to neutral breaker control switch with sequence device, lost motion device & two pairs of bell alarm contacts. 15. 12 ways static facia complete including accept, reset and lamp test push buttons. 16. Trip circuit supervision relays. 17. Numerical distance scheme alongwith test block etc. 18. Set of 3 directional over current relays and 1 directional earth fault relay 19. High speed tripping relay. 20. Synchronising selector switch. 21. Push button for dead bus closing. 22. set of voltage selection relay for double bus arrangement 23. Set of Trip Ckt. DC supply supervision scheme including one No. push button each for DC fail test and DC fail accept and one No. indicating lamp (amber) for DC fail visual indication. 24. Over-load alarm relay To be mounted inside :1. Illumination lamp with door switch. 2. Space heater with switch. 3. Power socket with on/off switch. i)
1 1 3 1 3 1 1 1 1 1 1 1 1 1
1 2 1 1 2 1 1 1 1
1 1 1 1
Note:- Protection & Metering will be fed from 132KV line CVTs in case of 132KV feeder panels.
SECTION - 5 CHAPTER-3B
TECHNICAL SPECIFICATION FOR 132 kV & 33 kV CONTROL AND RELAY PANEL BOARDS FOR SUBSTATIONS WITH SUBSTATION AUTOMATION SYSTEM
C:\Documents and Settings\XENWB\Desktop\G-11 Website\Final Technical G-11- Pkg B 06.09.11\SECTION-5\Ch-3B C&R Panel (with automation).doc
CONTENTS -------------------------------------------------------------------------------CLAUSE NO.

1.0 2.0 3.0 4.0 5.0 6.0 7.0
TITLE
PAGE NO.
3 3 4 5 5 15 16
--------------------------------------------------------------------------------SCOPE STANDARDS SERVICE CONDITION PRINCIPAL PARAMETERS GENERAL TECHNICAL REQUIREMENTS TESTS DOCUMENTATION
ANNEXURES
A. B. C. D. TRANSMISSION LINE DATA SCHEDULE OF DEVIATIONS FROM THE SPECIFICATION LINE PARAMETERS DETAILS OF CARRIER EQUIPMENTS 18 19 20 21
---------------------------------------------------------------------------------
1.0 1.1
1.2
1.3
SCOPE: This specification covers the design, engineering, manufacture, inspection & testing at manufacturers work before despatch, packing, forwarding and delivery at site of 132kV & 33kV control & relay panels for S/Stns. having substation automation system. Unless specifically excluded from the offer, all fittings and accessories, not specifically stated in this specification but which are necessary for satisfactory operation of the scheme or to complete the work in a good workman like manner shall be deemed to have been included in the scope of supply of the Bidder. CO-ORDINATION : Circuit Breakers, CT's, PT's/CVT's & Isolating Switches etc. are being purchased against separate specification. The Contractor of control & relay panels shall be responsible for preparing complete wiring diagram of 33kV & 132 kV C&R panel boards and shall also undertake to mount & wire any equipment received from other supplier. The schematic of breakers & isolators are required to be incorporated in the panel schematic.
1.4 EXPERIENCE: 1.4.1 For 132kV & 33kV C&R Panels: The supplier of C&R panels shall be manufacturer of relays and all the main relays on the C&R panels shall be of his make only. The suppliers own make relay includes the relays manufactured by their Principals/Associates and they have their service centre with them. 2.0 STANDARDS : 2.1 The equipment offered shall conform to latest relevant Indian Standards listed hereunder or equivalent IEC :Sr. No. Standard Title 1. IS: 5 Colour for ready mix paints. Marking & arrangements for switchgear, bus bars, main 2. IS: 375 connections & auxiliary wiring. PVC insulated cable for working voltage upto and 3. IS: 694 including 1100 V. 4. IS: 722 AC Electricity meters. IS: 1248 Direct acting indicating analogue electrical measuring 5. Part-I& IV instruments & their accessories. Dimensions for panel mounted indicating & recording 6. IS: 2419 electrical instruments. 7. IS :3231 Electrical relays for power system protection. 8. IS :8686 Static protective relays. Degree of protection provided by enclosures for low 9. IS :2147 voltage switchgear & control gear. 2.2 The works covered by the specification shall be designed, engineered, manufactured, built, tested and commissioned in accordance with the Acts, Rules, Laws and Regulations of India. The equipment to be furnished under this specification shall conform to latest issue with all amendments of standard specified above.
2.3
2.4
2.5
2.6
2.7
2.8 2.9
2.10 3.0 3.1
In addition to meeting the specific requirement called for in the Technical Specification, the equipment shall also conform to the general requirement of the relevant standards and shall form an integral part of Specification. The Bidder shall note that standards mentioned in the specification are not mutually exclusive or complete in themselves, but intended to compliment each other. The Contractor shall also note that list of standards presented in this specification is not complete. Whenever necessary the list of standards shall be considered in conjunction with specific IS/IEC. When the specific requirements stipulated in the specification exceed or differ than those required by the applicable standards, the stipulation of the specification shall take precedence. Other internationally accepted standards which ensure equivalent or better performance than that specified in the standard referred shall also be accepted. In case governing standards for the equipment is different from IS or IEC, the salient points of difference shall be clearly brought out alongwith English language version of standard or relevant extract of the same. The equipment conforming to standards other than IS/IEC shall be subject to Employer's approval. The bidder shall clearly indicate in his bid the specific standards in accordance with which the works will be conformed. SERVICE CONDITIONS: Equipment to be supplied against this specification shall be suitable for satisfactory continuous operation under the following tropical conditions:i) Location IN THE STATE OF HARYANA ii) Max. ambient air temp (C) 50 iii) Mi89n. ambient air temp (C) -2.5 iv) Maximum Relative humidity (%) 100 v) Minimum Relative humidity (%) 26 vi) Average annual rainfall (mm) 900 vii) Max. wind pressure (kg/sq. m.) 195 viii) Max. altitude above mean sea level (meters). 1000 ix) Isoceraunic level (days/Year) 50 x) Seismic level (horizontal acceleration) 0.3 g xi) Average number of dust storm 35 (days per annum)
Note:-i)Moderately hot and humid tropical climate conducive to rust and fungus growth. The climatic conditions are also prone to wide variations in ambient conditions. ii)Air conditioning or any special arrangement for making the control room dust proof shall not be provided in any of the S/Stn. 3.2 All control wiring, equipment & accessories shall be protected against fungus growth, condensation, vermin & other harmful effects due to tropical environments.
3.3 AUX. POWER SUPPLY : i) A.C. Supply Voltage variation Frequency variation ii) D C Supply
: : : :
415/240 Volts, 3-phase, 4-wire, 50 Hz 10% 3% 220 Volts, 2 wire available from S/Stn.
Variation
battery(insulated) 10%.
3.4. 132 kV & 33 kV voltages will be three phase having normal frequency of 50 Hz subject to a variation of 3%. Neutrals of the Power Transformers at the S/Stn. covered in this specification are solidly earthed. 4.0 4.1 PRINCIPAL PARAMETERS: The panel shall have the principal dimensions as detailed below:i). Depth of panels = 610 mm ii).a) Height of switchboard above base frame = 2210 mm b) Height of base frame = 102 mm iii). Type of Panels = Simplex Control & Relay Panel The offer of the bidder not conforming to above requirement shall be out rightly rejected. ARRANGEMENT OF PANELS: The panels shall be fabricated so that even if the serial of panels is changed no difficulty will be faced in the placement of panels and cabling etc. The sequence of various panels in a panel board at a S/Stn. shall be supplied to successful bidder. GENERAL TECHNICAL REQUIREMENTS: MATERIAL & WORKMANSHIP: All material used in the construction of the panels/relays shall be of the best quality obtainable of their respective kind and whole of the work shall be of the highest class, well finished and of approved design and make. Castings shall be free from blow-holes, flaws, cracks or other defects and shall be smooth grained and of true dimensions and forms. The draw out mechanism in respect of draw out relays should be smooth and convenient so as to give adequate service during their use. DEPARTURE FROM THE SPECIFICATION: Should the tenderer wish to depart from the provisions of this specification either on account of manufacturing practice or for any other reasons, he will draw specific attention to the proposed points of departure on the prescribed Performa (enclosed) at annexure-B in his tender and submit such full information, drawings and specifications as will enable the merit of his proposal to be appreciated. In the event of contractor drawings, specification and tables etc. disagreeing with this specification during the execution of the contract this specification shall be held binding unless the departures have been fully recorded as required above. PAINTING: All unfinished surfaces of steel panels and frame works shall be sand blasted to remove rust scale, foreign adhering matter & grease. A suitable rust resistance primer shall be applied on the interior & exterior of steel which will be followed by application of an under coat suitable to serve as base for finishing coat. The finishing coat shall be as under: Exterior Stove enameled light grey as per shade No.631 of IS: 5. Interior stove enameled white. Base frame Stove enameled glossy black.
Note:4.2
5.0 5.1
5.2
5.3
5.4.
TESTING EQUIPMENT AND TESTING FACILITIES ON THE RELAYS: The tenderer shall recommend suitable testing equipment (alongwith quantity) required for field testing of protective schemes and other relays offered against this specification. The actual quantity to be ordered shall be determined by the Purchaser. Also adequate testing facilities should be provided on the relay so as to test them without the necessity of their removal or making any extra connections. The Bidder will clearly indicate the testing procedure to be followed in respect of relays offered. The transmission lines shall be either in form of overhead conductor or combination of overhead conductor & underground cable. The tentative transmission line data in respect of 132kV lines covered in this specification is given at Annexure-A. The standard chart providing the details of per unit values of Z1, Z2 & Z0 on 100 MVA base per 100 km of line for calculating these values for full lengths of lines are enclosed at Annexure-C. The tentative details of carrier equipment are enclosed at Annexure-D. The suitability of distance scheme offered with reference to the above parameters may be seen. Guaranteed test sheets shall be submitted by the tenderer. Relevant literature shall be supplied along with the bid for proper appreciation of the offered equipment. SUPERVISORY SERVICES: VOID
5.5
5.6
5.7 5.8
TRANINING OF PERSONNEL: as per Clause 12 of Section I General. GENERAL DESCRIPTION:
5.8.1. SIMPLEX C&R PANEL BOARDS: The panels shall be of `simplex' type & consisting of separate cubicles (for each circuit complete with side covers) made of sheet steel of thickness not less than 10 SWG for the base frame, door frame and front portions of the cubicles and not less than 14 SWG for door, side, top & bottom portion having provision for extension at both ends with internal wiring, illumination with door operated off & on switch. The cubicle shall be suitable for floor mounting with its bottom open. Each cubicle shall be fitted with flush mounted steel hinged door & lock at the back & all the equipments will be mounted in front. The supply shall include suitable grouting bolts and nuts etc. All holes and extension windows shall be blanked and access doors shall be provided with compressible liners at the edges. These simplex panels offered may, therefore, match in following respects:i) Height-wise and depth-wise matching. The control & relay Panels shall be completely dust & vermin proof. The enclosure shall provide degree of protection not less than IP-31 in accordance with IS: 2147 and shall be suitable for tropical use. NOTE:- For testing purpose a small opening with a cap to close the same is required to be provided to extend the testing leads on front side of the relay panel.
5.9
GENERAL REQUIREMENTS OF RELAYS: 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. 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 contractors scope of supply. All main protective relays shall be 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. 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 personal computer installed in the substation. However, the supply of PC is not covered under this clause. b) The relay shall have suitable communication facility for future connectivity to SCADA. The relay shall be capable of supporting IEC 61850 protocol (with fibre optical port) and shall be compatible with existing SAS (may be of other make). c) Numerical relays should have clock (Real Time Clock) with inbuilt battery back up having life span of about 10 years. d) Numerical relays shall have adequate no. of output contacts and LEDs to meet the specification / Scheme requirement. All numerical relays shall be supplied preconfigured as per specification / scheme requirements / approved drgs. 5.10 TRIP CIRCUIT SUPERVISION RELAY: The relay shall be capable of monitoring the healthiness of each trip coil and associated circuit of circuit breaker during "on & off" conditions. The relay shall have time delay on drop-off of min. 200 milli seconds and shall be provided with operation indicator. For monitoring of entire trip circuit (from control & relay panel terminal to the trip coil of circuit breaker) both in òpen' & `close' position of the circuit, 2 No. automatic trip circuit supervision relays are proposed for 132kV & 33kV Panels except 1No. Automatic trip circuit supervision relay is proposed for 33kV Line and Capacitor Panels. 5.11 D.C. FAIL ALARM RELAY: A suitable relay for monitoring the Trip Circuit D.C. wiring of the control and relay panels shall be provided. The relay shall have time delay on drop-off of min. 100 milli seconds and shall be provided with operation indicator. VOLTAGE SELECTION SCHEME: The 132kV & 33kV bus PTs exist on all the phases of both the 132kV & 33kV buses at substations having double bus arrangement. Proper voltage selection scheme shall be provided on panels.
5.12
5.13 PROTECTION SCHEME: Note:- The Protection Scheme shall be suitable for 5A current (instead of 1A) in case of 33kV Level. 5.13.1 PROTECTION SCHEME FOR POWER TRANSFORMERS. A) TRANSFORMER DIFFERENTIAL PROTECTION : The relay shall i) Be triple pole numerical type. ii) Have 3 instantaneous high set over-current units.
iii) iv) v) vi) vii) viii) ix)
x) xi)
Have second harmonic restraint or other inrush proof feature and be stable under normal over fluxing condition. Have fifth harmonic by pass filter or similar other arrangement to prevent mal-operation of the relay under operating conditions. Be suitable for rated current of 1A and include necessary ICTs for ratio & phase angle correction. Have operating current setting sufficiently low (15% or less) so as to cover practically the whole of the transformer against all types of faults. Have adjustable bias setting range of 20- 50%. Have maximum operating time of 30milli seconds at 5 times the rated current. Be provided with necessary terminals & links to measure current in restraining circuits & in the operating circuits of all the phases under load without making any wiring changes. Cover the lightning arrestors (proposed to be provided very close to the transformer) in the zone of protection. The Scheme shall have in-built features of disturbance recorder and event logger. For disturbance recorder and event logger features, it shall have 8 analog and 16 digital channels (out of which at least 8 shall be external digital inputs). It 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 synchronization. Further, it shall have facility to synchronize its time generator from Time Synchronization 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 alarm in case of absence of synchronizing pulse within specified time. The disturbance recorder shall meet the following requirements: The frequency response shall be 5 Hz on lower side and 250 Hz or better on upper side. Scan rate shall be 1000 Hz/Channel or better. Prefault time shall not be less than 100 milliseconds and the post fault time shall not be less than 2 seconds (adjustable). If another system disturbance 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. The event logger shall meet the following requirements: The time resolution shall be 1milli second. Cope with up to 40 changes in any one 10milli seconds interval. The date and time should be printed to the nearest 1milli second followed by a message describing the point which has operated. Events occurring whilst a previous event is in process of being printed are to be stored to await printing.
a)
b)
Xii) B)
Display resolution of differential/pickup current should be 0.01A (10mA).
NON DIRECTIONAL THREE OVER CURRENT+ ONE EARTH FAULT PROTECTION WITH HIGH SET: The 3 O/C & 1 E/F elements shall be either independent or composite units. The relay shall be single pole inverse definite minimum time lag having definite min. time of 3 secs. at 10 times settings. Over current relay with a setting range of 50%-200% of 1 Amp. supplemented with high set units having a setting range of 500% to 2000% of 1 Amp. shall be provided. Earth fault relay with a setting range of 20%-80% of 1 Amp. supplemented with high set units having a setting range of 200% to 800% of 1 Amp. shall be provided. The relay shall be numerical type. RESTRICTED EARTH FAULT PROTECTION : It shall be single pole type for the clearance of earth faults in the protected zone. The relay shall be of high impedance type with a suitable setting to cover at least 90% of the winding & shall have a setting range of 10% to 40% of 1 Amp. or suitable voltage setting. The relay shall be complete with tuned 50 Hz circuit & stabilizing resistance. The tuned circuit will help reject harmonics produced by CT saturation and thus make the relay operative for fundamental frequency only. The stabilizing resistance may appropriately be set to avoid mal-operation under through fault conditions. The relay shall be numerical type. 8No. auxiliary relays for various transformer trip functions (Main Buch. Trip, OLTC Oil Temp. Trip, Winding Temperature Trip, Oil Temp Trip, Pressure Relief Trip, Surge Relay Trip and two no. spare) shall be provided. OVER FLUXING PROTECTION: An over fluxing detecting relay for the protection of the transformer against overfluxing conditions is proposed to be provided on each of the transformer C&R panels covered by this specification. The relay shall be numerical in design with adjustable setting so as to avoid its operation on momentary system disturbances. The relay shall be suitable for 110 Volts. The relay shall have inverse time characteristics, matching with transformer over-fluxing withstand capability curve. The relay shall provide an alarm with v/f setting range of 100% to 130% of rated values and time delay continuously settable from 0.1 to 6 seconds to draw the operator's attention about the existence of over-fluxing conditions. The tripping time shall be governed by v/f versus time characteristics to cause tripping of transformer controlling circuit breaker if the over-fluxing conditions continue to exist.
C)
D)
E)
Note:- The over fluxing relay in built with the numerical differential protection relay is acceptable provided it meets the above specification. F) OVER LOAD ALARM RELAY: It is proposed to provide an over current (i.e. single phase) relay for initiating an alarm during transformer overload condition on the T/F C&R panels. The relay shall have CONTINUOUS VARIABLE setting range of 50-120% of 1Amp. and shall be supplemented by a continuously variable timer of 1 to 10 seconds. The relay shall be arranged to sound an alarm when the transformer exceeds the setting for a given period of time to draw the operator's attention.
Note:- The over load alarm relay in built with the numerical differential protection relay or Over current & Earth Fault Protection Relay is acceptable provided it meets the above specification. 5.13.2 PROETCTION SCHEME FOR LINES A) NON-SWITCHED DISTANCE PROTECTION SCHEME [FOR 132kV LINES]: The main protection scheme for these lines will be distance scheme working on definite distance measuring principle both for phase & earth faults. The scheme shall:i) be numerical & modular in construction. Relay shall have continuous self monitoring & diagnostic feature. ii) have high speed non-switched distance relays for three phase systems to clear all type of line faults within the set reach of the relay. iii) It should cover at least line sections completely with 20% in hand margin. iv) measure all type of faults without the need to switch the measuring elements to the faulty phase or phases. Zone switching to extend the reach of the measuring elements is not allowed. The reach of each zone shall be independently & individually adjustable and shall have setting in steps of 1%. Memory circuits with defined characteristics shall be provided in all three phases to ensure correct operation during close-up 3 phase faults and other adverse conditions. v) have a max. operating time up-to trip impulse to circuit breaker (complete protection time including trip relay time) under source to line impedance ratios (SIR) :0.01-4 as 50ms under all possible combinations of fault at 50% of zone-1 reach. vi) have stepped time-distance characteristics and shall have at least four independently variable time graded distance protection zones to cover two adjacent line sections out of which Zone-1, 2 & 3 should be selectable in forward direction and Zone-4 should be selectable in reverse direction. vii) The relay shall have mho or quadrilateral or other suitably shaped characteristics for zone-1, 2, 3 & 4. The relay shall have an adjustable characteristics angle setting range of 30 - 85 degree or shall have independent resistance(R) & reactance(X) setting. viii) ensure that this long coverage is consistent with limitations imposed by heavy loading and sound phase component of fault current. If the characteristics of starting relays are such that it cannot pick-up because of very low in-feed, under-voltage relays may also be used as supplementary relays. ix) have two independent continuously variable time setting range of 0-3 seconds for zone-2 and 0-5 seconds for zone-3 & 4. x) have a maximum resetting time of less than 55milli-seconds (including the resetting time of trip relays). xi) have facilities for offset features with adjustable 10-20% of Zone-3 setting. xii) For correct measurement of earth faults necessary equipment for residual compensation shall be included. It shall have residual compensation variable from 30-150%. xiii) operate instantaneously when circuit breaker is closed to zero-volt 3 phase fault. xiv) be suitable for three phase tripping.
10
xv)
xvi) xvii)
xviii) a1) a2) a3) a4) a5) xix) a1) a2) a3) a4) xx)
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 80 times rated current without damage for a period of 1 sec. have adequate contacts to meet the complete scheme requirements & if required incorporate separate high speed self reset trip relays. have suitable number of potential free contacts. Multiplication relays, if required, shall be provided for Event Logger, Disturbance recorder & Data acquisition system. include power swing blocking protection which shall be of triple pole type have suitable setting range to encircle the distance protection described above. have a continuously adjustable time delay on pick up of setting range 0-2seconds. block tripping during power swing conditions. be of numerical type include fuse failure protection which shall monitor all the three fuses of PTs/CVTs and associated cable against open circuit. inhibit trip circuits on operation and initiate annunciation. remain inoperative for system earth faults. be of numerical type. be suitable for 1 Amp. rated CT secondary, 110V (phase to phase ) VT supply and 220 V DC supply. Mode of conversation of DC supply from 220 V DC to the voltage level required for their scheme may be mentioned in detail. Requirement of CTs & VTs for the satisfactory working of the scheme may also be indicated in the tender. The Scheme shall have in-built features of broken conductor detection, distance to fault locator, disturbance recorder and event logger. THREE OVER CURRENT+ ONE EARTH FAULT PROTECTION: The 3 O/C & 1 E/F elements shall be either independent or composite units. It shall include VT fuse failure relays for alarm purposes. DIRECTIONAL OVER CURRENT RELAY : The relay shall have IDMTL characteristic with a definite minimum time of 3.0 seconds at 10 times setting. have a variable setting range of 50-200% of 1 Amp. have a characteristic angle of 45 degree lead. include operatio indicator. be suitable for 110V VT secondary. be numerical type. DIRECTIONAL EARTH FAULT RELAY: The relay shall be numerical type. have IDMTL characteristic with a definite minimum time of 3.0 seconds at 10 times setting.
xxi) B)
i) ii) iii) iv) v) vi)
i) ii)
11
iii) iv) v) vi)
have a variable setting range of 20-80% of 1 Amp. have a characteristic angle of 45 degree lag. include operation indicator. be suitable for connection across open delta formed by 110/3 volt rated secondary of VT. FEEDER OVER LOAD ALARM RELAY: It is proposed to provide a single pole over current relay for the purpose of monitoring the load flow on feeders to sound an alarm whenever load flow in the line exceeds the setting for a given period of time to draw the operator's attention. The relay shall have CONTINUOUS VARIABLE setting range of 50-200% of 1 Amp. and shall be supplemented by a continuously variable timer of 1 to 10 seconds. The Feeder over Load Alarm Relay in-built with numerical distance protection relay or Over current & Earth Fault Protection Relay is acceptable provided it meets the above specification. PROTECTION SCHEME FOR BUS COUPLER: NON DIRECTIONAL THREE OVER CURRENT + ONE EARTH FAULT PROTECTION WITH HIGH SET: The 3 O/C & 1 E/F elements shall be either independent or composite units. The relay shall be single pole inverse definite minimum time lag having definite min. time of 3secs. at 10 times settings. Over current relay with a setting range of 50%-200% of 1Amp. supplemented with high set units having a setting range of 500% to 2000% of 1Amp. shall be provided. Earth fault relay with a setting range of 20%-80% of 1Amp. supplemented with high set units having a setting range of 200% to 800% of 1Amp. shall be provided. The relay shall be numerical type.
C)
Note:-
5.13.3
5.13.4 PROTECTION SCHEME FOR CAPACITOR C&R PANELS: A) NON DIRECTIONAL THREE OVER CURRENT+ ONE EARTH FAULT PROTECTION WITH HIGH SET: The 3 O/C & 1 E/F elements shall be either independent or composite units. The relay shall be single pole inverse definite minimum time lag having definite min. time of 3 secs. at 10 times settings. Over current relay with a setting range of 50%-200% of 1 Amp. supplemented with high set units having a setting range of 500% to 2000% of 1 Amp. shall be provided. Earth fault relay with a setting range of 20%-80% of 1 Amp. supplemented with high set units having a setting range of 200% to 800% of 1 Amp. shall be provided. The relay shall be numerical type. B) TIME DELAY RELAY:A time delay relay must be included with adjustable setting range of 0-5 minutes to provide a time lag before which the bank shall not be again switched on (to avoid closing of the circuit breaker on a trapped charge). UNDER VOLTAGE PROTECTION :One inverse time under voltage relay having setting range of 50% to 90% of 110/3 volt (Phase-to-neutral) shall be provided to disconnect the capacitor bank under low voltage conditions.
C)
12
D)
OVER VOLTAGE PROTECTION :One inverse time over voltage relay suitable for operation with 110/3 volt AC supply (Phase to neutral) with setting range of 100% to 130% shall be provided.
UNBALANCE PROTECTION :The unbalance protection shall be provided through current unbalance relay connected to the NCT in neutral of capacitor bank connected in double star. Two such relays, one each for alarm & trip are required. The setting of the relay shall be 10% to 40% of the CT secondary (i.e. 1A for 132 kV& 66kV voltage levels and 5A for 33 kV voltage levels) followed by a time delay through a timer of 0.1 sec. for transient free operation of the protection. The relays shall be numerical type. The relay should not operate for healthy state spill current in neutral. Number of units of failure on which alarm shall come and tripping is initiated, be clearly mentioned for proper setting of the relays. Note:- The under voltage Relay and over voltage relay in-built with numerical unbalance protection relay is acceptable provided it meets the above specification. 5.14 TRIPPING RELAY: High speed tripping relay shall i) be instantaneous ( operating time not to exceed 10 milli-seconds.) ii) reset within 20 milli-seconds. iii) Be 220 Volt DC operated. iv) Have adequate contacts to meet the scheme requirement v) Be provided with operation indicators for each element/coil. RELAY SETTINGS : The successful bidder will be responsible for calculating the relay setting of the protection schemes included in the bid and obtain HVPN's M&P wing clearance before their adoption. Any data\ information in regard to the power system required by the supplier for this purpose shall be supplied by HVPN. TIME SYNCHRONISATION EQUIPMENT: i) The Time synchronisation equipment shall receive the co-coordinated Universal Time (UTC) transmitted through Geo Positioning Satellite System (GPS) and synchronize equipments to the Indian Standard Time in a substation. ii) Time synchronisation equipment shall include antenna, all special cables and processing equipment etc. iii) It shall be compatible for synchronisation of Event Loggers, Disturbance recorders and SCADA at a substation through individual port or through Ethernet realized through optic fibre bus. iv) 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). v) Equipment shall meet the requirement of IEC 60255 for storage & operation. vi) The system shall be able to track the satellites to ensure no interruption of Synchronisation signal.
E)
5.15
5.16
13
vii) viii) ix) x) xi)
The output signal from each port shall be programmable at site for either one hour, half hour, minute or second pulse, as per requirement. 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: Voltage signal : Normally 0-5V with 50milli Seconds minimum pulse duration. In case any other voltage signal required, it shall be decided during detailed engineering. Potential free contact (Minimum pulse duration of 50milli Seconds.) IRIG-B RS232C The equipment shall have a periodic time correction facility of one second periodicity. Time synchronisation equipment shall be suitable to operate from 220V DC as available at Substation. 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.
5.17. SMALL WIRING : a) All wiring shall be of switch board type consisting of stranded /single annealed copper conductor insulated with polyvinyl chloride insulation suitable for 650 volts service and in accordance with IS : 694. b) The wiring of the following circuits shall not be less than the size specified below: CTs, PTs & CVTs circuits : 2.5 mm2 Control, alarm & supervision circuits etc. : 1.5 mm2 c) All wires will be continuous from one terminal to the other and also will have no tee - junction en-route. The connections shall be securely made with the help of connecting lugs to ensure non-oxidation of the bare copper conductor. At the terminal connections, washers shall be interposed between stud type terminals and holding nuts. All holding nuts shall be secured by locking nuts. The connection studs shall project at least 6 mm from the lock nut surface. d) Bus wires shall be fully insulated and run separately. MCBs shall be provided to enable all the circuits in a panel to be isolated from the bus wire. Wherever practicable, all circuits in which the voltage exceeds 125 volts shall be kept physically separated from the remaining wiring. The function of each circuit shall be marked on the associated terminal boards. e) All wiring diagrams for the control and relay boards shall be drawn as viewed from the back of the cubicle and shall be in accordance with IS:375 or equivalent IEC. Multi core cable tails shall be so bound to its cable that each wire may be traced without difficulty. f) All potential bus wiring, non-trip and trip alarm bus wiring, AC & DC control supply, panel lighting bus wires and such other wiring which runs from panel to panel within a C&R panel board shall be laid out in gutters and shall be suitably screened. In case of `simplex' type C&R boards these common wires will run through bus wire holes. 5.18. TERMINAL BOARDS, TEST BLOCKS & SPARE CONTACTS: a) Terminal block connectors built from cells of moulded dielectric and brass stud inserts shall be provided for terminating the outgoing ends of the panel wiring and the corresponding tail ends of control cables. Insulating barriers
14
b) c)
d)
e)
f)
shall be provided between adjacent connections. The height of the barriers and the spacing between terminals shall be such as to give adequate protection while allowing easy access to terminals. Provision shall be made on each pillar for holding 10% extra connectors. The terminal blocks shall be suitable for 650 Volts service and for connection with both copper and aluminum wires. Terminal boards shall be mounted in such a manner as to afford easy access to terminations and to enable ferrule numbers to be read without difficulty. Wire ends shall be so connected at the terminals that no wire terminal gets marked due to succeeding connections. Terminal board rows shall be adequately spaced and shall not be less than 100 mm apart so as to permit convenient access to wires and terminations. Labels in the form of engraved plastic plates shall be provided on the fixed portion of terminal boards. No live metal parts shall be exposed at the back of terminal boards. Switch board type back connected test block with contacts shall be provided with links or other devices for shorting terminals of CT leads before interrupting the normal circuit for injection from an external source or for inserting testing instruments in the circuit without causing open circuit of the CT. The potential testing studs shall preferably be housed in narrow recesses of the block, wherever required, shall be placed as close to the equipments as possible. Test blocks shall be of flush mounting pattern and the number of test blocks being provided on each control and relay panel shall be stated in the tender. The purpose of all the relays (including the auxiliary relays) switches, lamps & push buttons etc. is required to be indicated just below the respective equipment through engraving or painting. Spare contacts of relays are required to be brought on T.B's and shall be indicated on the drawings.
5.19. BUS WIRES: The VT, DC, AC, trip alarm , non-trip alarm & DC fail etc. inter panel bus wire terminals shall be brought on Bus T.B's as well as on T.B's so that any panel specified herein can be used separately at the Substation specified in this specification. The said bus wires for the panels specified in case of existing substations shall be matched with the bus wires of the C&R panels already available at site, the drawing for matching purposes for which shall be supplied to the successful bidder. The bus wire terminals shall be indicated on the panel schematic drawings as well. The bus wire diagram shall also be supplied alongwith the schematic drawings for each panel. 5.20. FERRULES : Wire No. shall be indicated on panel schematic and wiring diagrams and accordingly engraved ferrules with the same numbers and letters as indicated in the said diagrams shall be provided on the terminal ends of all wires for easy identification of circuits for inspection and maintenance. Ferrules shall be of strong & flexible insulating material with glossy finish to prevent adhesion. These shall be engraved and marked clearly and shall not be affected by dampness. Ferrule numbering shall be in accordance with IS: 375. The same ferrule number shall not be used on wires in different circuits on a panel. At those points of interconnection between the wiring carried for equipments of different suppliers where a change of
15
number cannot be avoided double ferrules shall be provided on each wire with the appropriate connection diagram of the equipment. 5.21. SPACE HEATERS: Tubular space heaters suitable for connection to the single phase 220 Volts AC supply complete with switches located at convenient positions shall be provided at the bottom of each control and relay panel to prevent condensation of moisture. The watt loss per unit surface of heater shall be low enough to keep surface temperature well below visible heat. 5.22. ILLUMINATION: The C&R panel shall be provided with 220/240 Volts AC interior lighting. The lamp shall be free from hand shadows. A door operated button switch shall be provided in each simplex panel. Each simplex panel shall be provided with one no. illumination lamp with door switch. POWER SOCKET : Single phase 240 volt AC, 5-Pin, 5/15A power socket with power on/off switch shall be provided in each simplex panel. SAFETY EARTHING: Earthing of current free metallic parts or metallic bodies of the equipment mounted on the switch boards shall be done with bare copper conductor. Copper bus of size 25 mm x 6 mm extending through entire length of a control and relay board shall be provided. The earthing conductor shall be connected by Rose Courtney terminals and clamp junctions. The neutral point of star connected secondary windings of instrument transformers and one corner of the open delta connected LV side of potential transformer, if used shall be similarly earthed with the main earth bar of the switch board earthing system. Multiple earthing of any instrument transformer shall be avoided. An electrostatic discharge point shall be provided in each panel connected to earth bus via 1 Mega Ohm resistor. NAME PLATE: An easily accessible engraved or painted panel name plate shall be provided inside each panel. It must include G.A. drawing No., purchase order No., Contractor's reference No., name of S/Stn. as per purchase order and name of circuit. In addition to this, an engraved plate indicating the purchase order no. alongwith name of S/Stn. is required to be affixed on the panel at appropriate height so that it is readable while standing in front of the panel. These are required to be indicated on the G.A. drawings also. An engraved label indicating the purpose of all the relays & switches shall also be provided. PANEL DETAILS: The mountings on various 132kV & 33kV C&R panels against various Substations specified herein shall be as under. The bidders shall give the details of the various panel mountings in the same serial as specified herein as under for the convenience of checking of the same w.r.t. the provision in the specification. Any trip relay, auxiliary relay, timers, contact multiplication relay, ICT, IVT & test block etc. required for the completeness of the scheme shall be added by the Bidder as per scheme requirements and no cost addition on these accounts shall be considered at a later date.
5.23
5.24
5.25
5.26
16
The following is the general criteria for the selection of the equipments to be provided in each type of panel. (A) LINE PROTECTION PANEL Each Line Protection panel for transmission lines shall consist of following: Sl. No. Description 132kV 33kV 1. Main-1 Numerical Distance protection Scheme 1 Set NIL 2. Main-2 Numerical Distance protection Scheme NIL NIL 3. Directional back up Over-current and E/F protection scheme 1 Set 1 Set(with high set) 4. Overload alarm scheme 1 Set 1set 5. 3 phase Trip Relays 2 Nos. 1 Nos 6. Voltage selection scheme 1 set 1 set 8. Flag relays , carrier receive relays ,aux. Relays, timers etc as per scheme Requirements Lot Lot 9. Under Voltage relay for isolator/earth Switch 2 Nos 2 Nos TRANSFORMER PROTECTION PANEL Each protection panel for Transformer shall consist of the following: Sl.No. Description HV side MV/LVside 1. Transformer Differential Protection scheme 1 Set Nil 2. Restricted Earth fault protection scheme 1 Set 1Set@ @ Not applicable for autotransformer 3. Non-Directional back up O/C and E/F scheme with high set feature 1 set 1 set 4. Over Fluxing Protection scheme 1 Set. NIL 5. Overload alarm scheme 1 Set NIL 6. Three phase trip relays 2 nos. 2 nos. 7. Voltage selection scheme 1 set 1 set 8. Flag relays ,aux .relays, timers etc as per scheme requirement including transformer alarms and trip functions Lot Lot BREAKER RELAY PANEL for 132kV and 33kV Voltage Levels Each breaker relay panel shall consist of the following: Sl.No. Description With out A/R 1. DC supply Supervision scheme 1 set 2. Trip Circuit supervision relays# 2 Nos. # Trip supervision relays shall be 1No. for each 33KV Line and Capacitor Circuit breakers. 3. Flag relays, aux relays, timers, trip relays as per scheme requirements Lot 4. Special Energy Meter(Main) as per Interutility 1 No.* Metering System Specification of Sec-5 Chapter-5 of Contract agreement * applicable only for 33kV T/F I/C Panels BUS COUPLER PROTECTION PANEL Each bus coupler Protection panel shall consist of following:
(B)
(C)
(D)
17
Sl. No. Description 132kV 1. Non-Directional Overcurrent and E/F protection scheme with Highset 1 Set 2. 3 phase Trip Relays 1 Nos. 3. Flag relays , aux.Relays timers etc as per scheme Requirements Lot (E) CAPACITOR PROTECTION PANEL Each capacitor Protection panel shall consist of following: Sl. No. Description 33kV 1. Neutral Unbalance protection Scheme 2 Set 2. Over Voltage Protection Scheme 1 Set 3. Under Voltage Protection Scheme 1 Set 4. Non Directional Overcurrent and E/F protection scheme with high set 1 Set 5. Time Delay relay 1 Set 6. 3 phase Trip Relays 1 Nos 7. Voltage selection scheme 1 set 8. Flag relays, aux. Relays, timers etc as per scheme Requirements Lot 9. Under Voltage relay for isolator/earth Switch 2 Nos Note:- The CT secondary current is 5A for 11kV & 33kV in all panels. 6.0 6.1 TESTS: TYPE TESTS: The equipment offered should be type tested. Test reports should not more then seven years old reckoned from date of bid opening in respect of all the tests carried out in accredited laboratories (based on ISO/IEC) by a reputed accreditation body or witnessed by HVPN or another electric power utility and be submitted by the successful bidder to HVPNL for approval as schedule given in Bar Chart. a) Insulation tests as per IEC 60255-5 b) High frequency disturbance test as per IEC 60255-4 (Appendix -E) -Class III (not applicable for electromechanical relays) c) Fast transient test as per IEC 1000-4, Level III(not applicable for electromechanical relays) d) Relay characteristics, performance and accuracy test as per IEC 60255. 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 h) Conformance tests as per IEC 61850 ROUTINE TESTS: As per quality assurance program (QAP). ACCEPTANCE TESTS: Following tests shall be carried out at the manufacturers works after complete assembly in presence of HVPNL representative, unless dispensed with in writing by the HVPNL:-
6.2 6.3
18
i) ii) iii) iv) 7.0 7.1 a) b)
Checking wiring of circuits and their continuity. One minute high voltage test. Insulation resistance of complete wiring, circuit by circuit with all equipment mounted on panel. Checking the operation of protection schemes. DOCUMENTATION: The successful bidder shall submit four sets of G.A. and schematic drawings for HVPNLs approval incorporating following details also. Schematic drawings of breakers are to be incorporated in the panel schematic drawings. Trip details of transformer are to be incorporated in the panel schematic drawings. After receipt of HVPNLs approval, the bidder shall submit final drawings for each circuit of the following drawings:i) Boardwise arrangement drawing (applicable for the panel board at a Sub station having more than one panel). ii) G.A.drawing alongwith G.A. legend and foundation details. iii) Schematic drawings alongwith legend & internal wiring details of main relays like transformer differential relay, REF relay, local breaker back up schemes, distance protection scheme, bus-bar protection scheme, voltage selection scheme etc. iv) Equipment-wise & wire-wise wiring diagrams. Each set of drawings shall be bound separately. The bidder shall furnish specified no. of nicely printed and bound volumes of the instruction manuals in English language of the equipment. The instruction manual shall contain step by step instructions for all operational & maintenance requirements for all the protective and aux. relays, switches, instruments etc. mounted on the panel and shall include the following aspects. i) Storage for prolonged duration. ii) Unpacking. iii) Erection. iv) Handling at site. v) Pre commissioning tests. vi) Operating procedures. vii) Maintenance procedure. viii) Precautions to be taken during operation & maintenance work. ix) Catalogue numbers of all the components liable to be replaced during the life of the panels. x) Internal wiring diagrams of all the relays. Each set of instruction manuals shall be bound separately.
7.2
NOTE:-One master set for all the Circuits/Items shall be supplied with in a week of placement of order to the Design Directorate to facilitate the checking and approval of drawings.
19
ANNEXURE-A
TRANSMISSION LINE DATA (TENTATIVE)
--------------------------------------------------------------------------------------------------------------------------------Sr. Name of Circuit Line Conductor size No. length Sq. inch ACSR in KM. Copper equivalent ---------------------------------------------------------------------------------------------------------------------------------
--------------------------------------------------------------------------------------------------------------------------------* The line lengths and conductor size shall be supplied to successful Bidder.
20
ANNEXURE-B
SCHEDULE OF DEVIATIONS FROM THE SPECIFICATION
In the table the Bidder shall set out all deviations clause by clause from the specification of the equipment offered. The bid shall be deemed to conform to Purchaser's specification in all respects unless specifically mentioned in this table. Sr.No. -----Clause No. ---------Detailed deviations with justification. --------------------------------------
21
ANNEXURE-C
LINE PARAMETERS (per UNIT)/100 MVA BASE/100 km WITH CONDUCTOR SIZE & POWER CAPACITY
Volta ge (kV) 132 132 D/C S/C No.of Ckt. Conduct or size (inch2) 0.20 0.20 Resistan ce R Reactanc e X Susceptan ce Y Resistanc e R0 Reactanc e X0 Line Capacity (MW )
0.0445 0.0890
0.1167 0.2335
0.0970 0.0485
0.15648 0.19776
0.64289 0.76814
112 56
Remarks: 1. Size of Earth wire for:-
132 kV =
7/2.5 mm
2. Resistance of conductor at 20 C. 3. Resistivity of Earth Assumed = 100.
22
ANNEXURE-D
DETAILS OF CARRIER EQUIPMENT
The carrier terminals available in carrier equipment for feeders are as under:-
CARRIER BOOST
CARRIER SEND (MAIN-I)
+ VE
CARRIER SEND (MAIN-II)
+ VE - VE
DIRECT TRIP (SEND)
+ VE - VE
CARRIER HEALTHY (MAIN-I) CARRIER HEALTHY (MAIN-II)
CARRIER SIGNAL RECEIVE (MAIN-I)
CARRIER SIGNAL RECEIVE (MAIN-II)
DIRECT TRIP (RECEIVE)
23
SECTION V CHAPTER 4 SECTION: SUBSTATION AUTOMATION SYSTEM 1.0

1.1
GENERAL 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. 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. Peripheral equipment like printers, display units, key boards, Mouse etc.
1.2
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. It shall include communication gateway, intelligent electronic devices (IED) for bay control and inter IED communication infrastructure. An architecture drawing for SAS is enclosed. 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. System design
1.4
1.5
2.
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C:\Documents and Settings\XENWB\Desktop\G-11 Website\Final Technical G-11- Pkg B 06.09.11\SECTION-5\Chapter-4 (SAS).doc
2.1
General system design The Substation Automation System (SAS) shall be suitable for operation and monitoring of the complete substation including future extensions as given in Section-Project. 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 offered 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, signaling and testing facilities, measuring as well as memory functions, event recording and evaluation of 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 (described in other sections of technical specifications) housed in Panel room suitably located in switchyard and Station HMI in Control Room building for overall optimization in respect of cabling and control room building..
2.2
System architecture The SAS shall be based on a decentralized architecture and on a concept of bayoriented, 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 to the switchgear without any need for interposition or transducer.
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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 realized using IEC 61850 protocol with a redundant managed switched Ethernet communication infrastructure. The communication shall be made in 1+1 mode, excluding the links between individual bay IEDs to switch, such that failure of one set of fibre shall not affect the normal operation of the SAS. However it shall be alarmed in SAS. Each fibre optic cable shall have four (4) spare fibres. 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 synchronising 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 The high-voltage apparatus within the station shall be operated from different places: Remote control 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, synchrocheck, etc. (see description in Bay level control functions). 2.3.1 Select-before-execute
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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) (b) Bus Earth switch Interlocking 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.
2.3.5
User configuration The monitoring, controlling and configuration of all input and output logical signals and binary inputs and relay outputs for al 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. 3.1
System Level Functions Bay level functions
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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. Bay protection functions Separate IEDs shall be provided for bay control function and bay protection function. 3.1.1. 3.1.1.1. Bay control functions 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 (for power transformer bays) Operation counters for circuit breakers and pumps Hydraulic pump/ Air compressor control and runtime supervision Operating pressure supervision Display of interlocking and blocking 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 : 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
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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. Synchronising between live line and live bus with synchro-check function Voltage selection The voltages relevant for the Synchrocheck 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. Bay protection functions 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 timetagged events. This shall give alarm if 70% memory is full. The disturbance recorder function shall be as per detailed in section C&R
3.1.2. 3.1.2.1.
3.2. 3.2.1.
System level functions Status supervision
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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 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. 3.2.2 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. Measurements 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. The measured values shall be displayed locally on the station HMI and in the control centre. The abnormal values must be discarded.
3.2.3.
The analogue values shall be updated every 2 seconds. Threshold limit values shall be selectable for alarm indications. 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. Station HMI 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.
3.2.4.
3.2.4.1.
3.2.4.2
Control operation from other places (e.g. REMOTE) shall not be possible in this operating mode. Presentation and dialogues
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General The operator station HMI shall be a redundant with hot standby and shall provide basic
functions for supervision and control of the substation. The operator shall give commands to the switchgear on the screen via mouse clicks or keyboard commands. 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 and blocking 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, colours, 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 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-beforeexecute" 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
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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. 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. 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 measurand.
3.2.4.6.
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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 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
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etc., 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. It shall also be possible to use the keyboard for command activation. 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 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
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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. ii. iii. 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. Weekly trend curves for real and derived analogue values. 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. Provision shall be made for logging information about breaker status like number of operation with date and time indications. Equipment operation details shift wise and during 24 hours. 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. Printout on adjustable time period as well as on demand system frequency and average frequency. Reports in specified formats which shall be handed over to successful bidder.
iv.
v. vi.
vii.
viii. 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. Disturbance analysis
3.2.9.
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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 al 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. Automatic sequences 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. Gateway 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 centres 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 fibre, VSAT or leased line , the details of which shal 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
3.2.11.
3.3. 3.3.1
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and between Substation Automation system and Regional System Coordination Centre (RSCC). However, the communication channels available for this purpose are specified in section project.
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 nonvolatile 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 substation automation such as Bay to station HMI, gateway to remote station etc. S System Hardware : Redundant Station HMI, HMI View Node, Remote HMI and Disturbance Recorder Work station: The contractor shall provide redundant station HMI in hot standby mode. 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 al 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 colour display. Al event and
4.0 4.1
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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. Visual Display Units/TFT's ( Thin Film Technology) 4.1.2 The contractor shall provide three display units, one for station HMI, one for redundant HMI and one for DR work station. These shall have high resolution and reflection protected picture screen. 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. The HMI shall be able to switch the key board and cursor positioning device, as unit among all the monitors at a consol vis push button or other controls. 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 printers mounted in the control room shall be provided with a separate printer enclosure each. The enclosure shall be designed to permit full enclosure of the printers at a convenient level. Plexiglas windows shall be used to provide visual inspection of the printers and ease of reading. The printer enclosures shall be designed to protect the printers from accidental external contact & each should be removable from hinges at the back and shall be provided with lock at the front. 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. Mass Storage Unit 4.1.4 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 of CD-ROM / DVD-ROM with 700 MB or more capacity. The unit should support at least Read (48X), Write(24X), and Re-Write (10X) operations, with Multi-Session capability. It should
4.1.3
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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. The bidder shall keep provision of 100% spare capacity for employer use. One switch shall be provided to connect all IEDs for two adjacent bays of 132kV yards and all 33kV bays of one 132/33kV T/F of 33kV Yard to communication infrastructure. 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-beforeoperate control principles as safety measures for operation via the HMI. They shall 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 132kV & 33kV bays (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 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
4.2
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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 Air-conditioned kiosk The Air-conditioned Kiosk offered shall house Bay level units, bay mimic, relay and protection panels, PLCC panels etc. one each for two adjacent bays in 132kV Levels and one each for all 33kV bays of one 132/33kV T/F. In case of spare bay the kiosk shall have necessary space for accommodating the future bay IEDs. The layout of equipment/panel shall be subject to HVPNLs approval. The Kiosk shall be provided with fire alarm system with at least two detectors and it shall be wired to SAS. The detailed requirement of Kiosk is enclosed as Annexure-II. The air conditioner provided in Kiosk shall be controlled and monitored from substation automation system. One additional Kiosk for each voltage level, if required, shall be provided for housing bus bar protection panels at suitable location in switchyard.
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. 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. Station level software
5.0
5.1.1 Human-machine interface (HMI) 5.1.1.1 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 specific user requirements. Systems shall contain a library with standard functions and applications.
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5.1.2 5.1.1.1
Bay level software 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 synchronising with the remaining system without any manual interface. This shall be demonstrated by contractor during integrated system test. 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. Network Management System: The contractor shall provide a 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. Maintain a graphical display of SAS connectivity and device status. Issue alarms when error conditions occurs Provide facility to add and delete addresses and links
5.1.1.2
5.1.1.3
(b) (c) (d)
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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. 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: Type Tests: 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 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 i i. Wet heat iv. Humidity (Damp heat Cycle) v. Vibration vi. Bump
6.0
6.1 6.1.1
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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 IEDs applicable type test certificates shall be submitted. The manufacturing 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. If the FAT comprises only a certain portion of the system for practical reason, it has to be assured that this test configuration contains at least one unit of each and every type of equipment incorporated in the delivered system. 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). .3 .3 66 Integrated Testing; The integrated system tests shall be performed as detailed in subsequent clauses as per following configuration: Redundant Station HMI, DR work station, two switches (i.e. for two diameter) along with all IEDs for the Dia and printers.
All other switches for complete sub-station as detailed in section project shall be simulated as needed. 6.3.1 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. 6.3.2 Integrated System Tests:
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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. 6.4 6.4 Field Tests: The field tests shall completely verify all the features of SAS hardware and software. 7.0
7.1
SYSTEM OPERATION Substation Operation NORMALOPERATION 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). 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
7.1.1
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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 and its peripheral devices e.g. printer etc. In the event of Power failure, necessary safeguard software shall be built for proper shutdown and restart.
9.0
DOCUMENTATION The following documents shall be submitted for employers approval during detailed engineering: (a) (b) (c) (d) (e) System Architecture Drawing Hardware Specification Sizing Calculations of various components Response Time Calculation Functional Design Document
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 t be provide in dxf format. List of Drawings Substation automation system architecture Block Diagram Guaranteed technical parameters, Functional 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 ) Panel Room Layout drawing
Design
Specification
and
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Control Room Lay-out Test Specification for Factory Acceptance Test (FAT) Product Manuals Assembly Drawing Operators Manual Complete documentation of implemented protocols between various elements Listing of software and loadable in CD ROM Other documents as may be required during detailed engineering
Two sets of hard copy and Four sets of CD ROM containing all the as built documents/drawings shall be provided. 10.0
10.1
TRAINING, SUPPORT SERVICES, MAINTENANCE AND SPARES Training Contractor personnel who are experienced instructors and who speak understandable English shall conduct training. The contractor shall arrange on its own cost al 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 al technical manuals and al 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 inhouse 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 participants. The Contractor shall quote training prices individual y for each of the courses as indicated in BPS. Employer will have the option to cancel any or all-training courses. In the case of cancellation, the rate quoted against the respective course will not be paid to the Contractor. 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:
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(a) (b)
(c) (d)
(e)
(f)
System Hardware Overview: Configuration of the system hardware. Basic theory of operation, maintenance Equipment 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. System Expansion: Techniques and procedures to expand and add equipment such as loggers, monitors, and communication channels. 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. 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. Practical training on preventive and corrective Operational Training: 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. 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 System Initialization and Failover: Including design, theory of operation, and practice Including the execution of diagnostic procedures and the Diagnostics: interpretation of diagnostic outputs, Software Documentation: Orientation in the organization and use of system software documentation. 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.
(b)
(c) (d) (e) (f)
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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) (b) (c) (d) (e) (f) Overview: Block diagrams of the application software and data flows. Programming standards and program interface conventions. Application Functions: Functional capabilities, design, and major algorithms. Associated maintenance and expansion techniques. Software Development: Techniques and conventions to be used for the preparation and integration of new software functions. Software Generation: Generation of application software from source code and associated software configuration control procedures. Software Documentation: Orientation in the organization and use of functional and detailed design documentation and of programmer and user manuals. 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 two batches for two weeks each for following courses. S. No. 1 2 3 Name of Course Computer System Hardware Computer System Software Application Software
11.0 11.1
Maintenance 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. RELIABILITYAND 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: Mechanical and electrical design
12.0
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Security against electrical interference (EMI) High quality components and boards Modular, wel -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 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. 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 as having duration of 1/4th of an hour. 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). 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.
2)
3)
4)
12.1
Guarantees Required The availability for
the
complete
SAS
shall
be
guaranteed
by
the
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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
13.1
Spares Consumables: All consumables such as paper, cartridges shall be supplied by the contractor till the SAS is taken over by the owner. .
13.2
Availability Spares: In addition to mandatory spares as listed in section project for SAS, 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
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ii) iii) iv) v) vi) vii) viii) ix)
Redundant Station HMI (in Hot-stand by mode) Bay level units along with bay mimic Disturbance Recorder Work Station(Maintenance HMI) Colour Laser Printer 1 No. (For Reports & Disturbance records) Dot matrix printers - (one each for Alarms and log sheets) All interface equipment for gateway to RCC and RSCC Communication infrastructure between Bay level units, Station HMI, Printers, gateways, redundant LAN etc. as required Any other equipment as necessary.
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Annexure-I Basic Monitoring requirements are: -
Switchgear status indication Measurements (U, I, P, Q, f) Event Alarm Winding temperature of transformers ambient temperature Status and display of 415V LT system, 220V & 48V DC 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 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 Y-B phase B-R phase
For transformer Current R phase Y phase B phase WTI (for transformer ) Tap position (for transformer only) iii) For bus coupler Current R phase Y phase
B phase Page 1 of 5
ii)
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) c) d)
Frequency for Bus-I and Bus-II Ambient temperature (switchyard). LT system Voltage R-Y, Y-B, B-R of Main Switch Board i) section-I Voltage R-Y, Y-B, B-R of Main Switch Board ii) 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 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 Status of each pole of CB, Isolator, Earth switch i) CB trouble ii) CB operation/closing lockout iii) Pole discrepancy optd iv) Trip coil faulty v) vi) LBB optd vii) Bus bar protn trip relay optd viii) Main bkr auto recloser operated ix) Tie/transfer auto recloser operated x) A/r lockout Tie/transfer bkr a/r lockout xi) Direct trip-I/II sent xii) Direct trip-I/II received xiii) Main I/II blocking xiv) Main I/II-Inter trip send xv) xvi) Main I/II-Inter trip received
Page 2 of 5
xvii) xviii) xix) xx) xxi) xxii)

xxiii)
xxiv) xxv) xxvi) xxvii) xxviii) xxix) xxx)

xxxi)
xxxii) xxxiii) xxxiv) xxxv) xxxvi) xxxvii) xxxviii) xxxix) xl) xli) xlii) xliii) xliv) xlv) xlvi) xlvii) 2.
O/V STAGE I operated O/V STAGE II operated FAULT LOCATOR FAULTY MAIN-I/II CVT FUSE FAIL MAIN-I PROTN TRIP MAIN-II PROTN TRIP MAIN-I PSB ALARM MAIN-I SOTF TRIP MAIN-I R-PH TRIP MAIN-I Y-PH TRIP MAIN-I B-PH TRIP MAIN-I START MAIN-I/II Carrier aided trip MAIN-I/II fault in reverse direction MAIN-I/II ZONE-2 TRIP MAIN-I/II ZONE-3 TRIP MAIN-I/II weak end infeed optd MAIN-II PSB alarm MAIN-II SOTF TRIP MAIN-II R-PH TRIP MAIN-II Y-PH TRIP MAIN-II B-PH TRIP MAIN-II start MAIN-II aided trip MAIN-I/II fault in reverse direction Back-up o/c optd Back-up e/f optd 220V DC-I/II source fail SPEECH CHANNEL FAIL PLCC Protection Channel-I FAIL PLCC Protection Channel-II FAIL
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 FUSE FAIL xv) MV BUS CVT FUSE FAIL xvi) OTI ALARM/TRIP xvii) PRD OPTD xviii) OVERLOAD ALARM xix) BUCHOLZ TRIP xx) BUCHOLZ ALARM xxi) OLTC BUCHOLZ ALARM
Page 3 of 5
xxii) xxiii) xxiv) xxv)

xxvi)
xxvii) xxviii) xxix) xxx) xxxi) 3.
OLTC BUCHOLZ TRIP OIL LOW ALARM back-up o/c (HV) optd back-up e/f (HV)optd 220v DC-I/II source fail TAP MISMATCH GR-A PROTN OPTD GR-B PROTN OPTD back-up o/c (MV) optd back-up e/f (MV)optd
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) HV BUS CVT 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 Busbar 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 Auxiliary system i) Incomer-I On/Off ii) Incomer-II On/Off iii) 415V Bus-I/II U/V iv) 415v bus coupler breaker on/off v) DG set bkr 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-II WTI Alarm & trip xi) LT transformer-I OTI Alarm & trip xii) LT transformer-II OTI Alarm & trip
Page 4 of 5
5.
xiii) xiv) xv) xvi) xvii)
PLCC exchange fail Time sync. Signal absent Alarm/trip signals as listed in Section: Battery and Battery charger 220v dc-I earth fault 220v dc-II earth fault
The exact number and description of digital inputs shall be as per detailed engineering requirement Apart from the above mentioned digital inputs, minimum of 200 inputs shall be kept for use in future.
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Annexure-II Specification of Kiosk The Kiosk shall be made of sandwich insulated panels 80 mm thick with poly Urethane Foam (PUF) as filler material between polyester pre-coated cold rolled steel. The insulation characteristics of PUF material shall conform to following requirement: Sr. No. 1. 2. 3. 4. 5. 6 7. 8. 9. 10. 11. 12. 13. 14. Particular Thickness Density Compressive Strength Tensile Strength Bending Strength Adhesion Strength Dimension Stability Temperature Range Thermal Conductivity Fire Resistance Water absorption Vapour Permeability Self Extinguishing Biodegradable Parameters 78.6 mm 40 kg/m3 1.2 kg.cm3 3.6 kg/m2 4.0 Kg/m2 2 2.9 Kg/m At -25oC : 0.1% at 38oC : 0.1% ant at 38oC : 0.4% -15oC to 95oC 0.02 kcal/hr/m/oC As per BS-4735 Horizontal Burn <125 mm 0.2% @ 100% RH 0.08/0.12 g/hr/m2 Yes Yes
The thickness of the inner-side and outer steel sheet except floor panel sheet shall be minimum 0.8 mm and 0.6 mm respectively. The outer bottom sheet shall be hot dip galvanised steel sheets of minimum 1.0 mm thickness to avoid rusting at bottom. The sandwich panels shall be manufactured by high pressure injection techniques. The floor of the kiosk shall be suitably designed for accommodating the control and relay IEDs in the panels. The adequate lighting shall be provided in the kiosk. The Kiosk shal have adequate space for working and maintain clearances as per requirement of Indian Electricity Rules. the kiosk shall be provided with locking arrangement. 2 Air-Conditioning: The air conditionings system shal be provided in the Kiosks to be used for housing panels having control and protection IEDs for performing sub-station automation and protection functions generally confirm to relevant IS codes as detailed ins section GTR. These kiosks shall be placed in the switchyard area generally unmanned; therefore, the air-conditioning system shall be rugged, reliable, maintenance free and designed for long life. Operation:
i.
Page 1 of 3
The air conditioning is required for critical application i.e. for maintaining the temperature for critical sub-station control and protection equipment. To provide redundancy for such critical applications, each kiosk shall be installed with environment control system comprising of two units of air conditioners working in conjunction through a micro processor based controller for desired operation. The system shall be designed for 24 Hours, 365 Days of the year to maintain the inside kiosk temperature for proper operation of the critical equipment. One of the air-conditioner shall be running at a time and on failure of the same or as described hereunder, the other unit shall start automatically. To ensure longer life of the system, the redundant units shall also be running in cyclic operation through the controller. However, during running of one air-conditioner unit, if inside temperature of the shelter reaches to a predefined (i.e. 35oC), the other unit shall start running to maintain the temperature to specified value (i.e. 23+2oC) and gives alarm for such situation. After achieving this temperature, the other unit shall again shut off. Sequence of Operation of the Unit: ii. 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 Construction: The air conditioning unit shall be completely self-contained. All components of the units shall be enclosed in a powder coated cabinet and colour of same shall be matched with kiosk colour. 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 kiosk. Required Features of Various Components: The compressor shall be very reliable, trouble free and long life i.e. hermitically sealed Scroll type of reputed make suitable for operation. Compressor should be installed on vibration isolated mountings or manufacturers recommended approved mounting. Valve shal 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. v. The kiosk shall be erected at least 300 mm above the finished ground level with suitable pedestal to avoid any entry of water.
iii.
iv.
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Proto Testing: One kiosk meeting the specified requirement as described above, shall be fabricated at the factory and offered for proto inspection at the factory. This proto shall be equipped with all required accessories like air-conditioning system, fire and smoke detector, lighting, various cut outs etc. The offered kiosk shall be inspected for finish, all fittings and accessories, opening including doors and locks. The kiosk shall be tested for dust and rain protection to check out any leakage and air tightness. The following main tests shall be carried out: (a) Illumination inside the kiosk shall be switched off and it shall be checked that no light enters through panel joints, holes and other joints in the kiosk. (b) Water Leakage Test (with a water pipe with suitable pressure from all sides for one hour.) (c) Working and functional tests of all accessories like air-conditioning system, fire and smoke detector, lighting arrangements as per technical specification (d) Start up test for air conditioner (e) Satisfactory operation of air conditioner installed on Kiosk. (f) The total heat load for panels and devices to be placed inside the kiosk including PLCC, all IEDs etc. shall be calculated and equivalent calculated heating load (maximum value from among the calculated values for various kiosk) shall be placed inside the kiosk and the kiosk shall be made operational for four hours with all accessories and inside & outside temperature of kiosk shall be recorded. On successful completion of proto testing, all other system shall be manufactured after incorporation of all alteration/modifications observed/suggested during/after proto testing. The detail test procedure shal be submitted by the contractor and get it approved from the owner before commencement of proto testing.
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TYPICAL ARCHITECTURAL DRAWING OF SUBSTATION AUTOMATION SYSTEM
HMI View Node Router
Station HMI
DRWork Station
Gateway
GPS
Clock
Redundant Managed Ethernet Station Bus

IEC 61850
IEC 61850
Switch for Dia 1
Switch for Dia. 2
Switch for Dia. 3
Switch for Dia. N
Fibre optic Connection

IEDs for Control & protection IEDs for Control & protection
IEC 61850
[
IEDs for Control & protection
IEDs for Control & protection
Note: 1. The redundant managed bus shall be realized by high speed optical bus using industrial grade components and shall be as per IEC 61850. 2 The IEDs can be housed along with its switches in AC Kiosks i.e one each for two adjacent bays in 132kV Levels and one each for all 33kV bays of one 132/33kV T/F. 3. Inside the sub-station, all connections shall be realized as per IEC 61850 protocol. 4. For gateway, it shall communicate with Remote Supervisory Control Centre (RSCC) on IEC 60870-5-101 protocol. 5. The router to Remote Control Centre (RCC) shall communicate on IEC 60870-5-101 protocol. 6. The printer as required shall be connected to station bus directly and can be managed either from station HMI, HMI view node or disturbance recorder work station.
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SECTION-5 CHAPTER-5
TECHNICAL SPECIFICATIONS FOR INTERUTILITY METERING SYSTEM AND COMMON METER READING INSTRUMENT (CMRI)
C:\Documents and Settings\XENWB\Desktop\G-11 Website\Final Technical G-11- Pkg B 06.09.11\SECTION-5\Chapter-5 (IUM).doc
TECHNICAL SPECIFICATION FOR INTER UTILITY METERING SYSTEM

1.0 2.0 The specification covers the design, manufacturing, testing, inspection, delivery of inter utility metering system and /or common meter reading instrument (CMRI). The energy meters specified herein shall be used for tariff metering for bulk, Inter -utility power flows in HVPNL/DISCOM. The meters shall be installed on each circuit as a self contained device for measurement of active energy & reactive energy in each successive 15-minute block and certain other functions as described in the following paragraphs. The meters shall be suitable for being connected through Test terminal blocks to the voltage transformer having a rated secondary line to line voltage of 110 V, and to current transformers having a rated secondary current of 1 A. Any further transformer/transducers required for their functioning shall be in built in the meters. Necessary isolation and / or suppression shall also be built in for protecting the meters from surges and voltage spikes that occur in the VT/CT circuits of the switchyards. The reference frequency shall be 50Hz. The microprocessor based 3 phase 4 wire meters shall conform to class 0.2S as per IS 14697 for Indian manufacturers or IEC- 62053-22 (2003) for foreign manufacturers & technical specification and meter shall be stand alone type. The meters shall bear BIS certification mark, if required as per Govt. of India Gazette notification. It will be the responsibility of the bidder to get these meters marked with BIS certification. The BIS certification shall be supplied with the tender. Meters shall be supplied with associated TTBs. The Meters shall have following features: Meter shall be stand alone type. For transfer of data, system should have multiple communication ports as described in the following paragraphs The active energy measurement (Wh) shall be carried out on 3 phase 4 wire principle with an accuracy as per class 0.2S of IS 14697/IEC- 62053- 22 (2003) In the meters the energy shall be computed directly in CT/VT secondary quantities and indicated in Watt-hours. The meters shall compute the net active energy (Wh) sent out from the Sub-Station during each successive 15 minute block, and store in its memory along with +/- sign. It shall also display on demand the net WH sent out during the previous 15 minute block, with a minus sign if it is a net Wh receipt. Further, the meter shall continuously integrate and display on demand the net cumulative active energy sent out from the Sub-Station upto that time. The cumulative Wh reading at each midnight shall be stored in the meters memory. The register shall move backwards when active power flows backwards into the Sub-Station.
3.0
4.0
5.0 a) b)
6.0
7.0
8.0
The meter shall count the number of cycles in VT output during each successive 15-minute block and divide the same by 900 to arrive at the average frequency. This shall be stored in the meter's memory as a 2-digit code, which shall be arrived at by subtracting 49 from the average frequency, multiplying by 50 and neglecting all decimals. For e.g. 49.89 Hz shall be recorded as 44. In case the average frequency is less than 49.0 Hz, it shall be recorded as 00. In case it is 51.0 Hz or higher, it shall be recorded as 99. The average frequency of the previous 15-minutes block shall also be displayed on demand in Hertz. The accuracy of the voltage measurement/computation shall be at-least 0.5%, a better accuracy such as 0.2% in the 95-105% range being desirable. The meters shall continuously compute the average of the RMS value (fundamental only) of the three lines to neutral VT secondary voltage as a percentage of 63.51 V and display the same on demand. The meter shall also compute the reactive power (VAR) on 3 phase 4 wire principle. Limits of error shall be corresponding to class 1.0 as per IS 14697 for reactive energy for Indian manufacturers or half (50%) of those permitted corresponding to class 2.0 for reactive energy as per IEC 62053-23 (2003) for foreign manufacturers, and integrate the reactive energy (VARh) algebraically in 2 separate registers, one for the period for which the average RMS voltage is 103% or higher and the other for the period for which the average RMS voltage is below 97%. The current reactive power (VAR) with a minus sign if negative, and cumulative reactive energy (VARh) reading of the 2 registers shall be displayed on demand. The readings of the 2 registers at each midnight shall also be stored in the meter's memory. In the meter, the reactive power and reactive energy transmittals shall be computed in VAR/VARh directly calculated in VT and CT secondary quantities. When lagging reactive power is being sent out from the Sub-Station. VAR display shall have no sign and VARh registers shall move forward. When reactive power flow is in the reverse direction. VAR display shall have a negative sign and VARh registers shall move backwards. The meter shall fully comply with all the stipulations of IS 14697/IEC- 60687-2000 (or latest revision) for class 0.2S for static watt-hour meters except those specifically modified by this specification. The reference ambient temperature shall be 50 deg. C. Error shall be as per IS-14697/ IEC- 62053- 22 (2003) for all power factor angles from 0 deg. to 360 deg. Each meter shall have a test output device (visual) for checking the accuracy of active energy Wh and reactive energy (VARh) measurement using a suitable test equipment. The test output shall be software configurable for active energy import/export and reactive energy import/export. No rounding off to the next higher last decimal shall be done for voltage and frequency displays. The three line to neutral voltages shall be continuously monitored by individual phase wise LED's, and in case any of these falls below 70%, the normally flashing lamp provided on the meters front becomes steady. The time blocks in which such a voltage failure occurs/persist shall also be recorded in the meter's memory. The lamp shall automatically resume flashing when corresponding VT secondary voltage is healthy again. LCD indication are also acceptable. The two
3
9.0
10.0
11.0
12.0 13.0
14.0 15.0
VARh registers specified in clause-10 shall remain stay-put while VT supply is unhealthy. 16.0 The meters shall operate with the power drawn from the VT secondary circuits, without the need for any auxiliary power supply. The total burden imposed by a meter for measurement and operation shall not exceed 10 VA on any of the phases. An automatic backup for the continued operation of the meter's calendar clock shall be provided through a long life battery, which shall be capable of supplying the required power for atleast two years. The meters shall be supplied duly fitted with the battery which shall not require to be changed for atleast 10 years, as long as total VT supply interruption does not exceed two years. The battery mounting shall be designed to facilitate easy battery replacement without affecting PCB of meter. Each meter shall have a built-in calendar and clock, having an accuracy of 30 seconds per month or better. The calendar and clock shall be correctly set at the manufacturer's works. The date (day-month-year) and time (hour-minute-second) shall be displayed on the meter front on demand. Clock adjustment shall be possible at site using the Meter Reading Instrument (MRI) or remotely using time synchronization signal through RS 485. For the purpose of getting the standard time, the computer (s) from where the meter will be read shall be equipped with GPS signal receiver. This computer and the GPS receiver, however, are not in the scope of this specification. When an advance or retard command is given, six subsequent time blocks shall be contracted or elongated by 10 seconds each. The meter shall not accept another clock correction command for seven days. The meter time shall automatically be corrected every time the remote computer interrogates it. All clock corrections shall be registered in the meter's memory and shall be suitably shown on the print out of the collected data Each meter shall have a unique identification code, which shall be marked permanently on the front as well as in its memory. All meters supplied to HVPN, as per this specification shall have their identification code starting with HVPN, which shall not be used for any other supply. HVPN shall be followed by a dash and a four digit running serial number. The series of four digit running serial no. indicating the unique identification code of each meter shall be provided by HVPN to the successful bidder. The measured value(s) shall be displayed through LED/back-lit LCD display with proper identification for indication of the following (one at a time) on demand. 19.1 19.2 19.3 19.4 19.5 19.6 19.7 19.8 19.9 19.10 19.11 Meter Serial No. Date (dd-mm-yy) Time (hr-min-sec) Cumulative Wh reading Average frequency of the previous 15-minute block Net Wh transmittal in the previous 15-minute block, with +/- sign Average percentage voltage Reactive power (VAR) with +/- sign Voltage high VARh register reading Voltage-Low VARh register reading Low Battery Indication 'd' 't' 'c' 'F' 'E' 'U' 'r' 'H' 'L'
17.0
18.0
19.0
20.0
21.(A) 21.1 21.2 21.3 21.4 21.5 21.6 21.(B) 22.0
A keypad or scrolling facility shall be provided on the front of the meter for switching on the display of the meter parameters selected and for changing from one indication to next. Meter shall have a non-volatile memory in which the following shall be automatically stored. Average frequency for each successive 15-minute block upto second decimal/as a two-digit code. Net Wh transmittal during each successive 15-minute block upto second decimal/with plus minus sign. Cumulative Wh transmittal at each midnight in 6 digits including one decimal. Cumulative VARh transmittal for voltage high condition, at each midnight in 6 digit including one decimal. Cumulative VARh transmittal for voltage low condition, at each midnight in 6 digit including one decimal. Date & time blocks of failure of VT supply on any phase, as a star (*) mark. Battery backed memory shall not be accepted. The meter shall store all the above listed data in their memories for a period of 35 days. The data older than 35 days shall get erased automatically. CMRI/DCD: To ensure inter operability of system at the meter reading instrument end, the common meter reading instrument (CMRI) or data collection devices (DCD) confirming to DOS platform and having min. 16 MB memory shall be used to enable different manufacturers to download into same hand held terminal & the meters of various makes to be read through the same hand held terminal. Each CMRI shall be complete with:a lead with optical head for coupling it to the meter, a lead for plugging it to a personal computer; an internal battery for powering the devices; a case for safely carrying it about a battery charger The total arrangement shall be such that one (1) operation can carry out the whole operation, in about five (5) minutes per meter. Portable Meter Reading Instruments (MRI)/data collection devices (DCD) shall have a key for starting the data tapping from the coupled meters memory, a key to start data transfer to the PC, and a lamp, which would light up on completion of data collection, remain on while the data is held in the device and would go off when all data has been transferred to the PC. Data tapping operation from CMRI/DCD shall not erase the data from the meters memory, or effect the meter operation in any way. The memory of the CMRI/DCD shall get automatically cleared when the data has been transferred to the PC only then the CMRI/DCD shall accept data from another meter. CMRI/DCDs shall also have necessary provision for meter clock correction. CMRI/ DCDs shall be compatible with earlier supplied meters in regard to data downloading etc.
23.0
i) ii) iii) iv) v)
23.1
Each meter shall have an optical communication port compatible to RS 232 on its front for tapping all data stored in its memory. In addition to the above each meter shall be provided with a RS485 port on one of its sides, from where all the data stored in the meters memory can also be tapped. Portable Meter Reading
5
Instruments (MRI)/data collection devices (DCD) of SANDS, ANALOGIC make have already been provided separately for this purpose, one for each SubStation, to serve as interface between the meters specified above and the local PC. Meter shall be compatible with earlier supplied CMRI/DCD. Each meter shall be provided with a lead having optical head for coupling the meter to CMRI/DCD. 23.2 Software Package: The existing metering system records all the parameters required for the Availability Based Tariff. Suitable software for CMRI shall be provided by the bidder for smooth downloading of the data to/ from the CMRI. For data analysis & billing, the different meter manufacturers shall provide the meter reading software to interpret the data collected through CMRI or through RS485 for conversion into a common ASCII format. The Data of the existing meters is available in the specified ASCII Format; details of which are enclosed at Annexure-II (Page1 to 3). A similar output in the same ASCII format (space delimited, fixed length values) shall be made available from the new meters by the successful bidder for future use of data for generation of BST & ABT Bills/Reports or any other purpose. In addition to this successful bidder shall make provision to supply load survey data in Excel format as per AnnexureIII.The supplier shall provide above software which would enable a local PC to:accept the data from the CMRI and/or from a interface device connected to the optical port/RS-485 port and store it in its memory in binary read only format. Polling feature along with a task scheduler to run the data downloading software at a pre-designated date and time repeatedly or by manually selecting a meter. A detailed activity log shall also be available for each downloading operation. Display the collected data on PCs screen on demand as per annexure-II & III in text format, with forward/backward rolling. Print out in text format the data collected from one or more meters as per annexure-II & III, starting from a certain date and time, as per operators instructions. Transmit the collected data, in binary format, through an appropriate communication link to the central computer, starting from a certain date and time, as per operators instructions. Store the collected data, in binary format, on a floppy disc/CD/Pen drive/DVD. The above software shall further ensure that absolutely no tampering (except total erasures) of the collected metering data is possible during its handling by the PC. The software shall be suitable for the commonly available PCs and shall be supplied to owner in a compatible form to enable its easy loading into the PCs available at the various Sub-Stations/Energy Accounting Centre. 23.3 The overall intention is to tap the data stored in the meter memory at any time from any of the two ports mentioned above and transmit same to a remote centre computer using communication links, through the local PC. It should also be possible to obtain a print out (hard copy) of all data collected from the meters, using the PC. The received/ downloaded meter data should be the original output from the meter. As a part of commissioning the Contractor shall load the software in the PCs at the respective substations, and fully commission the total meter reading scheme. He shall also impart the necessary instructions to substation engineers.
6
i) ii)
iii) iv)
v)
vi)
23.4
24.0
The whole system shall be such as to provide a print out (both from the local PC and the remote central computer) of the following form: 23 55 +16.28 56 +15.95 55 +15.32 54 +15.66 55 +14.93 55 +14.26 54 +14.85 56 +15.17 HVPNL **** 12345.6 01234.5 00123.4 99-04-28 57 +14.72 56 +13.83 55 +13.57 53 +12.91 01 52 +13.34 51 +12.76 52 +14.11 52 +15.28 All the meters shall be identical in all respects except for their unique identification codes. They shall also be totally sealed and tamper proof, with no possibility of adjustment at site except for a restricted clock correction. The meter shall safely withstand the usual fluctuations arising during faults in particular, VT secondary voltage 115% of rated applied continuously and 190% of rated for 3 seconds and CT secondary current 150% of rated applied continuously and 30 times of rated applied for 0.5 seconds, shall not cause any damage to or the mal-operation of the meters. The meter shall continue to function for remaining healthy phase(s), in case of failure of one or two phases of VT supply. In case of a complete VT supply failure, the computation of average frequency (as per 8.0) shall be done only for the period during which the VT supply was available in the 15-minute block. Any time block contraction or elongation for clock correction shall also be duly accounted for. The harmonics shall be filtered out while measuring the Wh, VAR and VARh and only fundamental frequency quantities shall be measured or computed. VOID VOID Every meter shall be indelibly marked with connection diagram showing the phase sequence for which it is intended and shall be attached on the meters. In case of any special precautions need to be taken at the time of testing the meter, the same shall be indicated alongwith the circuit diagram. VOID Sealing arrangement: Sealing arrangement for meters and TTBs shall be provided as under: TTBs: Each TTB shall have the provision for two seals. Meters: Meter body or cover & meter terminal blocks shall be sealable including each optical communication port. The meters shall be supplied housed in compact and sturdy; metallic or moulded cases of non-rusting construction and/or finish. The cases shall be designed for simple mounting on a plane, vertical surface such as a control/relay panel front. All terminals for CT and VT connections shall be arranged in a row along the meters lower side. Terminals shall have a suitable construction with barriers and cover, to provide a secure and safe connection of CTs and VTs leads through stranded copper conductors of 4.0 sq. mm. size.
25.0
26.0
27.0
28.0 29.0 30.0 31.0
32.0
33.0 33.1 33.2 34.0
The meters shall also withstand without any damage or maloperation reasonable mechanical shocks, earthquake forces, ambient temperature variations, relative humidity etc. They shall have an IP-51 category dust-tight construction, and shall be capable of satisfactory operation in an indoor, non-air conditioned installation. The contractor shall be responsible for total installation and commissioning of the meters (alongwith test blocks, if supplied separately)as per Owners advice, including unpacking and inspection on receipt at site, mounting the meters on control and relay panels at an appropriate viewing height, connection of CT and VT with 4cx4mm2 control cables to metering system, functional testing, commissioning and handing over. The Contractors personnel shall procure/carry the necessary tools, equipment, materials and consumables (including insulated wires, lugs, ferrules, hardware etc.). 35.0 35.1 Inspection & Testing: Type Tests: The equipment offered should be type tested. Type test report of similar equipment should not be more than seven years old, reckoned from the date of bid opening in respect of the following tests, as per relevant ISS-14697 and carried out in accordance with the procedure laid down in relevant ISS/IEC/Internationally recognized equivalent standard from any accredited test house/ Lab. For Indian manufacturers, the tests got conducted from Govt. test labs shall also be acceptable. These type test reports shall be submitted by the successful bidder to HVPNL for the approval as per schedule given in commercial document. Test for Insulation Properties Impulse Voltage Test. ac High Voltage Test Insulation Test Test of Accuracy Requirements Test on limits of error Test of meter constant Test of starting condition Test of no-load condition Test of repeatability of error Interpretation of test results Test of ambient temperature influence Test of influence quantities Test of Electrical Requirement Test of influence of supply voltage Test of influence short time overcurrent Test of influence of self-heating Test of influence of heating Test for power consumption Test for Electromagnetic Compatibility Radio interference measurement Fast transient burst test Test of immunity to electrostatic discharges Test of immunity to electromagnetic HF field Test for Climatic Influences
8
a) i) ii) iii) b) i) ii) iii) iv) v) vi) vii) viii) c) i) ii) iii) iv) v) d) i) ii) iii) iv) e)
i) ii) iii) f) i) ii) iii) iv) v) 35.2 35.3
Dry Heat Test Cold Test Damp Heat Cyclic Test Test for Mechanical Requirements Vibration Test Shock Test Spring Hammer Test Protection against penetration of dust and water Test of resistance to heat and fire Routine Tests: As per quality assurance program (QAP). Acceptance Tests:
a)
b)
c) i) c) e)
All equipment, after final assembly and before despatch from manufacturer's works shall be duly tested as per IS 14697 for compliance in both directions of power flow in presence of HVPNL representative, unless dispensed with in writing by HVPNL. The following acceptance tests shall be conducted:Test for Insulation Properties i) ac High Voltage Test ii) Insulation test Test of Accuracy Requirements i) Test on limits of error ii) Test of meter constant iii) Test of starting condition iv) Test of no-load condition v) Test of repeatability of error Test of Electrical Requirement Test for power consumption Functional checks for display and memory. Accuracy of voltage and frequency measurement. All DCDs/MRIs after final assembly and before dispatch from Manufacturers works shall be duly tested to verify that they are suitable for supply to the purchaser. In particular, each and every DCD/MRI shall be subjected to the following acceptance test:1. Functional checks 2. Downloading Meter Data from the Meter(s). 3. Compatibility with PC software 4. Downloading the meter data on PC 5. Functioning of advance and retard time commands. 6. Per meter downloading time verification 7. Capacity of DCD/MRI for data storage. Quality Assurance The quality control procedure to be adopted during installation of the specified equipment shall be mutually discussed and finalised in due course, generally based on the established and proven practices.
36.0
37.0
Any meter, which fails to fully comply with the specification requirements, shall be liable to be rejected by the purchaser.
9
38.0 39.0 39.1.1
VOID Following technical information shall be furnished by the bidders in their offers.: The prospective bidder shall be required to submit complete type test reports from Govt. approved laboratory alongwith bid. The type test reports shall not be more than seven years old reckoned from the date of opening of part-1 tender. Guaranteed Technical Particulars shall be supplied.
39.2
10
Annexure-I Standard Format for Meter Readings, Energy data First Row/*-- Header Information : Starting date & time and End date & time is defined First row Starting time 4 character (11th character to 14th character). Starting date 8 character (23rd Character to 30th Character), Ending time 4 character (35th Character to 38th Character), Ending date 8 character (47th Character to 54th Character) RTC Synchronization Status Indicator 1 Character (56th Character): 1 indicates RTC synchronized, 0 indicates RTC not synchronized. Second Row: Meter Sr. No 10 Characters (1st to 10th Character), Mid Night Net Wh 7 Character (15th Character to 21st Character), Reactive High Energy 7 Characters (26th Character to 32nd Character), Reactive Low Energy 7 Characters (37th Character to 43rd Character), Data Date 8 Characters (48th Character to 55th Character) Third Row is Blank Fourth row: 16 IP data in each row Starting Hour 02 Characters (1st , II nd Character), Avg. Freq 2 Characters (5th, 6th character), Status Indication 3 character (7th Character to 9th character), Net Energy 6 Character (10th to 15th Character) 2 Character left blank and all the data will be repeated 16 times Fifth Row : Same as 4th Row Sixth Row : Same as 4th Row Seventh Row : Same as 4th Row Eighth Row : Same as 4th Row Ninth row: Same as 4th row and at the end net energy of 24 hours at 215th Character (4 Character) Lines will be repeated from 2nd line onwards as above.
11
/*-- Header Information One Block At the begining of each day in Following Format: Meter SerialNo MidNight Net Wh Reactive High Energy Reactive Low Energy Date 16 IP data in each row and total 6 rows for complete 24 hours data Format for IP wise information: StartingHour AvgFreq StatusIndication NetEnergy AvgFreq StatusIndication NetEnergy ... StatusIndication gives following Information: * to indicate Supply Down.Supply failure might be momentary or might have lasted for several IPs rr to indicate time retard "aa" to indicate time advance Sum of net energies(for 96 IP) at the end of last row of the day having complete 24 hours data --*/
12
WEEK FROM 0000 HRS OF 28-06-05 TO 1224 HRS OF 01-08-05 0 AP-M038-75 95736.5 02793.0 05701.7 28-06-05 00 18 +22.48 03 +22.19 11 +22.38 08 04 46 +23.63 48 +23.99 42 +24.35 26 08 64 +18.50 62 +18.51 63 +17.60 67 12 48 +17.31 38 +18.39 43 +18.12 27 16 65 +10.68 55 +07.22 59 +04.76 62 20 12 +27.56 19 +29.27 10 +29.96 13 AP-M038-75 97537.9 02804.6 06093.8 00 09 +23.64 11 +23.53 12 +23.35 07 04 66 +24.77 57 +25.14 51 +25.75 45 08 76 +13.07 70 +12.96 64 +12.97 66 12 49 +27.45 42 +27.04 43 +27.03 45 16 68 +26.87 52 +25.64 54 +23.94 47 20 25 +28.96 08 +30.16 10 +30.31 05 AP-M038-75 99732.0 02849.2 06724.7 00 52 +25.10 58 +24.99 56 +24.70 60 04 57 +24.28 66 +24.81 60 +25.25 45 08 49 +12.34 42 +12.47 49 +12.53 56 12 01 +18.48 00 +16.06 00 +15.48 03 16 28 +22.65 28 +22.79 36 +22.97 23 20 00 +30.53 01 +12.91 12 +00.04 00 AP-M038-75 01742.8 02932.1 06980.9 +22.44 11 +24.75 44 +15.19 63 +18.23 54 +04.43 65 +29.97 22 29-06-05 +23.11 18 +26.42 60 +12.96 55 +27.30 56 +26.32 62 +30.44 10 30-06-05 +22.57 +25.84 +14.62 +14.67 +04.19 +29.61 10 +23.03 14 +23.11 14 +23.23 22 +23.28 28 +23.29 35 +23.45 41 +23.48 44 +23.66 44 +23.68 45 +23.54 52 +23.54 48 +26.40 46 +26.52 56 +23.32 69 +22.85 61 +21.83 55 +21.24 60 +24.44 65 +23.36 61 +20.22 60 +19.19 62 +18.72 59 +15.63 59 +16.02 52 +16.65 39 +16.46 43 +15.18 64 +15.14 65 +15.29 52 +14.87 49 +13.21 50 +13.79 51 +15.19 51 +16.20 56 * +03.30 51 * +00.03 47 +00.06 49 +00.03 25 +05.45 20 +10.40 29 * +04.08 30 * +04.11 18 +10.35 28 +10.45 00 * +10.48 59 +20.77 60 +23.64 70 +21.06 65 +15.04 68 +13.45 56 +14.38 47 +15.50 40 +17.67 51 +22.55 25 +25.24 09 +28.68 22 +27.72 18 +27.22 09 +26.55 12 +25.47 30 +25.02 23 +22.52 13 +24.89 13 +24.46 26 +24.59 04 +23.77 1801.35
+23.20 +27.94 +12.81 +27.72 +17.90 +28.50
29 63 49 54 59 28
+23.54 +28.62 +16.12 +26.70 +06.48 +28.42
34 62 48 52 58 25
+23.76 +28.75 +16.78 +26.24 +13.01 +28.15
38 56 48 51 65 16
+23.87 +27.99 +16.90 +26.67 +14.96 +27.31
35 77 52 51 75 13
+23.97 +23.31 +17.72 +26.93 +17.25 +26.43
31 78 51 41 70 22
+23.85 +19.45 +20.22 +26.91 +16.96 +26.01
43 74 43 45 66 29
+23.90 +19.25 +17.60 +25.73 +17.82 +25.47
51 67 51 44 64 21
+23.95 +18.95 +19.78 +26.27 +17.42 +24.75
52 65 52 50 63 35
+24.10 +13.97 +21.48 +26.58 +19.26 +25.16
55 72 57 40 51 30
+24.10 +12.92 +23.23 +26.25 +20.20 +25.57
49 72 47 47 49 43
+23.95 +13.11 +26.32 +26.17 +23.48 +25.50
59 74 35 57 54 48
+24.24 +13.07 +27.02 +26.55 +25.23 +25.30 2194.13
+24.79 48 +24.66 62 +25.77 49 +26.19 53 +12.61 53 +12.52 47 +15.57 15 +15.67 29 +22.46 18 * +21.03 56 +10.45 03 +30.33 00 01-07-05
+24.83 62 +26.65 49 +12.65 43 +18.41 00 +20.23 24 +31.96 10
+24.75 60 +26.50 45 +12.54 51 +25.66 14 +20.50 30 +30.78 51
+24.81 60 +25.73 69 +11.71 39 +24.74 61 +20.20 59 +19.79 33
+24.72 62 +22.24 61 +11.96 52 +24.23 43 +18.13 61 +24.10 13
+24.62 61 +19.69 48 +12.11 41 +24.59 01 +19.79 63 +27.75 19
+24.48 67 +18.96 47 +12.16 33 +24.20 20 +22.28 47 +26.72 13
+24.50 65 +18.55 58 +12.09 32 +24.24 40 +22.83 52 +24.58 38
+24.46 56 +14.72 58 +16.05 27 +24.17 48 +19.63 32 +26.18 19
+24.18 58 +12.39 61 +17.90 19 +23.44 47 +21.87 11 +25.82 30
+24.26 51 +12.53 55 +18.12 13 +23.43 26 +24.40 00 +25.66 41
+24.19 +12.66 +18.39 +22.54 +25.80 +25.66 2010.84
13
00 22 +25.35 16 +25.54 31 +25.56 25 04 47 +20.63 37 +20.84 35 +21.15 27 08 62 +13.56 61 +13.63 51 +13.60 56 12 22 +28.59 17 +28.81 34 +30.73 15 16 23 * +14.38 37 +16.67 39 +16.94 38 20 00 +22.83 00 +25.15 05 +24.43 00 AP-M038-75 03774.7 03035.5 07267.9
+25.25 35 +24.36 45 +13.60 31 +30.76 28 +07.42 63 +29.69 00 02-07-05
+25.44 27 +28.17 47 +13.62 41 +30.88 16 +14.18 49 +32.39 16
+25.58 29 +28.38 50 +13.85 46 +30.26 00 +16.78 36 +29.05 06
+25.44 35 +28.29 47 +13.93 48 +29.53 09 +17.89 44 +14.03 00
+25.39 47 +26.74 56 +13.72 42 +30.21 06 +17.89 60 +03.92 00
+25.45 55 +21.27 44 +13.86 16 +30.50 01 +19.38 56 +21.73 04
+25.59 55 +18.48 36 +13.71 18 +22.38 06 +23.89 34 +27.26 05
+25.69 53 +19.28 42 +13.70 15 +22.74 08 +21.55 26 +27.31 00
+21.36 56 +19.34 55 +13.48 00 +23.04 16 +21.29 07 +26.67 00
+20.34 48 +16.68 51 +15.30 09 +23.66 13 +15.15 00 +27.61 00
+20.40 49 +13.75 50 +23.83 02 +23.41 07 +11.78 00 +22.95 14
+20.32 45 +20.37 +13.67 51 +13.61 +26.60 05 +26.94 +23.06 03 * +22.03 +00.02 00 +02.29 +26.95 24 +27.10 2031.80
14
Annexure III
/* Header Information */ Meter Serial No. Load Survey Data From: 26/02/2010 To: 01/04/2010 Date 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 Time Slot 0:15 0:30 0:45 1:00 1:15 1:30 1:45 2:00 2:15 2:30 2:45 3:00 3:15 3:30 3:45 4:00 4:15 4:30 4:45 5:00 5:15 5:30 5:45 6:00 6:15 6:30 6:45 7:00 7:15 7:30 7:45 8:00 8:15 8:30 8:45 9:00 9:15 9:30 9:45 10:00 10:15 10:30 10:45 11:00 Coded Frequency 49 23 Net Wh 15.78 9.64 Time Retard/Advance aa rr PT Status Indicator (for low voltage indication) * *
15
2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 2/26/2010 Total
11:15 11:30 11:45 12:00 12:15 12:30 12:45 13:00 13:15 13:30 13:45 14:00 14:15 14:30 14:45 15:00 15:15 15:30 15:45 16:00 16:15 16:30 16:45 17:00 17:15 17:30 17:45 18:00 18:15 18:30 18:45 19:00 19:15 19:30 19:45 20:00 20:15 20:30 20:45 21:00 21:15 21:30 21:45 22:00 22:15 22:30 22:45 23:00 23:15 23:30 23:45 0:00
16
Date 2/27/2010 2/27/2010 2/27/2010 2/27/2010 2/27/2010 2/27/2010 2/27/2010 2/27/2010 2/27/2010 2/27/2010 2/27/2010 2/27/2010 2/27/2010 2/27/2010 2/27/2010 2/27/2010 2/27/2010 2/27/2010 2/27/2010 2/27/2010 2/27/2010 2/27/2010
Time Slot 0:15 0:30 0:45 1:00 1:15 1:30 1:45 2:00 2:15 2:30 2:45 3:00 3:15 3:30 3:45 4:00 4:15 4:30 4:45 5:00 5:15 5:30
Coded Frequency
Net Wh
Time Retard/Advance
PT Status Indicator (for low voltage indication)
17
SECTION-6 CHAPTER-1 TECHNICAL SPECIFICATION FOR 145 kV AND 36 kV BUS POST INSULATORS 1. SCOPE This specification covers design, Engineering, manufacture, stage testing, inspection and testing before despatch packing, forwarding and delivery at site of 145 kV & 36 kV outdoor type bus Post Insulators and its clamps as per quantities given in the schedule of requirement for use on the 145 kV & 36 kV Grid S/Stns. to support the bus bar at various switchyards under Haryana Vidyut Prasaran Nigam Limited. It is not the intent to specify completely all the details of design and construction of the insulator. However, the insulator shall conform in all respects to the high standard of engineering design and workmanship and shall be capable of performing in continuous commercial operation up to the Bidders guarantee in a manner acceptable to the HVPNL. The equipment offered shall be complete in all components necessary for its effective and trouble free operation. Such components shall be deemed to be within the scope of supply irrespective of whether those are specially brought out in this specification or not. All similar parts particularly movable ones shall be interchangeable. 2. STANDARD The Post Insulators and their Hardwares shall comply as regards general requirements, test voltages and test with the latest edition of IS 2544/1973 IS-5350 (P-II) 1973 IS-5350 (P-III) 1971/IEC-168/1979 except in so far as the same may be modified by this Specification. TYPE AND RATING The 145 kV & 36 kV Bus Post Insulators are required for outdoor-system conforming to IS 2544/1973 or latest version thereof suitable for heavily polluted atmosphere. The Post Insulators shall be specifically suitable to meet the particular requirements of ultimate torsional strength and cantilever loads etc. which they will be called upon to resist during service at the rated voltage. The principal rating of bus Post Insulators shall be as under: Sr. Particulars Unit No. i. Nominal system voltage kV 132 33 ii. Highest system voltage kV 145 36 iii. Rated frequency 50+/-2.5H iv. Minimumcreepage mm 3625 900 distance v. One minute power kV(rms) 275 70 frequencywithstand voltage vi. Impulsewithstand voltage kV(peak) 550 170 (+ve & -ve) vii. Minimumvisual discharge kV(rms) voltage level (extinction) >500 >500 viii. Radio interference Micro Volt voltage (Micro volt at 1 MHz) at a system voltage of 156 kV. ix. Cantilever strength Kg. 400 400 (Upright) x. Torsion strength nm 3000 1200 xi. Bending strength N 4000 1000
-1-
3.
Sr. No. xii. xiii. xiv. xv.
Particulars Tensile strength Compressive strength Applicable standard Pitch Circle Dia: a. Top b. Bottom Height of insulator No. of Insulator per stack
Unit N 50000 N 100000 IS: 5350, IS:2544, IEC 168 mm mm mm No. 127 178 1500 1 25000 50000
xvi. xvii. 4. 5.
76 76 508 1
CLIMATIC CONDITION As per section-1 Vol-II. GENERAL REQUIREMENT 145 kV & 36 kV Bus Post Insulator shall be either solid core or polycon type insulators complete with all fittings and accessories required for holding single bus bar conductor ACSR 0.4 Sq. inch Zebra. The bus Post Insulator pedestal shall be suitable for fixing on the supporting structure to be provided by the HVPNL. The bus Post Insulator shall be provided with a completely galvanised steel base designed for mounting on the support structure to be provided by the HVPNL. The base and mounting arrangement shall be such that the insulator shall be rigid and self supporting and no guying or cross bracings between phases shall be necessary. Cap to be provided on top of the insulator shall be of high grade cast iron or malleable steel casting. It shall be machine faced and hot dip galvanised. The cap shall have four nos. of tapped holes spaced on a pitch circle diameter to accommodate the terminal clamp for supporting the HVPNLs bus bars. The holes shall be suitable for bolts with threads having anticorrosive protection. The effective depth of threads shall not be less than the nominal diameter of the bolt. The Post Insulator clamps are to be fitted on the top of the bus Post Insulator for holding single conductor ACSR Zebra tightly and rigidly. The clamps shall be made of Aluminium alloy and shall comply with relevant ISS. The clamps shall be supplied with galvanised steel studs of the suitable size and maintain the requisite pressure to ensure good and tight joint of low resistance. The insulators shall be entirely free from sharp edges, ridges or points and shall not exhibit appreciable corona formation during service. Castings shall be free from blow holes, flaws, cracks and other defects and shall be smooth, close grained and of true forms and dimensions. The porcelain shall be white, finished brown glazed, non-porous of high di-electric, mechanical and thermal strength, free from defects and thoroughly vitrified. Cement used shall be of high quality, durable and high strength Portland cement. Cement is not to be treated as an adhesive medium between the porcelain and metal parts of an insulator. Preference will be given to a fixing medium of an approved metal alloy. Cement shall be a replenishment material for filling gap between the porcelain and metal parts to fix them.
6.
GALVANISING All the ferrous metal parts shall be hot dip galvanised smoothly, as per IS 3638 (as amended up to date). IS 2633 or any other equivalent authoritative standard. The material shall be galvanised only after shop operations upon it have been completed. The metal
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parts before galvanising should be thoroughly cleaned of any paint, grease, rust, scales or alkalis, or any foreign deposit which are likely to come in the way of galvanising process. The metal parts coating shall withstand minimum four for one minute dips in copper sulphate solution as per IEC-168. The bus Post Insulator unit shall be assembled in a suitable jig to ensure correct positioning of the top and bottom metal fittings relative to one another. The faces of the metal fittings shall be parallel and at right angles to the axis of the insulator and the corresponding holes in the top and the bottom metal fittings shall be in a vertical plane containing the axis of the insulator. All nuts, bolts and spring washers etc. required for the assembly of the complete insulator stack shall be in Bidders scope of supply. The bolts and nuts shall be hot dip galvanised and shall be of high strength generally conforming to IS-136 or any other equivalent international standard. 7. 7.1 TESTS Type Tests The equipment should be offered type test. Test reports should not more then seven years old reckoned from date of bid opening in respect of all the tests carried out in accredited laboratories (based on ISO/IEC) by a reputed accreditatic body or witnessed by HVPN or another electric power utility and be submitted by the successful bidder to HVPNL for approval as schedule given in Bar Chart. i) Visual examination ii) Verification of dimensions iii) Visible discharge test iv) Impulse voltage withstand test v) Dry power frequency voltage withstand test vi) Wet power frequency voltage withstand test vii) Temperature cycle test viii)Test for mechanical strength ix) Puncture test x) Porosity test xi) Galvanising test 7.2 7.3 Routine Tests As per quality assurance program (QAP). Acceptance Tests The following acceptance tests as stipulated in the relevant IS:2544 (1973) shall be carried out by the Supplier in presence of HVPNL representative, unless dispensed with in writing by the HVPNL. i) Verification of dimensions ii) Temperature cycle test iii) Test for mechanical strength iv) Puncture test v) Porosity test vi) Galvanising test
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8.
INSPECTION The inspection may be carried by the HVPNL at any stage of manufacture. The successful Bidder shall grant free access to the HVPNLs representative at a reasonable time when the work is in progress. Inspection and acceptance of any equipment under this Specification by the HVPNL shall not relieve the Contractor of his obligation of furnishing equipment in accordance with the Specification and shall not prevent subsequent rejection if the equipment is found to be defective. The Contractor shall keep the HVPNL informed in advance about the manufacturing programme so that arrangement can be made for inspection. The HVPNL reserves the right to insist for witnessing the acceptance/routine testing of the bought out items.
9.
GUARANTEED DATA Guaranteed technical particulars and other technical data in respect of equipment/material offered should be furnished duly signed along with the tender in the performa given in VolIII. Any other particulars considered necessary may also be given in addition to those listed in the schedule. DOCUMENTATION
10.
The successful bidder shall submit four sets of drawings for HVPNL approval. NOTE: All above drawings should be a minimum space (14x10cm) for stamping the approval of drawings by HVPNL. 11. MARKING Each porcelain insulator unit shall legibly and indelibly be marked to show the following: a) Name or Trade Mark of the manufacture. b) Month and year of manufacture. c) Country of manufacture. Marking on the porcelain shall be printed and shall be applied before firing.
12. PACKING AND FORWARDING 12.1 The equipments shall be packed in crates suitable to withstand handling during transport and outdoor storage during transit. The Contractor shall be responsible for any damage to the equipment during transit, due to improper and inadequate packing. The easily damageable material shall be carefully packed and marked with the appropriate caution symbols. Wherever necessary, proper arrangement for lifting, such as lifting hooks etc. shall be provided. Any material found short inside the packing cases shall be supplied by Contractor without any extra cost. Each consignment shall be accompanied by a detailed packing list containing the following information: a) Name of the consignee. b) Details of the consignment. c) Destination. d) Total weight of consignment. e) Sign showing upper/lower side of the crate. f) Handling and unpacking instructions. g) Bill of material indicating contents of each package.
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12.2
SECTION-6 CHAPTER-2 TECHNICAL SPECIFICATION FOR 220V (200AH) BATTERY BANKS

1.0 SCOPE: The scope of this specification covers design, manufacture, assembly, supply, testing at works, packing, forwarding, dispatch of VRLA batteries along with necessary accessories, fittings etc. to the destination. These equipments are to be complete in every respect, details to the functions designated to the entire satisfaction of the purchaser. It is required that the supplier accepting the contract agrees to furnish all apparatus, appliances and material whether specifically mentioned or not but which may be found necessary to complete, to perform and testing any of the herein specified equipment (s) for compliance with the requirements implied without extra charges. The erection/maintenance tools and specific tools if any will also form part of supply. 2.0 General Technical Requirement All the materials/components used in Battery Chargers and Valve Regulated Lead Acid Battery (VRLA) shall be free from flaws and defects and shall conform to relevant standards and good engineering practices:2.0.1 For 132 KV sub-stations, DC System shall consist of float-cum-boost charger and one (1) battery set for each of 220V system. 2.0.2 Bidder shall select number of cells, float and Boost voltage to achieve following requirement : System Voltage Maximum Voltage during Float Operation Minimum voltage available when no charger working and battery fully discharged up to 1.85 V per cell. 198 Volt Minimum Nos of Cell 107
2.1
220 Volt 242 Volt CLIMATIC CONDITIONS:
The equipment to be supplied against the specification shall be suitable for satisfactory continuous operation under the following tropical conditions: Max. ambient air temperature Max. daily average ambient temperature Max. yearly weighted ambient temperature Min. air temperature Max. humidity Min. relative humidity Average number of thunder storm days per annum Average annual rain fall Number of months during which tropical monsoon conditions prevail altitude above MSL Average number of rainly days per annum. Seismic level (Horizontal acceleration) Degree of pollution Intensity of solar radiation Max. Wind load 500 C 450 C 350 C (-) 50 C 100% 26 % 40 15 cm to 100 cm. 4 months (June to Sept). Varies from 61 meters to 815.00 mtrs. 120 days 0.3g. Heavy 1.0 KW/sq.m. 195 kg/sq.m.
-1-
3.0 3.1
Battery Type The DC Batteries shall be Normal Discharge type Valve Regulated Lead Acid (VRLA) and shall conform to IS 15549: 2004/IEC 60896-21 & 22, 2004 standard. These shall be factory filled, charged & suitable for a long life under continuous float operations and occasional discharges. The 220 V DC systems should be unearthed. Battery sets shall be capable of operating at a peak ambient temperature of 50 Deg.C. The offered battery shall be compact and shall require no maintenance. All safety equipment required for installation shall be provided by the manufacturer. Constructional Requirement Plates: Positive plates shall be made of flat pasted type using high corrosion resistant alloy for durability, maintenance free, long life both in cyclic as well as in float applications. The Grids are of Semi Radial Squarish grid to reduce internal Resistance and travel current in shorter time. Negative plates shall be heavy duty, durable flat plate using lead alloy pasted Semi Radial Squarish Grid. Negative plates shall be designed to match the life of positive plates and combination of positive and negative plates shall ensure long life, durability and trouble free operation of battery. Computer controlled/PLC operated in house equipment should be deployed for preparation of lead oxide and paste to ensure consistency in paste quality & properties. Conventional / manual type of paste preparation will not be allowed.
3.2
3.3
Containers & Lids The container & lids shall be made of polypropylene Copolymer material and shall have chemical and electro-chemical compatibility along with acid resistant and shall conform to UL-94/ ASTM-D-2863 standard. The material shall meet all the requirements of VRLA batteries and be consistent with the life of battery. 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. The container shall be capable of withstanding the rigours of transport, storage and handling. The containers shall be enclosed in a steel tray. For identification each cell / module shall be marked in a permanent manner to Indicate the Following information. I. II. III. Cell Serial number. Positive and Negative is embossed on the cover Month and Year of manufacturing.
3.4
Cell Covers The cell covers shall be made of suitable material compatible with the container material and permanently fixed with container by Hermetic Heat Sealing technique. It shall be capable to withstand internal pressure without bulging or cracking. Fixing of pressure regulation Valve & terminals posts in the cover shall be such that the seepage of electrolyte, gas escapes and entry of electrostatic spark are prevented.
3.5. Separators The separators used in manufacturing of battery cells shall be spun glass micro porous Matrix having high acid absorption capability & resistant to battery grade Sulphuric acid along with good insulating properties. Sufficient separator overlap and PVC shield protection to bottom edges of the plates is to be provided to prevent short circuit formation between the edges of adjacent plates. 3.6. Pressure Regulation Valve Each cell shall be provided with a pressure regulation valve. The valve shall be self re-sealable. The vent plug shall be made with suitable grade of fire retardant
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plastic material. Each valve opening shall be covered with flame barrier capable in preventing the ingress of flame into the cell interior when the valve opens and hydrogen / oxygen gas mixture is released. The valve unit shall be such that it cannot be opened without a proper tool. 3.7. Terminal Posts Both the Positive and Negative terminals of the cells shall be capable of proper termination and shall ensure its consistency with the life of battery. The terminals shall have adequate solid copper core cross-section to avoid overheating at maximum current load. 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 Positive and negative terminal posts of VRLA Battery shall be colored Red and Black to make it unambiguously identifiable. 3.8. Connectors, Nuts & Bolts, Heat Shrinkable Sleeves The connectors shall be non corroding lead coated copper of suitable size to enable connections of cells. Copper connections shall be suitably lead coated to withstand corrosion due to Sulphuric acid/fumes. Nuts and bolts for connecting the cells shall be made of stainless steel with good acid resistant characteristics. All inter cell connectors shall be protected with heat shrinkable silicon sleeves for reducing the environmental impact including a corrosive environment. 3.9. 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. 3.10. Battery Bank Stand All batteries shall be mounted in a suitable metallic stand/frame. The frame shall be powdered coated with acid resistant paint (2 coats) and should have protection against fungus growth and other harmful effect due to tropical environment. The suitable insulation shall be provided between stand/frame and floor to avoid the grounding of the frame/stand. The joining of the frames should not leave crevices and ensure proper and tight fit. 3.11. Capacity Requirements When the battery is discharged at 10 hour rate, it shall deliver 80% of C (rated capacity, corrected at 27 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 27Celcius) 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 35 Celsius 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
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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%. 3.12. 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 27 C. 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. 3.13. Accessories along with Battery System Each battery shall be supplied with following accessories and devices: a) Torque Wrench. b) Cell Test Voltmeter (-3-0-+ 3) Volts with least count of 0.01 Volt 3.14. Type Test of Battery The Bidder/Supplier shall supply type tested battery per IS 15549: 2004/IEC 60896-21 & 22 over the range of at least one capacity per design and should have met requirement of Service Life test as per above stated IEC standards within last seven years. The Bidder/Supplier shall submit necessary evidences enclosed along with tender documents. Sr.No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 Description Gas Emission High Current Tolerance Short Circuit Current and DC internal resistance Protection against internal ignition from external spark source Protection against ground short propensity Content & durability of required marking Material Identification Valve Operation Flammability Rating of material Intercell connector performance Discharge Capacity Charge Retention during storage Float Service with daily discharge for reliable mains power Recharge behavior Service life at an operating temperature of 400 C for brief duration exposure time Impact of stress temperature of 60oC for brief duration exposure time with 3 hours discharge test Abusive Over discharge Thermal runway sensitivity Low temperature sensitivity Dimensional sensitivity at elevated internal pressure & temperature Stability against mechanical abuse of units during installation
Test shall be conducted in accordance with IEC 60896-21 & 22,2004 3.14.1 Routine Test of Battery 1. Physical examination test 2. Visual Inspection 3. Dimensions, Mass & Layout 4. Marking & Packing 3.14.2Acceptance Test of Battery 1. Polarity Marking 2. Verification of Dimensions
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3.
Test of AH Capacity.
3.15. List of Factory & Site Tests for Battery Sr.No 1 2 Test Physical Verification C/10 Capacity test on the cell Factory Tests Site Tests Yes Yes
3.16. Installation and Commissioning Manufacturer of battery shall supervise the installation as recommended in O&M manual/or relevant standards. All necessary instruments, materials, tools and tackles required for installation, testing at site and commissioning are to arranged by battery manufacturer/Bidders. 4.0 4.1 MARKING AND PACKING: MARKING: The following information shall be indeligibly and durably marked on the outside of the cell. a) b) c) d) e) f) Nominal Voltage Manufacturers name, type and trade name. AH capacity at 10 hour rate. Voltage for float operation at 20 deg. C with tolerance of (+/-) 1%. Month & year of manufacturer Country of origin. S.No. of cell/cell No.
4.1.1 The cells and batteries may also be marked with the ISI certification mark, if any. 4.2 PACKING: The cells shall be suitably packed so as to avoid any loss or damage during transit. INSTRUCTION MANUAL: The manufacturer shall supply one copy of instructions manual for initial charging (if required)/treatment, and routine maintenance during service, with each and every battery set. The manufacturer shall supply 5 copies of instructions manual to the purchaser. The a) b) c) d) e) f) g) following information shall be provided on, the instruction cards. Designation of cell or battery Ampere hour capacity. Nominal voltage Manufacturers instructions for charging Voltage for float operation at 20 deg.C with tolerance (+/-) 1%. Maintenance instructions Environmental & safety provisions required.
5.0
6.0 TESTS: All the acceptance tests as per relevant standards mentioned shall be carried out for batteries in presence of our inspecting officer free of cost. Type test certificates (not older than 7 years from the date of opening of tender) are to be submitted for approval of purchaser.
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7.0
DRAWINGS: The tenderer will submit the detailed dimensional drawings for battery sets including stands. TYPE TEST CERTIFICATES: The tenderer will submit the complete type test certificates as per relevant standards mentioned (not older than 7 years from the date of opening of tender) for battery sets with their tenders, without which the offers are likely to be ignored. GUARANTEED TECHNICAL PARTICUALRS: Guaranteed Technical Particualrs for battery sets as per Annexure-A attached shall be furnished along with the tender.
8.0
9.0
10.0 ACCESSORIES: Each battery set shall be supplied complete with all necessary accessories viz. stand, inter connections, cell no. Plates with sticker, multi meter complete with leads, spanners. 11.0 BILL OF MATERIAL: The firm shall also have to furnish the bill of material used in battery set.
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SECTION-6 CHAPTER-3 Battery Charger 1. Battery Charger The DC system for 220V DC is unearthed. The Battery Chargers as well as their automatic regulators shall be of static type and shall be compatible with 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 LeadAcid 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 manufacturers 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. The 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 chargers output voltage shall remain within + 1% of the set value, for AC input voltage variation of + 1% frequency variation of + 5% a combined voltage and frequency variation of + 1% and a DC load variation from zero to full load. 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. All chargers shall have load limiters having drooping characteristics, which shall cause, when the voltage control is in automatic mode, a gradual lowering of the output voltage whet eh 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 charge the Charger nor shall it cause blowing of any of the Charger fuses. The Charger shall not trip on overload or external short circuit. 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. During Boot 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. The Charger output voltage shall automatically go on rising, when it is operating on Boost mode, as the Battery Chargers 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 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 -1-
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
1.11
1.12
1.13
1.14
1.15
Boost charging mode and the Load-limiter of Float charging mode is used as current setting device in boost charging mode. 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. 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 MCCBs should have auxiliary contacts for annunciation. Rectifier Transformer The rectifier transformer shall be continuously rated, dry air cooled (A.N) an of class F insulation type. The rating of the rectifier transformer shall have 10% overload capacity. 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 test acting HRC fuses shall be provided in each arm of the rectifier connections. Instruments One AC voltmeter and one AC ammeter along with 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 15 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. 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, MCCBs of suitable ratings shall also acceptable in place of Air Break Switch. 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 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. 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. 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. -2-
1.16
1.17
1.17.1 1.17.2
1.17.3
1.18
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 Owners 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. 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. Charger Construction The Chargers shall be indoor, floor-mounted, self-supporting sheet metal enclosed cubicle type. The Bidder 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 lugs for power cables shall be supplied by the Bidder. The lugs for power cables shall be made of electrolytic copper with tin coat. Power cable sizes shall be advised to the Bidder 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 Chargers 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 -1. All indicating instruments, control switches and indicating lamps shall be mounted on the front side of the Charger. 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 wired. 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 bare a ferrule or tag on each end for identification. At least 20% spare terminals shall be provided for control circuits. 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. 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 glossy -3-
white. Each coat of finishing synthetic enamel paint shall be properly staved. The paint thickness shall not be less than fifty (50) microns. 1.19 TESTS 1.19.1 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 in IS:4540 and short circuit test as per IS:2026. Following type tests shall be carried out for compliance of specification requirements:i) Voltage regulation test. ii) Load limiter characteristics test iii) Efficiency tests iv) High voltage tests v) Temperature rise test vi) Short circuit test at no load and full load at rated voltage for sustained short-circuit. vii) Degree of protection test viii) Measurement of ripple by oscilloscope. ix) Temperature compensation feature demonstration 1.19.2 The Bidder 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:i) Insulation resistance test ii) Checking of proper annunciation system operation 1.19.3 If a Charger fails to meet the specified requirements, the Bidder shall replace the same with appropriate Charger without affecting the commissioning schedule of the Sub-Station, and without any extra cost to the OWNER. 1.19.4 The Bidder shall present for inspection, the type and routine test certificates for the following components whenever required by the OWNER. (i) Switches (ii) Relays/MCCBs (iii) Instruments (iv) DC fuses (v) SCR (vi) Diodes (vii) Condensers (viii) Potentiometers (ix) Semiconductor (x) Annunciator (xi) Control wiring (xii) Push buttons and contactors Makes of above equipment shall be subject to Owners approval.
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SECTION-6 CHAPTER 4 TECHNICAL SPECIFICATION OF D.C. DISTRIBUTION BOARD. 1. SCOPE: This specification provides for design, Engineering, manufacture, stage testing, inspection and testing before dispatch, packing, forwarding and delivery at site of D.C. Distribution Board, complete with all fittings accessories and associated auxiliary equipment mandatory which are required for efficient and trouble free operation as per specified here under. It is not the intent to specify completely all the details of design and construction of equipment. However, the equipment shall conform in all respects to the high standard of engineering, design and workmanship and shall be capable of performing in continuous commercial operation up to the Bidders guarantee acceptable to the purchaser. The equipment offered shall be complete in all component necessary for its effective and trouble free operation along with associated equipment interlocks protection scheme etc. Such components shall be deemed to be within the scope of supply irrespective of whether those are specially brought out in this Specification and or the commercial order or not. All similar parts particularly movable ones shall be interchangeable. CLIMATIC CONDITIONS : As per Section-I Vol-II. STANDARD: All material and equipment shall comply in every respect with the requirements of the latest edition of the relevant Indian Standard IS:1651. MANUFACTURE AND WORKMANSHIP: All the material used in the construction of the equipment shall be of the best quality obtainable of their respective kinds and whole of the work shall be of the highest class, well finished and of approved design and make. Casting shall be free from blow holes, flaws and of the true form and dimensions. All machined surfaces shall be true and smooth and well finished. DUTY AND GENERAL ARRANGEMENTS: The power for the charging apparatus shall be given through an independent 4-core cable connection from an A.C. 50 cycles 3 phase 415 10% volts switchboard fed from a Station Transformer. D.C. Distribution shall be through fuse protected rotary switches mounted on a separate distribution board. TYPE OF EQUIPMENT: All equipment shall be located indoors. D.C. Distribution panel are to be mounted on the floor in the control room adjacent to the Battery room. Necessary doors and screens shall be provided wherever required. All equipment shall be vermin proof. The overall design of the entire equipment should be adequate for the duty in view to ensure trouble free and dependable service. The various cables for D.C. Distribution circuits, which are to be arranged by the Bidder shall have P.V.C. insulation. The conductors may be of copper or aluminum. All panel wiring to be provided by the supplier, shall consist of suitable colored/marked P.V.C. insulated cables. BUS BARS AND SUPPORTS: The bus bars shall be of aluminium having adequate cross-sections. The bus bars shall be so designed and mounted that their expansion and contraction does not subject, either the Bus Bars or their supports, to any stresses. All bus bars and connections shall be duly marked and colored for identification. INSTRUMENTS: All instruments shall have 96 sq mm dials and flush mounted on the panels. Moving coil spring controlled instruments shall be used except those for A.C. which may be of the moving
1.02 1.03
1.04
1.05
1.06
1.07
1.08
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1.09
1.10
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iron type. The error of indication shall not exceed 1% throughout the effective range of the meter. RESPONSIBILITY FOR DESIGNS: The Bidder shall assume full responsibility for co-ordinate and adequate design and shall conform to the best engineering practice for the operating conditions specified. In case the equipment covered by this specification is to be co-ordinate with other equipment, the Bidder shall furnish complete information and data as may be desired by the purchaser. GROUNDING: All metal parts should be grounded according to Indian Electricity Rules. Main ground Bus shall be provided by the purchaser. Special grounding lugs of adequate size shall be provided by the supplier on the charging equipment. INTER CHANGEABILITY: Corresponding parts of plant and equipment shall be made to gauge or jig and shall be interchangeable in every respect. DOCUMENTATION The successful bidder shall submit four sets of drawings for HVPNL approval.
1.12
The following drawing shall be supplied with the tender: i) Outline drawings of all apparatus showing sufficient details to enable the purchaser to determine whether the design proposed can be installed satisfactorily or not. NOTE: All above drawings should be a minimum space (14x10cm) for stamping the approval of drawings by HVPNL. 1.13 FOUNDATIONS AND FIXINGS: All plants and equipment shall be provided with a complete set of foundation holding down bolts, washers, nuts plants and other fixture as may be required and these shall be supplied by the Bidder. These fittings will be fixed by the purchaser in the foundations unless otherwise specified. All foundation bolts, fixtures etc. shall be supplied as soon as possible after the contract drawings have been approved. INSTRUCTION AND MARKING PLATES: All gauges, meters, instruments etc. shall have dials or scales calibrated in metric system of units. All name plates, instruction plate, warning signs and any marking what-so-ever on the equipment and its parts and accessories shall be in Hindi-English Language, using idioms, words and meaning as in current use in India. In order to facilitate sorting and erection at site every part of the plant and equipment shall be suitably marked. 1.15 TROPICAL TREATMENT & PAINT: All corrodible parts and surfaces shall be of such material and shall be provided with such paint or other protective finish that no part of the installed equipment shall be injuriously affected by the atmospheric moisture, heat and fumes. The panels shall be finally painted with light grey paint having shade No.631 of IS:5 with stove enameled finish. 1.16 PLACE OF MANUFACTURE AND INSPECTION: The Bidder shall state in his tender the place(s) of manufacture, testing and inspection of the various portions of the work included in the tender. The purchaser or his duly authorised agent shall have access to the Bidder's or sub Bidder's work at any time during working hours for the purpose of inspecting the manufacture and testing of materials, equipment and completed plant and the Bidder shall provide the necessary facilities for inspection. 1.17 TESTS: 1.17.1 Type Tests The equipment should be offered type test. Test reports should not more then seven years old reckoned from date of bid opening in respect of all the tests carried out in accredited laboratories (based on ISO/IEC) by a reputed accreditatic body or witnessed by HVPN or another electric power utility and be submitted by the successful bidder to HVPNL for approval as schedule given in Bar Chart. 1.14
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1.17.2 1.17.3
i) Verification of constructional requirements ii) Verification of marking iii) Verification of dimensions Routine Tests As per quality assurance program (QAP). Acceptance Tests The following acceptance tests for DCDB shall be carried out by the Supplier in presence of HVPNL representative, unless dispensed with in writing by the HVPNL. i) Dimension test ii) Visual check test iii) quantative check iv) Functional checks v) wiring HV Test vi) Insulation resistance test
1.17.4
SAMPLING SCHEME AND CRITERIA FOR ACCEPTANCE: The sampling scheme and criteria for acceptance for cells up to and including 600 AH capacity shall be in accordance with clause 5 1.4 of IS-8320-1976. The sampling scheme for cells of higher capacities shall be subject to agreement between the user and the manufacturer. 1.18 SPARE PARTS :The Bidder shall quote separately in his tender for spare parts as he world recommend for the main maintenance operation of the equipment for the period of 5 years. Of detailed list of such spares parts which item wise prices shall be given under schedule of requirement and prices. The purchaser may order spares subsequently as may be finally decided upon, at the rates given in the tender. All spares parts shall be interchangeable and shall be of same make material and both workmanship as the corresponding parts furnished with the main equipment. 1.19 DETAILS OF TECHNICAL PARTICULARS AND SPECIFICATION: Details of the technical particulars and specification required have been given in Appendix (b). Any other particulars considered necessary by the supplier may also be given in addition to the above listed in Data requirement sheet. 1.20 COMPLETENESS OF EQUIPMENT: Any fittings, accessories or apparatus which may not have been specifically mentioned in the specification, but which are usually necessary in the equipment shall be deemed to be included in the contract and shall be supplied by the Bidder without extra cost.
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APPENDIX 'A' SCHEDULE OF REQUIREMENT
D.C. DISTRIBUTION BOARD: The D.C. Distribution Board shall be housed in a sheet steel cubicle with adequate ventilation and it should be vermin proof as far as possible and should be provided with louvers for ventilation backed by fine wire mesh, which applies to both charging equipment and D.C. Distribution Board. The DCDB shall match with the battery charging equipment and should be complete with bus bars of suitable capacity, wiring, rating plates, glands and fixing bolts. The minimum size of cubical should be 600X700X1600 mm. The following components shall be provided on the D.C. distribution board: FOR 200 AH BATTERIES 1. Double pole ON/OFF rotary switch of 200 Amps. for 200 AH rating and with 2 Nos. HRC fuses of 100 Amps 2. Moving coil ammeter of 96mm sq. and range 0-200 amps. for 200 AH battery for measuring the load on the bus. 3. Change over contactor : a) 20 Amps. for 200 AH battery and change over Bidder AC/DC for switching indication over to DC. On failure of AC supply and also for emergency pilot light in the event of AC failure. b) 10 Amps HRC fuses for pilot light 4. a) Double pole D.C. Rotary switches with HRC fuses for each of following feeders: 132 kV closing supply 50 Amp. Capacity 1 No
1 set
1 No
1 No
2 Nos.
b) 33 kV -do1 No c) 11kV closing supply 100Amp. Capacity 1 No. d&e) spare 100 Amp. capacity 2 Nos. f&g) spare 50 Amp. capacity 2 Nos. 5. Double pole D.C. rotary switch of 10 Amps. rating with 10 Amp. HRC fuses for each of the following feeders: a) 11kV Tripping supply 10Amp Capacity 1 No b) 33 kV -do- 10 Amp Capacity 1 No c) 132 kV -do1 No d) Carrier telephone 10 Amp. capacity 1 No e) 132 kV Relay & Board panel 10 Amp capacity 1 No f) 33 kV Relay & Board panel 10 Amp capacity 1 No. g) Spare 10 Amp capacity 3 Nos. All the instruments shall be of flush mounted type. The rotary switches shall also be flush mounted except for the protection portion in the panels. All switches shall be mounted on the front panel and all the HRC fuses together with their fuse fittings on the front panel but within a chamber that can be opened by half doors, to occasion accessibility to the fuses. The various components shall be of the best quality and from reputed manufacturers. The layout of components, wiring workmanship reliability etc. shall be of the best quality. Adequate room should be provided within the charger/DC distribution board cubicles for easy accessibility of components and also to facilitate ventilation.
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SECTION-6 CHAPTER 5 TECHNICAL SPECIFICATION OF 415 VOLTS L.T. SWITCH BOARDS. 1. SCOPE : This specification covers design, Engineering, manufacture, stage testing, inspection and testing before despatch, packing, forwarding and delivery at site of 415 Volts AC LT Switch Board complete with all fittings, accessories and associated auxiliary equipment mandatory spares as per Volume II which are required for efficient and trouble free operation as specified hereunder. It is not the intent to specify herein all the details of design and construction of equipments. However, the equipment shall conform in all respects to the high standards of engineering, design and workmanship and shall be capable of performing in continuous commercial operation up to the Bidders guarantee in a manner acceptable to the Purchaser. The equipment offered shall be complete with all components necessary for its effective and trouble free operation along with associated equipment, interlocks protection schemes etc. irrespective of whether those are specially brought out in this specification and commercially added or not. All similar parts particularly movable ones shall be interchangeable. 1.02 CLIMATIC CONDITIONS : The equipment is required to operate satisfactorily under the following site conditions:i. Max. Temperature 500C ii. Min. Temperature -2.50C iii. Relative humidity a) Max. 100% b) Min. 26% iii. Average number of rainy days per annum Nearly 120 days iv. Average rain fall per year. 900 mm v. Average number of dust storm days per annum 35 vi. Isoceraunic level 45 vii. Max. Wind pressures 195 kg/sqmt. viii. Altitude above mean sea level Less than 1000 mt. 1.03 STANDARDS: The metal clad (preferably sheet metal) air break switch to be supplied against this Specification shall meet with the requirements laid down in IS-4064-1978 (part I & II) (latest edition). The HRC fuses shall comply with the Is-2208-1962 (latest amended). All other equipments shall also comply with the requirements of the latest edition of the respective Indian Standards. 1.04 MATERIAL AND WORKMANSHIP: All the materials used in the construction of the equipment shall be of the best quality obtainable of their respective kinds and whole of the work shall be of the highest class, well finished and of approved design and make of the true form and dimensions. All machined surfaces shall be true and smooth and well finished. 1.05 INTER CHANGEABILITY: Corresponding parts of plant and equipment shall be made to gauge or jig and shall be interchangeable in every respect. 1.06 DOCUMENTATION The successful bidder shall submit four sets of drawings for HVPNL approval. NOTE: All above drawings should be a minimum space (14x10cm) for stamping the approval of drawings by HVPNL. 1.07 FOUNDATIONS AND FIXINGS: All plants and equipment shall be provided with a complete set of foundation holding down bolts, washers, nuts plants and other fixtures as may be required and these shall be supplied
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1.08
1.09
by the Bidder. These fittings will be fixed by the purchaser on the foundations unless otherwise specified. INSTRUCTION AND MARKING PLATES: All gauge meters, instruments etc. shall have dials or scales calibrated in metric system of units. All name plates, instruction plate, warning signs and any marking what-so-ever on the equipment and its parts and accessories shall be in Hindi-English Language, using idioms, words and meaning as in current use in India. In order to facilitate sorting and erection at site every part of the plant and equipment shall be suitably marked. PAINTING The whole of the plant except bright parts, valves and such portions as are finished shall be painted with two painting coats of approved rust resisting paint in plain colours for packing and the parts not so painted shall be protected from deterioration during transit. All the ferrous parts shall be painted with battle ship grey paint by means of spray painting. The painting should be as per relevant ISS. All the non ferrous parts including the bus bars, thimbles, jumpers shall be tinned plated and sleeves of proper thickness and size shall be provided on all the jumpers. After erection at site every painted part shall be well cleaned filed and chopped and shall then receive two coats of best oil paint of approved colour, to be supplied by the Bidder without any extra cost.
1.10 TESTS: 1.10.1 TYPE TEST The equipment should be offered type test. Test reports should not more then seven years old reckoned from date of bid opening in respect of all the tests carried out in accredited laboratories (based on ISO/IEC) by a reputed accreditatic body or witnessed by HVPN or another electric power utility and be submitted by the successful bidder to HVPNL for approval as schedule given in Bar Chart. 1.10.2 Routine Test As per quality assurance program (QAP). 1.10.3 Acceptance Test The following acceptance tests shall be carried out by the Supplier in presence of HVPNL representative, unless dispensed with in writing by the HVPNL. i) Dimensional test ii) Continuity test iii) Insulation resistance test iv) High voltage test v) Inter locking test 1.11 INSTRUCTION BOOKS: Applicable parts, lists, catalogues and operating instructions in English Language specially prepared to cover all the equipment furnished under this specification which may be needed or prove useful in operation, maintenance, repair, dismantling or assembling and for the repair and identification of parts for ordering replacements shall be assembled under a common cover and submitted in duplicate for each unit to the purchaser free of cost. 1.12 REPRODUCIBLE DRAWINGS: The Bidder shall supply two sets of full size reproducible drawings (approved by the purchaser) along with detailed drawings of various major components/accessories etc. (showing sectional views, wherever necessary) on oil cloth to prove useful in the erection, operation maintenance and repair of the equipment. He shall also supply twenty sets of azo prints of the above mentioned drawings for use in field and design offices. 1.13 PARTICULARS OF THE SYSTEM: The equipment shall be suitable for 415 Volts 50 cycles, 3 Phase 4 wire system with neutral solidly earthed.
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1.14
RISE IN TEMPERATURE: The equipment shall be operated at maximum ambient temperature of 500C and as such the temperature rise of its parts should be proportionately below the figure provided in respective standards. EACH SWITCH SHALL COMPRISE OF: Metal clad floor mounting combination fuse switch board consisting of a suitable bus bar of 320 Amps rating for 15 Ckts. Triple pole and neutral bus bar chamber, mounted on a high floor stand arranged and equipped for the circuits given in the schedule of requirement and mounted above and below the bus bar chamber to form a suitable arrangement. The bus bar chamber shall have provision for adding two more switch units as given in the schedule at a later date. The switches shall be quick make and break type. The switch boards shall be installed indoors. The enclosing chambers shall be dust-tight and vermin proof. All equipments shall be suitable for reception of Alumiium cable rising from the ground. The details of equipment required for each switch board has been given in the schedule of requirement. BUS BARS: The bus shall be made of high conductivity copper or Aluminium and shall have adequate cross section so as to be capable of carrying 300 Amps in phase and 150 Amps. in neutral. The bus bar shall be so designed and mounted in the separate chamber such that their expansion or contraction does not subject either the bus bars or their insulation supports to any stresses. The bus bar shall be properly spaced so as to provide easy access during maintenance and inspection etc. There should be no joints in the bus bars. The current density for copper and aluminium bus bars must not exceed 1 A/cm2 and 87 A/cm2 respectively. CONNECTIONS: All the connections for the tees from the bus bars shall be bolted type and suitable spring washers shall be provided to ensure proper jointing and material of the bolts shall be of suitable metal. All the connections shall be provided with thimbles of suitable rating. METERING EQUIPMENT Metering equipment for the station transformer/Incomer shall be located between the L.T. side of the transformer and L.T. Bus Bars. The metering equipment shall include 300/5 Amps C.T.s having burden 15 VA with accuracy class 1 and 3 phase 4wire unbalanced load integrating electronic KWH meter. A 100 mm dial flush mounted MISC (moving iron spring controlled) Voltmeter and a 100 mm dial flush mounted MISC ammeter both with phase selector switch shall also be provided on each switchboard to indicate the bus bar voltage and total load on the station transformer/Incomer feeder. All the meters shall be enclosed in separate chamber to have a flush pattern type appearance. The meters shall be dust tight. EARTHING Two separate earths shall be run and each and every metallic parts of the stand/switches/bus bar chambers shall be earthed at two different places independently. The size of the earthing conductor for the switches and individual parts shall not be less than No. 8 SWG copper conductor and size of the main for earthing shall not be less than No. 3 SWG copper conductor. BUS BAR CHAMBER The bus bar chamber shall be made out of angle iron of suitable size as specified below along with other details: a) Thickness of sheet steel enclosures, doors, covers i) Cold rolled 2mm minimum ii) Hot rolled +2.5mm minimum
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b) c)
Degree of protection Colour finish shade i) Interior ii) Exterior
IP-54 as per BS2817/IEC-144 Glossy white Light grey Semi glossy shade
1.21
Earthing bus material size Copper 25x6 mm Purchasers earthing conductor Galvanised steel Material Size 30x6 mm f) Clearance in air of live parts i) Phase to Phase 80 mm ii) Phase to earth 80 mm LABELS: Each switch shall be provided with suitable labels paginated on hard plastic sheet and duly held in boss framed of the size 75x50 mm for the incoming and outgoing feeders. The hard plastic sheet shall be of white colour and will be painted in black for the outgoing feeders whereas it shall be painted bright red for the incoming feeders. INTERLOCKING Interlocks must be provided to ensure that the switch cover cannot be opened when the switch is in the closed position. It should however be possible for competent examiner to over ride this interlock and operate the switch with enclosure open. FIRE HAZARDS The switch and its associated apparatus shall be arranged to minimize fire hazards. CLEARANCES The clearances between phases and between phases and earth shall be as per IS-3072-1975 with latest amendments. CONTACTS All live contacts of the switch shall be adequately shrouded to prevent accidental contact when the equipment is either in the isolated or normal closed position and shall be silver plated of suitable thickness. The fixed contacts of the fuse switch unit shall be fully shrouded with arc resistant material. Material needs to be specified in the tender. CABLE AND BOXES: a) The incoming switch and outgoing switches shall be provided with cable and boxes of suitable size capacity and rating suitable for PVC cables. Suitable cleating arrangement shall also be provided for the cables entering the switch fuse units in the top tier. The cabling arrangement shall be such that cables outgoing from Isolator unit can be connected or disconnected easily and safely. RUPTURING CAPACITY The rupturing capacity of the bus bar switchgear/cartridges shall not be lower than 2 MVA at 415 volts. The individual fuse switch unit shall be provided in such a way that they can be removed from the front of the switch board for servicing and maintenance. MARKING All the switches shall be clearly marked with the following particulars: a) Reference to the standard. b) Rated voltage. c) Rated normal current. d) Rated marking capacity. e) Breaking capacity. f) Type of fuse/links to be used.
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d) e)
1.22
1.23 1.24
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1.26
1.27
1.28 1.29
g) 1. 2. 3. 4. 5. 6. 1.30
Name plate. Supplier name. Purchaser P.O. No. Rating. Serial no. Year of manufacturing.
OTHER PARTICULARS The Bidder should clearly furnish the following information in their offer: a) Material and plating of the contacts. b) Current density assumed. c) Temperature rise under continuous full load over the ambient temp. of 500C. d) Temperature rise under short circuit condition. e) Guaranteed Technical particulars as required in appendix-A. List of references if similar L.T. Switch Board already in service/supplied with complete details shall be furnished.
1.31
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ANNEXURE A SCHEDULE OF REQUIREMENTS A. 132kV Sub-Stations 415 V 3 Phase 4 wire L.T. Switch Board comprising of 15 circuits TP & N switch fuse units consisting of two incomer of 320 A, 1 voltmeter (0-500V) with suitable CTs and selector switch and 13 Nos. circuits of outgoing switchgear units and HRC fuses having the following ratings for 132 KV S/Stns. Sr. L.T.Feeders Switch rating Fuse rating (Amps) No. No. (Amps) (Amps) 1. Incoming from Station transformer 320 300 1 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Alternate Source Oil filtration set feeder Colony lighting feeder Yard lighting feeder Transformer fans & OLTC feeder Breakers operation feeder Outdoor street lighting feeder Water pump and sewerage pump Carrier room Battery charger Control panel indicator Spare feeder Provision for additional switch fuse unit To be mounted at a later stage. TOTAL 15 Nos. 320 200 160 160 100 32 32 63 32 32 32 160 300 160 100 100 63 25 25 50 25 25 25 100 1 1 1 1 1 1 1 1 1 1 1 1
NOTES: 1. Each circuit as indicated above shall have switch rating, HRC fuse rating and LT feeder labeling as mentioned against each. It shall include bus bar connections, terminals, cable glands and cable lugs etc. 2. Each Incomer shall be provided with the following equipment: i) One 100mm dial flush mounting moving iron spring controlled (MISC) ammeter of scale of 0-300A with phase selector switch. ii) One No. 100 mm dial flush mounting MISC voltmeter of range 0-500V with phase selector switch. iii) 3 Nos. 300/5A CTs having burden 15 VA and accuracy class 1 and instrument security factor. iv) One 3 phase , 4 wire unbalanced load integrating watt hour meter (operatable on 300/5A CTs). v) TTB for LT CT meter. 3. Make of each component must be listed in bid.. 4. The bus bar shall be designed for 320 A for phase and 150 A for neutral.
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SECTION-6 CHAPTER 6 FIRE FIGHTING EQUIPMENT 1.0 SCOPE Portable fire extinguishers of Carbon Dioxide type and Dry chemical Powder type shall be provided in adequate numbers for protection the Control Room Building and all other Buildings in the sub-stations. The protection shall cover all the rooms/areas of the buildings. The quantity and location of the extinguishers shall be as per the requirements of Fire protection Manual (Part-I) issued by Tariff Advisory Committee of India (TAC) and IS:2190. 1.1 Trolley Mounted fire extinguishers of 22.5 kg Carbon Dioxide type and 22.5 kg Dry Chemical Powder type shall be used for protection of all 220kV, 132/66kV Transformers and reactors in the S/Stn. Two DCP type and two CO2 type extinguishers shall be provided for each transformer/reactor. 2.0 PORTABLE TYPE FIRE EXTINGUISHERS: 2.1 This Specification lays down the requirement regarding fire extinguishers of following types: a) Carbon Dioxide type b) Dry Chemical powder type 2.2 All the portable extinguishers shall be capable of discharging freely and completely in upright position. 2.3 Each extinguisher shall have the instructions for operating the extinguishers on its body itself. 2.4 All extinguishers shall be supplied with initial charge and accessories as required. 2.5 Portable type extinguishers shall be provided with suitable clamps for mounting on walls or columns. 2.6 All extinguishers shall be painted with durable enamel paint of fire red colour confirming to relevant Indian Standards. 2.7 Capacities of each type shall be as indicated in the schedule of quantities. 2.8 Carbon Dioxide (CO2 type) extinguishers shall conform to IS:2878. 2.9 Dry chemical powder type extinguisher shall conform to IS:2171. 2.10 TESTS AND INSPECTION 2.10.1 All tests required to ensure that the equipment conforms to the Specification requirements and relevant standards and codes. 2.10.2 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 Bidder. All consumable and replaceable items required for this test would be supplied by the Bidder without any extra cost to the Purchaser. 2.10.3 Performance listing of extinguishers shall be in line of applicable Indian Standards. In case, where no Indian Standard is applicable for a particular type of extinguishers, the method of testing shall be mutually discussed and agreed to before placement of order for the extinguishers. 2.11 PERFORMANCE GUARANTEE The Bidder shall guarantee all equipment supplied by him against any defect due to faulty design, materials and workmanship. The equipment shall be guaranteed to operate satisfactorily at the rated conditions at site. 2.12 PAINTING Each fire extinguisher shall be painted with durable enamel paint of fire red colour conforming to relevant Indian Standards. 3.0 TROLLEY MOUNTED DRY CHEMICAL POWDER TYPE MOBILE FIRE EXTINGUISHER The Specification lays down the requirement regarding wheeled fire extinguisher of dry chemical powder type. Design, Manufacture, Material of construction and performance of mobile type fire extinguisher shall comply with the requirements of latest Indian Standards & shall have BIS approval (ISI marked).
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3.1
PERFORMANCE REQUIREMENT The capacity of the mobile dry chemical powder type fire extinguisher shall be 22.5 kg which means the total capacity of the container, when powder completely filled to the specified level shall be 22.5 kg. The fire extinguishers shall be used for Class B, C, and E fires. The extinguishers shall operate in the vertical position, mounted on solid rubber tyre trolley wheels. The effective throw during operation of the extinguishers shall not be less than 10 meter. A carbon dioxide cartridge fitted with valved discharge head, shall provide sufficient carbon dioxide to expel the dry chemical powder. DESIGN AND CONSTRUCTION The construction of wheeled fire extinguishers shall conform to IS standard and not be limited to the requirements mentioned here. The shape of the body of the fire extinguisher shall be cylindrical. It shall have adequate supporting arrangement. The balance of the fully equipped assembly shall be so arranged that it can be easily towed speedily behind a jeep or a car and also wheeled by a single operator. Two solid rubber tyred trolley wheels shall be fitted to the body of the mobile fire extinguisher. The rubber tyres shall have an effective life, and less than three (3) years. The extinguisher shall be fitted with a discharge hose and nozzle connection. The hose shall be of rubber or composite construction, having a length of 4.5-meter minimum. The bursting pressure of the hose shall be minimum 42 kgf/cm (g). The design of discharge nozzle shall be such that when the extinguisher is operated in still air the powder will be thrown in the form of a jet having a range of 10m (minimum) for a period of 50-60 seconds. The nozzle shall be fitted with a hand control device. Provision shall be therefore making a pressure test on the body. To minimize corrosion, the various components shall be provided with suitable anti-corrosive as per the requirement of applicable codes. Each mobile extinguisher shall be complete with initial charge, discharge fittings and accessories. TESTS AND INSPECTION Testing at manufacturers works. The manufacturer shall conduct all tests required to ensure that the equipment furnished will conform to this Specification requirements, relevant Indian Standards and applicable codes. Everybody shall be capable of withstanding an internal hydraulic pressure of 25 kgf/cm (g) without leakage or visible distortion, prior to painting, for a minimum period of 5 minutes. In destruction tests, if called for, ultimate failure shall occur at a test pressure not less than 32 kgf/cm (g) and if it occurs below 35 kgf/cm (g) there shall not be damage in any joint, seam casting of fittings. A performance demonstration test at site on five (5) percent or one (1) number, whichever is higher, shall be required to be carried out by the BIDDER. All consumable and replaceable items required for the test shall be supplied by the BIDDER without any extra cost to Purchaser. After conduction tests as in 1.1 and 1.4 the body shall be properly washed and drained off. After 24 hours, the interior shall be examined and it must be free from any stain, rust etc. PERFORMANCE GUARANTEE The BIDDER shall guarantee all equipment supplied by him against any defect due to faulty design, materials and workmanship. The equipment shall be guaranteed to operate satisfactorily at the rated conditions at site.
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3.2
3.3
3.4
3.5
PAINTING Each mobile fire extinguisher shall be painted with durable enamel paint of red colour conforming to relevant Indian Standard. The mobile foam type fire extinguisher shall be of make approved by Tariff Advisory Committee/NFPA/FOC/UL. Appliances conforming to the relevant BS/NFPA Standards are also acceptable provided the construction generally conform to the IS Standards so that spares refills/cartridges of Indian make conforming to IS Specification can be used after the operation of the extinguisher. Spare charge cartridges equivalent to requirements of 2 Nos. extinguishers shall also be supplied. TROLLEY MOUNTED CARBON-DIOXIDE TYPE MOBILE FIRE EXTINGUISHER This Specification lays down the requirements regarding wheeled fire extinguisher of carbon-dioxide. Design, manufacture, material of construction and performance of extinguisher as specified herein after shall comply with the requirements of latest applicable Indian Standards IS-2878 or equivalents and shall have BIS approval (ISI marked). PERFORMANCE REQUIREMENT The capacity of the extinguisher shall be 22.5 kg of carbon-dioxide when filled in the container to a filling ratio of about 0.66, 7. The extinguisher shall be designed for use where larger high intensity fire hazards are involved requiring versatility of action. These shall be used for Class B fire, i.e. fire in flammable liquid. Class C fire i.e. fire in gaseous substances under pressure and Class E fire, i.e. fires in live electrical equipment. The extinguisher shall be operated in upright position, by releasing a suitable valve. The range of effective operation of the extinguishers shall be about 4 meters.
4.0 1.1 1.2
1.3 1.3.1 1.3.2
1.3.3 1.3.4 1.4
DESIGN AND CONSTRUCTION The construction of wheeled fire extinguisher, carbon-dioxide type, shall in general conform to IS:2828 subject to the requirements mentioned hereunder: 1.4.1 The carbon-dioxide gas shall conform to IS:307. 1.4.2 The shape of the body of the extinguisher shall be cylindrical. The body shall be of steel cylinder. It shall have adequate supporting arrangement so that it can rest on the wheeled body in upright position and the operator be free to direct the stream. 1.4.3 The balance of the full equipped trolley unit shall be so arranged, that despite its considerable weight, it can be easily wheeled by one man. It should be capable of being towed speedily behind a jeep or car. 1.4.4 The cylinder shall be mounted on a trolley fitted with two cushion tyred wheels and fitted with suitable handle. The overall wheel diameter shall be about 280 mm. The frame of the trolley shall be made of welded steel section. 1.4.5 The design shall permit easy maintenance and operation with one man service. 1.4.6 The extinguisher shall be fitted with a high pressure flexible hose of about 9 m length and internal dia to hoses shall not be more than 12 mm. 1.4.7 A discharge horn made of fibre or any material non-conducting to electricity shall be fitted with a handle made of thermal insulating material capable of protecting operators hand from freezing effects. 1.4.8 Suitable provision for firmly securing the horn to the body, when it is not in use, shall be provided. The fixing device shall not interfere with the operation or mobility of the extinguisher. 1.4.9 The discharge valve or operating head shall be capable of being operated satisfactorily. It shall be made of material as specified in IS:2878. 1.4.10 There shall be no leakage of CO2 from valve or fitting during the use of extinguisher. Valve shall be provided with suitable safety device to prevent over pressure in cylinder. 1.4.11 A seal or device shall be fitted to indicate that the extinguisher has not been used. 1.4.12 Each extinguisher shall be complete with initial charge, discharge fittings and other accessories as required.
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1.5 1.5.1 1.5.2 1.5.3 1.5.4 4.5.5
1.5.5
TEST AND INSPECTION The extinguisher at ambient temperature shall expel at least 95% of its content as continuous discharge with in a maximum of 90 seconds and minimum of 30 seconds. The extinguisher without its attachment shall be shelved for 21 days after filling and shall be check weighed at the end of the period. There shall be no loss of mass. Carbon-dioxide cylinder shall be hydrostatically tested at a pressure of 236 kgf/cm (g) to prove leak tightness for a period of one hour. Hose assembly with its coupling shall be hydrostatically tested at a pressure of 315 kgf/cm (g) without failure. All tests required to ensure that the equipment conforms to the Specification requirements and relevant standards and codes shall be conducted by the manufacturer. Adequate time ahead of these shop tests the Purchaser shall be informed so that if he so desires, his representative may witness the tests. A performance demonstration test at site on five (5) percent or one (1) number, whichever is higher, shall be required to be carried out by the BIDDER. All consumable and rechargeable items required for the test shall be supplied by the BIDDER without any extra cost to Purchaser. PERFORMANCE GUARANTEE The BIDDER shall guarantee all equipment supplied by him against any defect due to faulty design, materials and workmanship. The equipment shall be guaranteed to operate satisfactorily at the rated conditions at site. PAINTING & MARKING Each extinguisher shall be painted in red and permanently marked in accordance with the requirements laid down in IS-2878. besides permanently making on the front of the extinguisher indicating its purpose, content and usage shall also be provided. The mobile Carbon-dioxide type fire extinguisher shall be of make approved by Chief Inspector of Explosives, Nagpur, India and Tariff Advisory Committee/NFPA/FOC/UL. VENTILATION SYSTEM Mechanical ventilation systems using exhaust fans shall be provided for all the rooms which are not considered for air conditioning. Capacity of the fan shall be selected so as to have the minimum air changes in the various rooms as below: Battery room, Pantry, toilets Changes/hr. All other rooms Changes/hr. : : 15 air 12 air
1.6
1.7
1.7.1
2.
For Battery room, the fan shall be bifurcated type spare proof construction.
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SECTION 6 CHAPTER 7 TECHNICAL SPECIFICATION FOR UNARMOURED COPPER CONTROL CABLES 1.0 1.1 SCOPE This specification provides for design, engineering, manufacture, stage testing, inspection testing before dispatch, packing, forwarding and delivery at site of unarmoured control cable. It is not the intent to specify complete herein all details of the design and construction of material. However, the material shall conform in all respects to high standards of engineering, design and workmanship and shall be capable of performing in continuous commercial operation up to the bidders guarantee acceptable to the HVPNL. The material offered shall be complete in all components necessary for its effective and trouble free operation. Such components shall be deemed to be within the scope of supply irrespective of whether those are specially brought in this Specification and or the commercial order or not. All similar parts particularly movable ones shall be interchangeable. STANDARDS Copper control cable to be supplied shall be PVC insulated. PVC sheathed unarmoured for indoor and outdoor applications in air, in ground, in water and in concrete trenches. The control cable shall conform in all respects to the requirements of IS-1554 (Part-I) 1988 and its subsequent amendments, if any at the time of placement of order. All CT/PT circuits control cables are to be of size 4 mm2 copper cable. The incoming AC and DC supply cable to JBs/MKs/C&R Panels/CBs will be of size 4 mm2 and 6mm2 copper and all other control cable will be of size 2.5 mm2 copper cable. Control cables meeting with the requirement of other authoritative standard, which ensure equal or better performance than the standards mentioned above, shall be considered. When the equipment offered by the bidder adopted and the standards specified in this Specification shall be clearly brought out in the relevant schedule. Four copies of such standards with authentic translation in English shall be furnished along with the offer. PRINCIPAL PARAMETERS(TECHNICAL) MATERIAL All the material used in the manufacture of the cables shall be of the best available quality with regard to strength, durability and shall also be manufactured according to best engineering practices. CONSTRUCTIONAL FEATURES The insulated core shall be provided with inner sheath, unarmoured but provided with an outer sheath as specified in IS-1554 (part-I) 1998 amended up to date. The control cable offered shall be suitable for use in system up to 1100 volts. The conductors shall be composed of plain annealed high conductivity copper which before stranding shall be approximately circular in section, smooth, uniform in quality
1.2
2.0 2.1
2.2
2.3 2.3.1
2.3.2
-1-
and free from scale, in-equalities, spills, splits and other defects. The conductors shall conform to appropriate dimensions and resistance as per IS-1554 (part-I) 1998. 3.0 3.1 GENERAL TECHNICAL PARTICULARS INSULATION The basic material employed as insulating compound shall consist of compounded polyvinyl chloride (PVC) or suitable copolymers of which major constituent shall be vinyl chloride or mixture of polyvinyl chloride and suitable copolymers which have been suitably compounded and processed so as to comply with the requirements of IS-1554 (part-I) 1988. The PVC compound going into the formation of insulation shall also comply with the provisions of IS-5831-1970 PVC insulation and sheath of electric cable. The insulation shall withstand the rigours of climate and site conditions and shall not crack or retract in normal use. The colour code of the cores of control cable shall be as per clause 10.1 of ISS-1554 (part-I) 1988. However, the outer PVC sheath shall be black or grey. The colour coding as employed in the formation of the cable for individual cores and sheath shall be indicated in the bid. The PVC/Co-polymer compounds going into the formation of the outer sheathing shall afford a high degree of mechanical protection besides being oil and weather resistant. MARKING Every cable drum shall be clearly marked with inedible ink or with suitable weather resistant paint and shall bear the following particulars: i) Manufacturer name and trade mark, if any. ii) HVPNL Order No. and Date. ii) Year of manufacture. iii) Nominal sectional area of conductor of the cable. iv) No. of cores. v) Type of cable and voltage for which it is suitable. vi) Length of cable on the drum. vii) Weight of tare. viii) Direction of rolling the drum. ix) Gross weight of the drum. TEST TYPE TESTS The copper control cables offered should be type tested. Type test report of similar cables should not be more than seven years old, reckoned from the date of bid opening in respect of the following tests, as per relevant ISS-1554/Part-I-1988 and carried out in accordance with the procedure laid down in relevant ISS/IEC/Internationally recognized equivalent standard from any accredited test house/ Lab. For Indian manufacturers, the tests got conducted from Govt. test labs shall also be acceptable. These type test reports shall be submitted by the successful bidder to HVPNL for the approval as per schedule given in commercial document. i) Test on conductors a) Annealing Test b) Conductor Resistance Test ii) Physical test for insulation and outer sheath. a) Tensile strength and elongation at break. b) Ageing in air oven.
3.2
4.0 4.1
-2-
c) d) e) f) g) iii) iv) v) vi) vii) 4.2
Shrinkage test. Hot deformation test. Loss of mass in air oven. Heat shock test. Thermal stability. Test for Thickness of Insulation and Sheath. Insulation resistance test. High voltage test (Water immersion test). High voltage test at room temperature. Flammability test.
ROUTINE TESTS : As per quality assurance program (QAP).
4.3
ACCEPTANCE TESTS: The following acceptance tests as stipulated in the relevant ISS-1554 (Part-I) shall be carried out by the Bidder in presence of HVPNL representative, unless dispensed with in writing by the HVPNL. i) Annealing Test (for copper) ii) Conductor Resistance test. iii) Test for Thickness of Insulation and Sheath. iv) Tensile strength and elongation at break of insulation and sheath. v) Insulation resistance test. vi) High Voltage test at room temperature.
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SECTION-6 CHAPTER-8 TECHNICAL SPECIFICATIONS FOR OUTDOOR NON SEALED TYPE THREE PHASE 11 KV/433V DISTRIBUTION TRANSFORMERS OF 200 KVA CAPACITIES 1.0 SCOPE: This specification covers the design, engineering, manufacture, shop testing, supply & delivery of oil immersed, naturally cooled, three-phase, 50 Hz, double-would, outdoor type Distribution transformers of 200KVA, capacity for use on systems with nominal voltages of 11 KV. Any other parts not specifically mentioned in this specification, but otherwise required for proper functioning of the equipment should be included by the tenderer in his offer. Transformers will be plinth mounted 2.0 STANDARDS: The transformers shall conform in all respect to IS: 1180-1981 & IS: 2026-1977 except where specified otherwise. Equipment meeting any other authoritative Standards which ensures an equal or better quality than the standards mentioned above will also be acceptable. In such cases the copy of standards (English Version) adopted should be enclosed with the tender. CLIMATIC CONDITIONS: As per Vol-II Section-1. PRINCIPAL PARAMETERS OF THE TRANSFORMER The transformer shall be suitable for outdoor service as step down transformer. The electrical parameters of the transformer shall be as follows:1) 2) 3) 4) 5) 6) Rated HV voltage Rated LV voltage Connection (HV) Connection (LV) Vector Group Material of winding 11 KV 433 volts Delta Star neutral brought out Dyn11 For 200 KVA Aluminium, double wound type ONAN
3.0
4.0
7) 8)
Type of cooling Max. current density in HV & LV Winding For aluminium wound 200 KVA T/F
a)
1.5A/mm2
9) 5.0
Method of system earthing
Neutral solidly earthed system
NO-LOAD VOLTAGE RATIO The no-load voltage ratio shall be 11000/433V.
-1-
6.0
TEMPERATURE RISE The transformer shall be capable of operating continuously at its normal rating without exceeding the temperature rise limit. The temperature rise shall not exceed the limits of 500C (measured by resistance) for transformer windings and 400C (measured by thermometer) in top oil above the ambient temperature when tested in accordance with IS. The transformer with higher temperature rise shall not be acceptable. Hot spot temperature shall not exceed 950C when calculated on an annual weighted average temperature of 350C as per IS:2026. The limits of temperature rise mentioned above will have to be satisfied by the manufacturer by carrying the Heat run test at the lowest negative tap by feeding losses corresponding to the rated current of the tap. LOSSES The no load and load losses for 11/0.433 KV shall not exceed the values given in the following table. KVA Rating No load losses in Watts (Max.) Full load losses in Watts (Max) At 75Deg.C. 200 400 3135
6.1
7.0
These losses are maximum allowable and there would not be any positive tolerance However, the manufacturer can offer losses less than above. The Bidder shall quote No-Load loss in KW at the rated voltage and frequency. The load loss in KW at rated voltage, frequency & out put, for the temperature 75 degree centigrade shall also be quoted. The Bidder shall guarantee these loss figures.
7.1
Noise level
80 dB
Transformer offers shall be rejected if audible sound level is higher than the values required by the owner.
8.0 IMPEDANCE: The recommended percentage impedance at 750C is 4.5% for 200KVA as per IS:2026. T/F with a tolerance
9.0 9.1
WINDING The primary (HV) windings shall be connected in Delta and the secondary (LV) winding in Star (Vector system DYn11) so as to produce a positive displacement of 30 degree from the primary to secondary vectors of the same phase. The neutral of secondary windings shall be brought out to a separate insulated neutral terminal. The neutral is to be solidly earthed in a separate earth pit and the transformer body is to be connected to station grounding system. HV windings shall consist of single coil design. The copper wires for coil formation shall be of sufficient cross-sectional area to impart desired mechanical strength. All delta leads from HT coils as well as HT line leads should be taken out through DPC. The current density in these leads should not exceed 0.8A/sq.mm.
9.2
The winding shall be so designed as to produce minimum out of balance forces in the transformers. Transformers of 200 KVA shall be aluminium wound and sizes above 200 KVA shall be copper wound. The current density for aluminium wound transformer shall be limited to 1.5A/mm sq. and for copper wound transformer shall be limited to 2.6A/mm.sq.
-2-
9.3
The winding design shall ensure that all the coil assemblies are of identical voltage ratio and shall be interchangeable and repairing of the winding could be made easily without special equipment. The conductor used in the coil shall be best suitable to the equipment and all the permanent current carrying joints in the winding and leads shall be properly sleeved and crimped/brazed instead of jointing with solder or welding. All LV coils ends shall be provided with brazed/crimped lugs and HV coil ends by brazing/crimping. Double paper covering shall be used for winding insulation both for HV & LV windings. Electrical grade epoxy coated insulated paper shall be used for inter-layer insulation of the HV & LV coils, corrugated cylinder made of pre-compressed board shall be provided between HV & LV winding. Angle shaped and rings made from pre-compressed board shall be used between end coil and the core. OR For 200 KVA transformers DPC insulation shall be used, Electrical Grade Insulation Kraft paper in layers of total thickness not less than 4 mm shall be used for interlayer insulation, DPC and Kraft paper used shall be of uniform density and free from any foreign particles and shall conform to IS:698/56 and latest amendments thereof. The end turn of each layer shall be properly and fully covered to avoid interlayer flashover. Corrugated Cylinder made from precompressed insulation board should preferably be used between LV and HV windings. The insulation of coils shall be vacuum impregnated in oil to develop full electrical strength in the windings. All material used in the insulation and assembly of the winding shall be insoluble non catalytic and chemically inactive in the hot transformer oil and shall not soften or otherwise be adversely effected under operating conditions. The core and coil assembly shall be fully dried out in Air Drying Oven till the coils are shrunken to the designed level and are completely dried. Only then they will be impregnated in the transformer oil.
9.4
9.5
9.6 9.7 9.8 10.0 10.1
Minimum gap of 25 mm shall be maintained between the end coils and core. The overloading capacity of transformer shall be as per IS-6600. The value of unbalance current shall not be more than 2% of the full load current. CORE CONSTRUCTION The core shall be constructed from high grade, non-aging Cold Rolled Grain Oriented (CRGO) silicon steel laminations conforming to grade M4 or better. The maximum flux density in any part of the cores and yoke at normal voltage and frequency shall be such that the flux density with + 12.5% voltage variation from rated voltage or frequency variation of -5% shall not exceed 1.6 Tesla. The bidder shall provide saturation curve of the core material proposed to be used. The design of magnetic circuit shall be such as to avoid static discharge development of short circuit within itself or in the earthed clamping structure. Each lamination shall be insulated such that it will not deteriorate due to mechanical pressure and the action of hot transformer oil. 10.4 a) Core material shall be directly procured either from the manufacturer or through their accredited marketing organization of repute and not through any agent. 10.4 b) All parts of the core shall be of robust design, capable of withstanding any shock to which they may be subjected during handling, lifting, transportation, installation and
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10.2
10.3
service including short circuit condition. Clamping of core and winding assembly with tank should be done by angle iron pieces, bolted to tank wall. 10.4 c) Adequate arrangement shall be provided to enable the core and winding be lifted by lifting lugs. Use of seconds CRGO steel for core construction is strictly prohibited. Bidder can offer transformer made of other superior (Low, Loss) for material and they should furnish design details in their bid. Successful bidders should submit require type test certificates after issue of P.O. but before material offered for inspection. The core material should be imported directly from the reputed manufacturer. Core material shall be processed by slitting only. Core cutting/slitting be done in front of inspecting officers deputed by HVPN. 11.0 11.1 TANK CONSTRUCTION The tank shall be of robust construction in accordance with the best engineering practice. The main tank of the transformer shall be fabricated from tested quality of mild steel of adequate thickness i.e. minimum 4.00 mm. (for side walls) and 6.00mm (for top & bottom plates). The tank shall be valid (V shape welding fillet) inside of tank two outside welding of tank to bear more pressure to avoid bursting. To provide rigidity and to meet the pressure inside the tank, due to short circuit current, the tank shall be suitably stiffened. The stiffeners wherever applicable are provided on all the four side walls of the tank, designed not to retain water. The tank cover shall be slightly sloping towards HV bushing and shall provide facilities for draining of water. The transformer tank shall be complete with al accessories, lifting lugs and shall be designed as to allow the complete transformer tank, filled with oil to be lifted by crane or other means without risk of any damage and transported by Rail/Road without straining any joint and without causing leakage of oil. Bolted inspection covers shall be provide on tank and top cover to inspect core, winding and have access to the bottom of bushing. The tank shall be capable of with standing the pressure of +/- 1 kg/cm2 without deformation. The permanent deflection of plate after pressure has been released shall not exceed the values given below: LENGTH OF PLATE 750 mm 751-1250 mm 12.0 FINISH The exterior of the transformer tank and other ferrous fittings shall be thoroughly cleaned, scraped and given a priming coat and two finishing coats of durable oil and weather resisting paints or enamel. The colour of the finishing coats shall be dark admiralty grey conforming to No. 632 of IS:5-1961 Colours for Ready Mixed Paints (second revision).
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11.2
11.3
11.4
11.5
11.6
DEFLECTION 5 mm 6 mm
13.0
CLEARANCES The external electrical clearance between phase to phase and phase to earth shall be in accordance with Clause 7.1 of IS: 2099 shall not be less than the values given below:Voltage Medium Clearance Phase to Clearance Phase to Phase (mm) earth (mm) 11 KV Air 255 205 433V Air 75 55
The aforesaid clearances are minimum and no negative tolerance on these clearances shall be allowed. 14.0 14.1 BUSHINGS Terminal arrangement: The transformer shall be fitted with three high voltages and four low voltage outdoor types porcelain bushing of appropriate voltage and current rating. Each terminal including the neutral shall be distinctly marked and coloured for phase voltage on both HV and LV sides. The system of marking shall be in accordance with the latest amendment of relevant IS. The electrical characteristics of high voltage bushing shall conform to latest version of IS: 2099 and IS: 3347. The low voltage bushing shall conform to latest version of IS: 7421. All porcelain bushing shall be homogeneous, free from flaws effecting its mechanical strength or dielectric quality. They should be well vitrified, uniformly glazed, tough and impervious to moisture. The creepage distance of all the bushing shall be 25mm per KV of highest system voltage suitable for heavily polluted atmosphere and the protected creepage distance not less than 50% of total. Bushing terminals: To avoid bimetallic action at the point of connection to the copper windings and to the external aluminium cables/conductors, both- HV & LV bushing stems shall be made of aluminium alloy/copper confirming to the requirement of IS:3347. The terminal connectors shall receive ACSR on HT side. The terminals shall be directly screwed on to the stem to secure effective sealing the bushing. The transformers shall be provided with bimetallic connectors bushings both on HV & LV Side. FITTINGS AND ACCESSORIES The transformer shall be fitted with the following fittings & accessories. Two earthing terminals Oil level indicator Lifting lugs and platform lugs Rating, diagram and terminal marking plate(s) Silica gel breather of approved design containing min. 0.25kg dehydrated silica get Drain-cum-Sampling valve (steel) welded to the tank. Thermometer pocket with dial type thermometer on tank cover. Air Release Plug Pressure relief device in the form of explosion release vent.
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14.2
14.3
14.4
15.0 15.1 (a) (b) (c) (d) (e) (f) (g) (h) (i)
(j) (k) (l) (m) (n)
Filling hole having P1-1/4 thread (with cover) on the conservator. Filter valve-2 nos. on top and bottom ends of tank at opposite sides. Conservator with filling hole and drain plug. Porcelain bushings with arcing horns and terminal connectors on HV side. Porcelain bushings on LV side and HV side conforming to IS-3347, part-1 and III of the latest version thereof with brass studs fitted with single gap arcing horns. Off load tap changer (for above 200 KVA transformers with tapping range of +3% to 6% in steps of 3% each with a locking device. Bimetallic terminal connector for HV/LV Bushings connecting to ACSR. PSR Radiators duly tested for leakage and pressure. Plain rollers ( 4 nos. bi-directional) suitable for use on 1000 mm gauge track with clamping device or base mounting arrangement as required. The fittings listed above are indicative and any other fittings which are generally required for satisfactory operation of the transformer are deemed to be included in the quoted price of the transformer.
(o)
(p) (q) (r)
Note: (i)
16.0 16.1
CONSERVATOR A conservator shall be provided with each transformer. The oil level gauge and the plain silica gel breathing device shall be fixed to the conservator which shall also be provided with a drain plug and a filling hole with a cover .In addition, the cover of the main tank shall be provided with an air release plug to enable trapped air to be released unless the conservator is so located as to eliminate the possibility of air being trapped in the main tank. The inside diameter of the pipe connecting the conservator to the main tank shall be within 20 to 50 mm and it should project into the conservator in such a way that its end is approximately 20 mm above the bottom of the conservator, so as to create a sump for collection of impurities. The minimum oil level (corresponding to -50C) should be above the sump level. Breather pipe should be connected at top of the conservator tank with two bends at right angles. SEALING GASKETS All sealing washers and gaskets shall be made of oil and heat resistant Nitrile/Neoprene rubber/synthetic rubber bonded cork type RC-70C Gaskets. The oil level in the transformer shall be made up to the required level while the transformer filled with oil is maintained at a temperature of 450C. All steel screws, nuts and fasteners exposed to atmosphere shall be either galvanized or cadmium plated. TRANSFORMER OIL The transformer shall be supplied complete with first filling of oil. The insulating oil shall comply with the requirements of IS:335/1983 with latest version thereof. Oil shall be filled under vacuum with a vacuum type filtering machine. BASE MOUNTING ARRANGEMENT The under base of all transformers shall be provided to make them suitable for fixing mounting on plinth.
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16.2
17.0
18.0
19.0
20.0
21.0
RATING AND TERMINAL MARKING PLATES(S) Each transformer shall be provided with non-detachable rating diagram and terminal marking plate(s) of weather proof material, fitted in a visible position and showing the complete information as given under clause 16 of IS:1980 (Part-I)-1981or any authoritative standards for transformers including the following details:i) HVPNL order no. & Date ii) Date of inspection iii) Property of HVPN. RADIATORS These shall be made of ERW tubes with minimum side thickness of 18 SWG. These tubes should be used in vertic formation without any bending and properly welded on both ends to common headers. These radiators should be individually test for leakage and pressure tests etc. before welding with the main tank.
22.0
TESTS AND INSPECTION All the tests shall be carried out in accordance with clause 16 of IS (Part-I) 1977 ROUTINE TESTS: All transformers shall be subjected to the following routine tests at the manufacturers works in accordance with IS 2026 and 1180 (Part-I): Measurement of winding resistance. Ratio, Polarity and phase relationship. Measurement of Impedance voltage/short circuit impedance. Load losses. No load losses and no load current. Insulation resistance. Induced over voltage withstand. Separate source voltage withstand. Oil leakage test. Magnetic balance test and magnetizing current and low voltage. TYPE TESTS The following type tests shall be made on the transformers in addition to the routine tests from (a) to (f) as indicated in 22.1 above: Temperature rise test shall be carried out on one unit from each lot as offered for inspection.
22.1
a) b) c) d) e) f) g) h) i) j) 22.2
i)
ii) Air pressure tests: The tank shall be fixed with a dummy cover with all fittings including bushings in position and shall be subjected to the following pressure created inside the tank: a) b) 0.8 kg/cm2 above the atmospheric pressure for 10 minutes. A vacuum corresponding to (-) 0.7 kg/cm2 for 10 minutes. Permanent deflection of flat plate after pressure has been released, shall not exceed the value given below: LENGTH OF PLATE Upto 750 mm 751-1250 mm i) DEFLECTION 5 mm 6 mm
Impulse voltage withstand test on all the three limbs of HT side as per clause 13 of ISS 2026/1991/Part-II conducted at some recognized/Govt. Test house not more than 7
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ii)
iii)
years old from the date of bid opening shall required to be submitted. The dispatches shall only be allowed after successful conductance of this test. SHORT CIRCUIT TEST: This test shall be made in accordance with the details specified in IS 2026/1977 conducted at some recognized/Govt. Test house OR from reputed Lab Abroad not more than 7 years old from the date of bid opening shall required to be submitted. The dispatches shall only be allowed after successful conductance of this test. If short circuit tests on unit of similar design of transformer with capacity as per schedule had been conducted earlier than certificate shall be produced along with tender and the test need not be conducted. Unbalance Current Test: The value of unbalanced current indicated by the ammeter shall not be more than 2% of the full load current. No supplies will be allowed to be despatched without inspection by the HVPNL/its representative and without carrying out the impulse and short circuit tests satisfactorily.
22.3
FLUX DENSITY TEST: The Bidder shall arrange to conduct the flux density test on one of the cores of the transformers in each lot so as to ensure that the flux density does not exceed the maximum specified limit of 1.6 Tesla at normal voltage & frequency. OIL TEST At least two samples of oil shall be drawn out of any two sizeable lots from total ordered quantity to ensure that the oil used complies with the requirements of the Specification as per ISS-335. However, inspecting officer can draw oil samples from any number of lots if considered necessary so as to ensure that transformer oil conforming to ISS is being used. The despatches for such lots shall be allowed only after receipt of satisfactory oil test results. OIL LEAKAGE TEST: The air pressure tests provided as a routine test shall be carried out on 10% of the transformers in each lot. The firm shall ensure to get this test carried out strictly as per relevant ISS. PHYSICAL CHECK ON VARIOUS DIMENSIONS (INTERNAL & EXTERNAL WEIGHT CLEARANCE ETC.) One No. transformer from each lot shall be opened for checking of core weight, size and weight of HT & LT conductor, quantity of oil and various clearances etc. INSPECTION The inspection shall be carried out by an outside inspection agency to be nominated by the Nigams representative. All tests & inspection shall be made at the place of manufacturer unless otherwise specifically agrees upon between the manufacturer and the HVPNL at the time of placing the order. The manufacturer shall afford the inspector representing the HVPNL all reasonable facilities, without charge, to satisfy himself that the material is being furnished in accordance with this Specification. The HVPNL has the right to have the tests carried out at its own cost by an independent agency whenever there is any dispute regarding the quality of supply. If the transformer fails in the tests, the cost shall be borne by the Bidder and if it passes, the cost shall be borne by the Nigam. INSULATION RESISTANCE OF WINDINGS: The minimum insulation resistance values in Mega ohms between winding and earth when the transformer is filled with oil should be as below: -
22.4
22.5
22.6
22.7
22.8
23.0
-8-
INSULATED RESISTANCE VALUES IN MEGA OHMS BETWEEN WINDING AND EARTH 200C 800 400 300C 400 200 400C 200 100 500C 100 50 600C 50 25
11000 Volt(HV) 433 Voltage(LV)
The insulation resistance values will be measured with a 2500V, preferably motorized meggar and of some good standard manufacturer such as M/s Evershed & Vignole make. 24.0 TEST VOLTAGE Transformers shall be capable of withstanding the power frequency and impulse test voltages prescribed as below: NOMINAL SYSTEM VOLTAGE 11KV (rms) 25.0 HIGHEST VOLTAGE 12KV (rms) SYSTEM IMPULSE TEST VOLTAGE 75KV (peak) POWER FREQUENCY TEST VOLTAGE 28KV (rms)
TOLERANCE OF ELECTRICAL PERFORMANCE Tolerance shall be according to clause 11 of IS:2026 (part-I/General:1977). DRAWING AND LITERATURE The successful bidder shall submit the equipment drawing(s) in quadruplicate, to the CE/P&D, HVPNL, Panchkula for his approval. Such drawing(s) will be commented/approved by HVPNL within four weeks of their receipt. The successful bidder will re-submit such drawing(s) duly reflecting the HVPNLs comments within 2 weeks of their receipt, which will be approved by the HVPNL within 2 weeks. The successful bidder shall supply 6 copies each of approved drg. and descriptive literature containing handling, erection & maintenance instructions to the CE/P&D, HVPNL, Panchkula for distribution amongst field organisation. Reproducible(s) of the approved drawing(s) will also be supply by the successful bidder. Also, a copy of each of the drawing(s) & descriptive literature will accompany the equipment for use by the stores/field offices drawing it for application on Nigams power system.
26.0
27.0 PACKING Transformers shall be delivered suitably packed. Although the method of packing is left to the discretion of the manufacturer, it should be robust enough for rough handling, that is occasioned during transportation by rail/road. 28.0 GUARANTEED DATA Guaranteed Technical particulars and other Technical data in respect of equipment/material offered shall be furnished duly signed along with the tender in the Performa attached as Vol-III. Any other particulars considered necessary may also be given in addition to those listed in the schedule.
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SECTION 6 CHAPTER 9 TECHNICAL SPECIFICATION FOR 33 kV CLASS COPPER WOUND DISTRIBUTION TRANSFORMERS (CONVENTIONAL TYPE) FOR 200 KVA CAPACITY WITH INTERNAL CSP (COMPLETELY SELF PROTECTED) FEATURES 1 SCOPE This specification covers the design, engineering, manufacture, testing, supply and delivery of oil immersed, naturally cooled, three phase, 50Hz, double wound, outdoor type distribution transformers of 200KVA capacity with completely self protected (CSP) distribution transformers for outdoor substations in earthed neutral system with nominal voltage of 33 kV Sub-Station auxiliary distribution systems. It is not the intent to specify completely herein all the details of the design and construction of equipment. However, the equipment shall conform in all respects to high standards of engineering, design and workmanship and shall be capable of performing in continuous commercial operation upto the Bidders guarantee, in manner acceptable to the purchaser, who will interpret the meanings of drawings and specification and shall have the power to reject any work or material which, in his judgment is not in accordance therewith. The offered equipment shall be complete with all components necessary for their effective and trouble free operation. Such, components be deemed to be within the scope of Bidders supply interceptive of whether those are specifically brought out in this specification and / or the commercial order or not. Transformers will be plinth mounted. STANDARDS Unless otherwise modified in this specification the transformer shall conform in all respect to the relevant Indian / International Standard Specification, with latest amendments thereof some of them are listed below: Indian Title International Standards standards
IS-2026:1977-81 IS-335/1983 IS-3639:1968 IS-2099:1986 IS-7421-1988 IS-3347 IS-12444 IS-5/1964 IS-6600/1972 CBI&P Specification of Power Transformer Insulating Oil for transformer & switchgear Fittings & Accessories for Power Transformer Higher Voltage Porcelain Bushings Low Voltage Porcelain Bushings Dimensions for Outdoor Bushings Specification for Copper wire rods Specification for colours for ready mixed paints Guide for loading of oil immersed Transformers Manual on transformer, Publication No.275 IEC-76 BS-148 ASTM D-1275 IEC 296-1969 DIN 42531 to 33, 23, 3 ASTM B-49
1.1
2.
The bidder shall use ISS, however, wherever this standard is not available, corresponding IEC may be followed. Material conforming to ISS or the internationally accepted standards, which ensure equal or higher quality than the standards mentioned above, would also be acceptable. In case the Bidders who wish to offer material conforming to the standards, salient points of difference between the standards adopted and the specific standards shall be clearly brought out in relevant schedule. Four copies of such standards with authentic English translations shall be furnished along with the offer.
-1-
3.
4.
CLIMATIC CONDITIONS As per Vol-II Sec-1.

TYPE AND RATING The transformers shall have core type construction and ONAN cooled as mentioned below and shall be suitable for outdoor service as step-down-transformers. The rating and electrical characteristics of the transformers shall be as follows: Continuous capacity 200KVA Rated HT voltage 33kV Rated LT voltage 433V 250V Frequency 50Hz 5% No. of phases 3 Connection (HT) Delta Connection (LT) Star Neutral brought out Vector Group Dyn-11 Taps No. of taps shall be -5% to +10% with 2.5% steps. Type of cooling ONAN No Load Voltage ratio 33000/433V at principle tap
i.) ii.) iii.) iv.) v.) vi.) vii.) viii.) ix.) x.) xi.) 5.
WINDINGS
The primary winding shall be connected in delta and the secondary winding in star (Vector symbol Dyn-11) so as to produce a positive displacement of 300 from the primary to the secondary vectors of the same phase. The neutral of the secondary winding shall be brought out to a separate insulated terminal. All transformers shall be oil immersed weather proof and suitable for outdoor installation. The windings and connections, insulation material shall not soften, ooze out, shrink or collapse during service. No strip conductor wound on edge shall have a width exceeding six times its thickness. The conductors shall be transposed at sufficient intervals to minimize eddy currents and equalize the current and temperature distribution along the windings. The windings and connections shall be properly brazed to withstand shocks during transportation or transient conditions during service. The adequate pre-shrinkage of the coil assembly using pre-compressed press board material having low moisture content for the radial spacer blocks shall be ensured by the manufacturers so that there is no displacement of the radial spacer blocks due to frequent short circuits on the transformers. All windings after being wound and all fibrous hygroscopic materials used in the construction of the transformer shall be dried under vacuum and impregnated with hot oil. In addition to this the drying process be sufficiently extended for proper stabilization of the coil assembly. More than one cycle of soaking in oil followed by retightening of the coil assembly should be adopted. The coil clamping rings wherever used shall preferably be of flat insulated steel laminations. Auxiliary laminated material except bakelised paper shall not be used. The clamping arrangement shall exert equal pressure on all columns of spacers of the transformer windings built of sections or disc-coils separated by spacers. In no case, spiral winding will be used either for HV or LV windings. The radial spacer blocks must be made of pre-compressed pressboard material, which will not soften while in contact with oil or fray out into fibers or edges. The slots should be so dimensioned that the blocks will not come out of the slots. Uniform distribution of coil clamping force shall be designed by using an adequately large number of coil clamping bolts and by transferring the clamping force from clamping bolts to the clamping plates through intermediate members, which can spread the clamping force over a large area. All joints shall be brazed/crimped considering the vibrations due to short circuits and load fluctuations.
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6. a) b)
DESIGN AND CONSTRUCTION Core: Material CRGO sheet. The core shall be of high grade cold rolled grain oriented annealed silicon steel laminations having low loss & good grain properties, coated with oil proof insulation, bolted/clamped together to the frames firmly to prevent any vibration. All core clamping bolts if provided shall be effectively insulated. The complete design of core must ensure permanency of the core losses with continuous working of the transformer. The value of the flux density allowed & the design & grade of laminations used shall be clearly stated in the offer. Flux Density: Flux Density at normal voltage (for grade-41 CRGO Laminations) shall not be more than 1.6 Tesla. Over Flux: Over Flux in the transformer core shall be limited to 12.5% to ensure that in the event of over-voltage to the extent of 12.5%, the core does not get saturated. No Load Current: No Load Current at 100% voltage shall not be more than 2% of the full load current subject to tolerance as per ISS. No Load current at 12.5% over voltage shall not exceed 4% of the full load current. The supplier shall furnish necessary design data in support of this stipulation. Minimum number of steps of core shall be 5 Nos. Core Clamping: The core-clamping channel shall be of size 75mm x 40mm with 2 No. 12mm dia MS Bolts for clamping efficiently. For top yoke (channel), if cuts of holes are made for LV connection, suitable reinforcement to channel shall be made. MS channel shall be painted with oil & corrosion resistant paint before use. Core base and bottom yoke shall be supported with 75mm x 40mm MS channel with proper bolting together. In no case flat or cut channels shall be accepted. TEMPERATURE RISE The temperature rise shall not exceed limits of 500C (measured by resistance) for transformer windings & 400C (measured by thermometer) for top oil, when tested in accordance with IS-2026-1977. The hot spot temperature shall not exceed 950C when calculated on an annual weighted average temp. of 320C as per ISS:2026. The limits of temperature rise mentioned above will have to be satisfied by the manufacturer by carrying the heat run test at the lowest negative tap by feeding losses corresponding to the rated current of the tap. IMPEDANCE The percentage impedance at 750C shall be 4.5% subject to tolerance as per IS-2026. COOLING All transformers shall be capable of giving a continuous output without exceeding the specified temperature rise with ONAN cooling TRANSFORMER OIL The transformer oil shall comply with the requirement of ISS-335 Specification for insulating oil for transformers. TAP CHANGING MECHANISM The transformers shall be provided with off circuit tap selector switch on HV windings for HV variation from 5% to +10% in steps of 2.5% to give a constant LV. These steps shall be operated by hand, and provisions shall be made for indication of tap position and locking on any particular tap. FITTINGS The following standard fittings shall be provided: a) b) Two no. suitable earthing terminals. Oil level gauge indicating three positions of oil marked as follows: i) Minimum 50C.
c) d) e)
f) g) a) b) c) d) 7.
7.1
8. 9.
10.
11.
12.
-3-
ii) At c) d) e) f) g) h) i) j) k) l) m) n) o) p) q) 13.
300C.
iii) Maximum 980C. Lifting lugs & pulling lugs. Rating and terminal marking plates. Silica gel breathing device of weather proof design with minimum silica gel 400 gm. Drain cum sampling valve made of steel of the type suitable to the tank. Thermometer pocket with 4 inch dial type thermometer. Filling hole having P 1-1/4 thread conservator. 1 No. filter valve with plug 25mm diameter at the top for filtration. Air release plug on the top cover. Conservator tank along with a drain valve, filling hole & valve between conservator and tank. Base channels. Explosion vent/Pressure relief device operate at a pressure of 0.3 to 0.5kg/cm2. Off load tap changer with tapping device. Uni-directional flat rollers. Bimetallic terminal connector on HV/LV Bushings (Universal type). Radiators as required. CONSERVATOR On transformers, provision of conservator is obligatory. When a conservator is fitted, the oil gauge and the breathing device shall be fixed to the conservator which shall also be provided with a drain plug and a filling hole with a cover. In addition, the cover of the main tank shall be provided with an air release plug to enable trapped air to be released unless. The conservator is so located as to eliminate the possibility of air being trapped within the main tank. The inside diameter of the pipe connecting the conservator to the main tank shall be within 20 mm to 50 mm and it should project into the conservator in such a way that its end is approximately 20 mm above the bottom of conservator, so as to create a sump for collection of impurities. The minimum oil-level (corresponding to 50C) should be above the sump level. TANK TANK CONSTRUCTION The main tank of the transformer shall be made of good quality steel sheet having a minimum thickness of 4 mm for the sides of the tank and a minimum thickness of 6.00 mm for top and bottom plates for all ratings. The tanks shall be suitably stiffened at two places along the height to make them sturdy. The stiffeners shall be provided on all the 4 sides of the tank. The tank shall be capable of withstanding a pressure upto +1Kg/cm2 and (-0.7) Kg/cm2 (Gauge pressure) for 30 minutes. The word HVPNL PROPERTY shall be engraved on the top cover plate and side of the tank body. No negative tolerance shall be allowed. The permanent deflection of plate after pressure has been released, shall not exceed the values given below: Length of plate DEFLECTION 750 MM 5 mm 751-1250 mm 6 mm RADIATORS These shall be made of ERW tubes with min side thickness of 18 SWG. These tubes should be used in vertical formation without any bending and properly welded on both ends to common headers. These radiators should be individually test for leakage and
-4-
14. 14.1
14.2
14.3
pressure tests etc. before welding with the main tank. FASTENERS: All bolts, studs, screw threads, pipe threads, bolt heads and nuts shall comply with the appropriate Indian Standards for metric threads, or the technical equivalent. Bolts or studs shall not be less than 6 mm in diameter except when used for small wiring terminals. All nuts and pins shall be adequately locked. Wherever possible bolts shall be fitted in such a manner that in the event of failure of locking resulting in the nuts working loose and falling off, the bolt will remain in position. All ferrous bolts, nuts and washers placed in outdoor positions shall be treated to prevent corrosion, by hot dip galvanizing, except high tensile steel bolts and spring washers which shall be electro-galvanised / plated. Appropriate precautions shall be taken to prevent electrolytic action between dissimilar metals. Each bolt or stud shall project at least one thread but not more than three threads through the nut, except when otherwise approved for terminal board studs or relay stems. If bolts nuts are placed so that they are inaccessible by means of ordinary spanners, special spanners shall be provided. The length of the screwed portion of the bolts shall be such that no screw thread may form part of a shear plane between members. Taper washers shall be provided where necessary. Protective washers of suitable material shall be provided front and back or the securing screws. 2 No., anti-theft fasteners of steel on two diagonally opposite corners of the tank shall be provided. All nuts & pins shall be adequately locked.
15 15.1
15.2
15.3
15.4 15.5 16.
BUSHING AND TERMINALS Terminal arrangement: The transformer shall be fitted with three high voltages and four low voltage outdoor types porcelain bushing of appropriate voltage and current rating and LT bushing shall be provided on the side of the tank. Each terminal including the neutral shall be distinctly marked and coloured for phase voltage on both HV and LV sides. The system of marking shall be in accordance with the latest amendment of relevant IS. The electrical characteristics of high voltage bushing shall conform to latest version of IS:2099 and IS 3347. The low voltage bushing shall conform to latest version of IS: 7421. All porcelain bushing shall be homogeneous, free from flaws effecting its mechanical strength or dielectric quality. They should be well vitrified, uniformly glazed, tough and impervious to moisture. The creepage distance of all the bushing shall be 25mm per kV of highest system voltage suitable for heavily polluted atmosphere and the protected creepage distance not less than 50% of total. The bushings terminal connectors for both HT and LT shall be of clamp type to directly receive Aluminium/ conductors/ cables without requiring use of lugs. The terminal connectors shall be directly screwed on the stem to secure effective sealing of the bushings. The bushings rods and nuts shall be made of brass suitable for bushings as per requirement of IS-3347 mentioned in 15.1 above. Neutral bushing of LV side should be similar to LV bushing. Neutral shall be earthed through a separate bushing on the transformer tank. SEALING GASKETS All sealing washers/gaskets should be of grade RC-70C or RC-80B of neoprene Bended Cork as per IS-4253 (P-II) 1980 (Latest edition). FINISH The exterior of the transformer tank and other ferrous fittings shall be thoroughly cleaned, scraped and given a priming coat and two finishing coats of durable oil and weather resisting paints or enamel. The colour of the finishing coats shall be dark grey conforming to No. 632 of IS:5-1961 Colours for Ready Mixed paints (second revision). RATINGS AND TERMINAL MARKING PLATES Each transformer shall be provided with non-detachable rating and terminal marking
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17.
18.
19.
20
21
plates of weather proof material fitted in a visible position and showing the complete information as given under clause 16 of IS-1980 (Part-I) 1981 or any authoritative standards for transformers including the following details: i) Purchase order No. & date ii) Date of inspection iii) Property of HVPNL. MOUNTING ARRANGEMENTS The under base of all transformer shall be provided to make them suitable for fixing on a plinth. LOSSES The losses of each transformer shall be stated in the tender ONAN rating at full load at 750C which shall be less than :Sr. No. KVA rating of No Load losses in Watts Full Load losses Rating T/F (max.) Watts (max.) at 75oC 1. 200 500 3000 EQUALISATION FORMULA: The losses of each transformer shall be stated in the tender ONAN rating at full load at 750C. For the purpose of arriving at comparable prices, the iron & copper losses shall be capitalized as per formula given below:=3,86,700( Wi + 0.45 Wc + 0.45 Wp) Where Wi = Iron (No load) Losses Wc = Copper (Load Losses) Losses are subject to IS tolerance, the component losses shall be increased by 15% tolerance permissible as per ISS-2026. In case firm losses are quoted, the tenders should clearly state that under no circumstances the losses will not be more than the quoted firm losses. Please note that the capitalization of losses as are subject to tolerance, the component losses would be increased by 15% if it is question of acceptance of supplies the tolerance would be limited to Total losses : 10% of total losses Component losses : 15% of each component losses Provided that the tolerance for total losses is not to exceed 10%. Total losses comprises of no load & load losses. In case, during testing the losses of transformers are found on higher side than the quoted one, then transformer shall liable to be rejected. COMPLETELY SELF PROTECTED (CSP) FEATURES The Transformers shall have the following CSP features: Internal HV fuse on the HT side of transformer: Specification for the HV fuse: Expulsion/any other suitable type of fuse placed in series with the primary winding. The fuse is mounted normally inside of the primary bushing for the three phases and it is connected to the high voltage winding through a terminal block. This has to protect that part of the electrical distribution system, which is ahead of the distribution transformers from faults, which occur inside the distribution transformers i.e. either on the windings or some other part of the transformers. It shall be ensured that the fuse does not blow for faults on the secondary side (LT side) of the transformer i.e. the blowing characteristics of the fuse and LT breaker shall be so coordinated such that the fuse shall not blow for any faults on the secondary side of the transformer beyond LT breakers and those faults shall be cleared by the LT breaker only Internally mounted oil immersed LT breaker on the LV side of the transformer
22 22.1
22.1.1
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22.1.1.1
22.1.1.2 22.1.1.3 22.1.1.4 22.1.1.5 22.1.1.6 22.1.1.7 22.1.1.8 22.1.1.9
NOTE:-
23 23.1
a) b) c) d) e) f) g) h) i) j) k) l) m) n)
3 Pole LT Circuit Breaker: All LT faults after the breaker shall be cleared by this breaker. As such it shall be designed for perfect coordination with the HT fuse link. The bidder shall furnish the time/current characteristic for LT circuit breaker of 33kV fuses for various current multiples. The two characteristics shall be drawn on the same sheet to indicate coordination between the circuit breaker and fuse. The Bidder shall carry out coordination test as indicated above and this forms one of the tests as for acceptance test. The breaker shall be coordinated thermally with the transformer design to follow closely the variations of coil acceptance test. The breaker shall be coordinated thermally with the transformer design to follow closely the variations of coil temperature due to fluctuating load and ambient temperatures This is to be accomplished by connecting the breaker in series between the secondary windings and the secondary bushings. The breaker shall be located in the same oil as the core and coil assembly so that the bimetal are sensitive to the temperature of oil as well as the load current. The circuit breaker shall also be closed and opened manually standing on ground. The current carrying parts of breakers shall be copper plus a set of copper tungsten current interrupting contacts. The cross section of the current carrying parts of the breakers shall withstand the full load current at a current density not more than 2.5 A/Sq.mm (for additional mechanical strength the area should be more). Unit P.F & 0.8P.F 125% load 100% load 75% load 50% load 25% load Regulation at The bidder may offer microprocessor based MCCB with line current characteristics confirming to IS: 156600 of appropriate rating & good quality from reputed manufacturer in the metal-box of the distribution transformer instead of internal LV breaker. The breaker-trip setting shall be done considering loading of 130% loading for 6 hours duration at an average ambient temperature of 400C for internal breaker as well as MCCB (if approved) TESTS AND INSPECTION All the tests shall be carried out in accordance with clause 16 of IS (Part-I) 1977 ROUTINE TESTS: All transformers shall be subjected to the following routine tests at the manufacturers works in accordance with IS 2026 and 1180 (Part-I): Measurement of winding resistance. Ratio, Polarity and phase relationship. Measurement of Impedance voltage/short circuit impedance. Load losses. No load losses and no load current. Insulation resistance. Induced over voltage withstand. Separate source voltage withstand. Ratio, Polarity and phase relationship. Measurement of Impedance voltage/short circuit impedance. Load losses. No load losses and no load current. Insulation resistance. Induced over voltage withstand.
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o) p) q) 23.2
Separate source voltage withstand. Oil leakage test. Magnetic balance test and magnetizing current and low voltage. TYPE TESTS The following type tests shall be made on the transformers in addition to the routine tests from (a) to (f) as indicated in 19.1 above: Temperature rise test shall be carried out on one unit from each lot as offered for inspection. Air pressure tests: The tank shall be fixed with a dummy cover with all fittings including bushings in position and shall be subjected to the following pressure created inside the tank: 0.8 kg/cm2 above the atmospheric pressure for 10 minutes. A vacuum corresponding to (-) 0.7 kg/cm2 for 10 minutes. Permanent deflection of flat plate after pressure has been released, shall not exceed the value given below: Length of plate DEFLECTION Upto 750 mm 5 mm 751-1250 mm 6 mm Impulse voltage withstand test on all the three limbs of HT side as per clause 13 of ISS 2026/1991/Part-II conducted at some recognized/Govt. test house not more than 7 years old from the date of bid opening shall required to be submitted. The dispatches shall only be allowed after successful conductance of this test. SHORT CIRCUIT TEST: This test shall be made in accordance with the details specified in IS 2026/1977 conducted at some recognized/Govt. test house not more than 7 years old from the date of bid opening shall required to be submitted. The dispatches shall only be allowed after successful conductance of this test. If short circuit tests on unit of similar design of transformer with capacity as per schedule had been conducted earlier than certificate shall be produced along with tender and the test need not be conducted. Unbalance Current Test: The value of unbalanced current indicated by the ammeter shall not be more than 2% of the full load current. No supplies will be allowed to be dispatched without inspection by the purchaser/its representative and without carrying out the impulse and short circuit tests satisfactorily. FLUX DENSITY TEST: The supplier shall arrange to conduct the flux density test on one of the cores of the transformers in each lot so as to ensure that the flux density does not exceed the maximum specified limit of 1.6 Tesla at normal voltage & frequency. OIL TEST At least two samples of oil shall be drawn out of any two sizeable lots from total ordered quantity to ensure that the oil used complies with the requirements of the Specification as per ISS-335. However, inspecting officer can draw oil samples from any number of lots if considered necessary so as to ensure that transformer oil conforming to ISS is being used. The dispatches for such lots shall be allowed only after receipt of satisfactory oil test results. OIL LEAKAGE TEST: The air pressure tests provided as a routine test shall be carried out on 10% of the transformers in each lot. The firm shall ensure to get this test carried out strictly as per relevant ISS. PHYSICAL CHECK ON VARIOUS DIMENSIONS (INTERNAL & EXTERNAL WEIGHT CLEARANCE ETC.) One No. transformer from each lot shall be opened for checking of core weight, size and weight of HT & LT conductor, quantity of oil and various clearances etc. INSPECTION The inspection shall be carried out by an outside inspection agency to be nominated by the Nigams representative. All tests & inspection shall be made at the place of manufacturer unless otherwise specifically agrees upon between the manufacturer and the purchaser at the time of placing the order. The manufacturer shall afford the
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i) ii)
a) b)
iii)
iv)
v)
23.3
23.4
23.5
23.6
23.7
23.8
24
25 26
27
28
inspector representing the purchaser all reasonable facilities, without charge, to satisfy himself that the material is being furnished in accordance with this Specification. The purchaser has the right to have the tests carried out at its own cost by an independent agency whenever there is any dispute regarding the quality of supply. If the transformer fails in the tests, the cost shall be borne by the supplier and if it passes, the cost shall be borne by the Nigam. TEST VOLTAGE Transformers shall be capable of withstanding the power frequency and impulse test voltages prescribed as below: HIGHEST SYSTEM IMPULSE TEST POWER NOMINAL VOLTAGE VOLTAGE FREQUENCY TEST system VOLTAGE VOLTAGE 33 KV (RMS) 36 KV (RMS) 170 KV (PEAK) 70 KV (RMS) TOLERANCE OF ELECTRICAL PERFORMANCE Tolerance shall be according to clause 11 of IS: 2026 (part-I/General: 1977). DRAWING AND LITERATURE The successful bidder shall submit the equipment drawing(s) in quadruplicate, to the CE/MM, HVPNL, Panchkula for his approval. Such drawing(s) will be commented/ approved by HVPNL within four weeks of their receipt. The successful bidder will resubmit such drawing(s) duly reflecting the purchasers comments within 2 weeks of their receipt, which will be approved by the purchaser within 2 weeks. The successful bidder shall supply 6 copies each of approved drg. and descriptive literature containing handling, erection & maintenance instructions to the CE/MM, HVPNL, Panchkula for distribution amongst field organisation. Reproducible(s) of the approved drawing(s) will also be supply by the successful bidder. Also, a copy of each of the drawing(s) & descriptive literature will accompany the equipment for use by the stores/field offices drawing it for application on Nigams power system. PACKING Transformers shall be delivered suitably packed. Although the method of packing is left to the discretion of the manufacturer, it should be robust enough for rough handling, which is occasioned during transportation by rail/road. GUARANTEED DATA Guaranteed Technical particulars and other Technical data in respect of equipment/material offered shall be furnished duly signed along with the tender in the Performa attached as Vol-III. Any other particulars considered necessary may also be given in addition to those listed in the schedule.
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SECTION-6 CHAPTER 10 TECHNICAL SPECIFICATION FOR LT TWO CORE, 3 CORE AND FOUR CORE PVC INSULATED UNARMOURED CABLE OFF SIZES FOR WORKING VOLTAGE UPTO & INCLUDING 1100 V, FOR SERVICE CONNECTIONS.
1.
2.
3.
SCOPE:- This specification provides for design, manufacture, inspection at manufacturers works, testing before dispatch, supply and delivery of unarmoured 2 core, 3 core and 4 core PVC sheathed Aluminium conductor cables for voltage upto 1.1 kV. STANDARD:- LT distribution unarmoured cables shall be suitable for service voltage of 1100 volts (640 volts to earth) and made from high conductivity Aluminium conductor insulated with PVC compound and having inner and outer sheathing of PVC compound. The cables shall be strictly in conformity with ISS-1554/Part-I/1988 with latest amendments/ edition if any and shall be ISI/ IEC marked. The inner and outer sheathing shall be carried out as per relevant ISS. However, material manufactured as per any other International Standard which offers equivalent or materials better in quality and workmanship as compared to mentioned standards shall also be acceptable. Aluminium conductor complying with IS:8130-1984 shall be used. CLIMATIC CONDITIONS:- The cable shall work satisfactorily under the following climatic conditions:50oC -2.5oC 100% 26% Below 1000 meters above mean sea level. vi) Average no. of Rainy days per annum. 120 vii) Average annual Rain fall. 900 mm viii) Maximum wind pressure 195 Kg/ meter2 TECHNICAL PARTICULARS:- The cable shall be suitable for use on 50 Hz three phase AC solidly earthed Neutral power system working voltage of 3 x 240/ 415 Volt. Sheathing:a) 4 Core Cables:- The Contractor has the option to provide inner and outer sheathing of PVC compound by single or separate pressure extrusion process as per relevant ISS. b) 3 Core Cables. c) 2 core cable. i) Inner and outer sheathing shall be provided by separate operation process only. ii) Where inner and outer sheathing are to be provided with PVC compound (by separate operation) the sheathing are to be provided by pressure extrusion process. iii) Where inner sheathing is to be provided with thermo plastic material or proofed tape which shall not be harder than PVC used for insulating and outer sheathing shall be provided with pressure extrusion process. Note:- Cable with sheathing by sleeves extrusion shall not be accepted. SIZES:- The normal sizes of the cables shall be as per schedule of requirements as per requirement. TESTS:TYPE TESTS:The equipment should be offered type test. Test reports should not more then seven years old reckoned from date of bid opening in respect of all the tests carried out in accredited laboratories (based on ISO/IEC) by a reputed accreditatic body or witnessed by HVPN or i) ii) iii) iv) v) Maximum ambient temperature Minimum ambient temperature Maximum relative humidity Minimum relative humidity Altitude
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4 4.1
5. 6. 6.1
6.2 6.3
7.
8.
8.1
another electric power utility and be submitted by the successful bidder to HVPNL for approval as schedule given in Bar Chart. i) Tensile Test ii) Wrapping Test iv) Annealing Test v) Resistance Test ROUTINE TEST As per quality assurance program (QAP) ACCEPTANCE TEST:- The following acceptance tests as stipulated in the relevant IS8130:1984 shall be carried out by the Supplier in presence of HVPNL representative, unless dispensed with in writing by the HVPNL. a) Tensile test. b) Wrapping test. c) Resistance test. d) Annealing test. MANUFACTURER IDENTIFICATION:- HVPNL alongwith brand name, manufacturer name, voltage rating, size and year of manufacture in English shall be embossed on the outer sheath of the cable at regular intervals of approximately 1 to 1.5 metre. INSPECTION AND TEST:- An authorised representative of the HVPNL shall inspect, examine and test the equipment/ material in respect of quality, size and ratings as per ISS/ IEC mentioned above at the manufacturers works during or after the manufacture of goods prior to dispatch on receipt of a clear notice of minimum two weeks in advance to be reckoned from the date of receipt of the same by the HVPNL. No material will be allowed to be dispatched without prior inspection and approval. The inspecting officer of the HVPNL may also inspect the material during the course of manufacture. In case, inspection of any consignment is waived off by the HVPNL, the Contractor will be required to furnish the requisite test certificates (for acceptance as well as routine tests) for approval. It will be the responsibility of the Contractor to make adequate arrangements for testing of material at their works without any additional charge to the HVPNL. All testing instruments and appliances will be made available and material destroyed/ consumed during testing will be to the account of the Contractor. SAMPLING OF CABLES:a) Scale of sampling:- Samples shall be taken and tested from each lot for ascertaining the conformity of the lot to the required specifications. b) The number of samples to be selected as per table given below at random (the randomness of selection, random number tables shall be used as per IS:4905-1968. No. of drums to be taken permissible number of as sample (a). S.No. of drums/ No. of No. of drums to be Permissible number of coils/ reels in lot. taken as sample. refectives. (n) (n) (n) Upto 50 3 0 51 to 100 5 0 101 to 300 13 0 301 to 500 20 1 501 to above 31 2 The inspector shall have the option to take the sample (s) from any point in the length of any drums selected at random for carrying out various tests and total length of that particular drum(s) of such two pieces because of this sampling in such a particular case will be considered as one length. PACKING:- The cable shall be packed and supplied in non-returnable wooden drums provided with cast iron bushings to resist any damage during transit. Material offered for inspection should be duly packed provided with blank lead seals for the purpose of sealing by the Inspecting Officer. The Contractor will put their own seals also on the two ends of the cables.
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9.
10.
DRUM LENGTH:- The cable shall be supplied in standard lengths as under:Cable upto 185 sq.mm. = 500 Metres + 5% Cable above 185 sq.mm. = 250 Metres + 5% Non standards lengths not less than 100 metres each shall be acceptable upto 5% of the ordered quantity. A tolerance of + 5% is permissible allotted to each consignee with overall + 2% tolerance on the ordered quantity for completion of order. MARKING:- The marking on the drums shall have the following informations:a) Trade mark, if any. b) Name of the manufacturer. c) Nominal cross sectional area of conductor of the cable. d) Year of manufacture. e) Type of cable and voltage for which it is suitable. f) Length of cable on the drum/ reel. g) Approximate gross weight. h) Number of cores and colour of cores. i) Net weight of the cable. j) Drum/ reel identification no. k) Purchase Order No. and Date. l) Consignees name with designation. m) ISI mark/ IEC mark. n) Direction of rotation of drum/ reel (by means of an arrow). o) Reference IS:1554/Part-I/1988.
11.
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1.
SECTION-6 CHAPTER-11 TECHNICAL SPECIFICATION FOR 11 kV CROSS LINKED ETHYLENE INSULATED PVC SHEATHED SINGLE CORE AND THREE CORE POWER CABLES SCOPE This specification covers the design, manufacture, testing, inspection at manufacturers work, supply & delivery F.O.R. destination of 630mm2 Single Core XLPE insulated PVC sheathed Cable and three core XLPE cable suitable for solidly grounded system size as per clause(5) mentioned below. PARTICULARS OF THE SYSTEM The cable should be suitable for use on 50 Cycles, 3 Phases solidly earth neutral system & working voltage of 11kV. STANDARDS The cable covered under this Specification shall conform in all respects with the latest editions of IS-7098 (Part-2) 1985 & IS-8130-1984 & IEC:502 of the latest version thereof. TECHNICAL PARTICULARS 11kV, Single Core under ground XLPE insulated PVC sheathed cable suitable for working potential of 11kV on earthed system manufactured in accordance with IS-7098 (Part-2) 1985 with latest amendments. The Aluminium conductor shall comply with requirements specified in IS:8130-1984. The insulation shall be chemically cross-linked polyethylene confirming to the physical, electrical and ageing property as required in latest edition of IS-7098 (Part-2) 1985. Cable shall be provided with both conductor screening and insulation screening. The conductor screening shall be non-metallic and shall be consisting of either semi-conducting tape or a layer of semi-conducting compound or combination of two. The insulation screening shall consist of non-metallic semi conducting tape of extruded semi conducting compound layer in combination with non-magnetic metallic shield. Armouring shall be arranged over the core and it shall be of non-magnetic material. The material for the Armouring shall be as per relevant ISS. Over the Armouring the cable shall be provided with extruded PVC outer sheath. The composition of PVC compound shall be type ST-2 of iS5831-1984. The colour of outer sheath shall be black or grey. SIZE The different size of the cable shall be: a) Single Core 630mm2 . b) Three Core 300mm2. c) Three Core 185mm2. d) Three Core 50mm2. TESTS Type Tests The equipment should be offered type test. Test reports should not more then seven years old reckoned from date of bid opening in respect of all the tests carried out in accredited laboratories (based on ISO/IEC) by a reputed accreditatic body or witnessed by HVPN or another electric power utility and be submitted by the successful bidder to HVPNL for approval as schedule given in Bar Chart. i) Physical tests for insulation and outer sheath. ii) Bending test. iii) Di-electrical power factor test. iv) Heating cycle test followed by di-electrical power factor as a function of voltage and partial discharge test. v) Impulse withstand test. The remaining type test report as per clause 3 of ISS-7098/IEC-871 shall be submitted by the successful bidder within three months from the date of placement of order. These type test reports shall be from Govt./Govt. approved test house OR from reputed Lab Abroad and shall not be more than seven years old, reckoned from the date of placement of order. The failure to do so will be considered as a breach of contract. ROUTINE TESTS AND ACCEPTANCE TESTS All routine and acceptance tests shall be carried as per relevant ISS in the presence of Nigams representative.
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2.
3.
4.
5.
6. 6.1
6.2
7.
8.
INSPECTION The material shall be inspected and tested before dispatch by an authorised representative of the Nigam in respect of quality. The inspecting officer shall also satisfy himself about the correctness of length of cables as provided in Instruction No. 208 of E.B. Manual of Instruction 1963 Edition amended vide O/O No. G/BD-33(57) 75 dt. 18.04.75 now HVPNL. In case the Bidder is not in a position to get these tests carried out at his works, such tests may be got carried out by him at any Govt. recognized test agency OR from reputed Lab Abroad at his own expense. TEST CERTIFICATES The Bidder shall supply test certificates from a Govt. agency OR from reputed Lab Abroad in respect of quality as per IS:7098(part-II) 1985 with latest amendments thereof for approval of the HVPNL. PACKING The cable shall be supplied in non-returnable wooden drum as per IS:10418:1982 so constructed, as to enable the cable to be transported on each drum. The cable wound on such drum shall be one continuous length. The ends of cables shall be sealed by means of non-hygroscopic sealing material.
9.
10.
MARKING The marking on the drum shall have the following information: a) Reference to Indian Standard & cable code. b) Name of the manufacturer & trade name. c) Nominal cross section area of conductor for the cables. d) Number of core. e) Sequential No. at each meter. f) Type of the cable & voltage for which it is suitable. g) Length of cable on the drum. h) Approximate gross weight. i) Net weight of the cable. j) Drum identification number. k) P.O. No. and date. l) Consignees name with designation. m) Year of manufacture. Note: Cable should be marked with ISI Certification mark. 11. DRAWINGS & INSTRUCTION MANUAL The tenderer shall supply the following drawings with the tender: i) Detailed drawing of the cable showing conductor, screening insulation, Armouring, outer sheath etc. ii) Detailed drawing showing jointing of cable and sealing of end boxes. Copies of instruction manuals for testing, installation jointing operation and maintenance of cables, shall also be submitted with the offer for reference of the HVPNL.
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SECTION 6 CHPATER 12 33kV CAPACITOR WITH ALLIED EQUIPMENT 1. GENERAL: This specification covers the basic requirements in respect of Capacitor Banks with internal/external fuse, mounting racks, supporting structures complete in all respect along with series reactors wherever required for installation at various 220/66/33kV S/Stn. STANDARDS The shunt capacitor bank and associated equipment shall conform to the latest additions of the following standards except to the extent explicitly modified in the specification and shall also be in accordance with requirements specified in Chapter- GEN and Chapter- TR of this specification. a) Capacitor IEC/871-1/87/ IS:13925(Part-1) 1998 b) Series Reactor IS:5553 c) Internal fuse IEC593 d) External fuse IEC549/IS 9402 GENERAL ARRANGEMENT OF CAPACITOR BANKS a) The Capacitor banks shall be of outdoor type suitable for operation in the climatic conditions as given in this specification and mounted on steel racks and structure with suitable insulators as required to be supplied by the bidder. b) The bidder shall furnish details of connections between the Capacitor units and groups together with layout diagram showing the basic arrangement of banks complete with dimensions. DESIGN CRITERIA REQUIREMENTS AND CONSTRUCTIONAL DETAILS OF CAPACITORS. i) 33kV rating Capacitor Bank shall be made up either by two groups of star connected or single groups star connected banks un-earthed, with a floating neutral but connected by a neutral protective current transformer (NCT) of suitable ratio to operate Protective relays. ii) The protective scheme shall be by a two step relay one step current arranged as follows: If the failure of one or more units causes an over-voltage of less than 10% tolerable on the other remaining healthy units, then the unbalance current shall cause in the first step to sound an alarm. But if more than the above number of units fail causing a voltage rise of more than 10% then the unbalance current shall cause to trip and isolate the capacitor bank instantaneously. iii) The per phase and individual star group rating shall be built by series parallel combination of individual unit so as to achieve the desired bank rating. The individual capacity rating shall be as per IS:13925 Part-I. All parallel units in one series group shall preferably be arranged in different tiers, that is, one series group shall be duly insulated from one another by post insulators adequate to withstand the voltage that may be impressed and shall be sufficient to withstand even in case of total failure be duly insulated from the earth potential by supporting post insulators. Although the tolerances in the output rating of each individual units shall be as per IS:13925. Yet it shall be ensured that in a completely assembled bank, the departures from the nominal rating and within the specified tolerances values shall
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2.
3.
4.
iv)
v)
not cause nuisance alarm or tripping since such alarm or tripping shall be to meet only with the protective requirements specified. vi) The tolerance in the output ratings shall not cause departures in the line currents by that value specified in IS: 13925. Besides it shall also be ensured that these unsymmetrical current shall not cause unsymmetrical voltage rise, whether for a short period or during prolonged operation. Individual units shall be designed to meet with the requirements of the permissible overloads as specified as per IS: 13925. Each unit shall also be provided with internal discharging devices complying with the requirements of IS. The voltage rating of the NCT shall be decided by the Contractor by taking into consideration the voltage impressed on the NCT due to: a) Failure of one or more parallel units in a series bank. b) Voltage impressed on the NCT when all the parallel units in one series bank fail simultaneously. The bidders shall furnish along with the bid design calculations for the same.
vii)
viii)
5.
CAPACITOR UNITS: a) Each capacitor unit in the Bank shall be self contained outdoor type having 2 bushing suitably rated for series/parallel connections with other units to form the capacitor bank of rated capacity at 50Hz. The bushing shall be of porcelain and shall be joined to case preferably by welding. b) The capacitor unit shall be manufactured using imported and of best quality obtainable in the international market, non-PCB impermanent and polypropylene as di-electric. Vendors technical specification and test certificate shall be furnished alongwith the bid. The impregnation shall be carried out under high degree of vacuum and the unit shall be of totally sealed type. c) Each capacitor unit shall be provided with a internal discharge resistor designed to drain the phase voltage of the bank to 50 V or less within 5 minute after disconnection from the supply. d) Each capacitor unit shall be suitable for continuous operation at least 1.3 times the rated current at rated voltage of the bank and frequency. This over current factor shall include the combined effect of presence of harmonics and over voltage upto 1.1 times rated voltage. e) The container of capacitor unit shall be of stainless steel or CRCA steel painted with suitable anti rust primer and two finishing coats of paint as per manufacturers standard practice. The container shall be made from contraction due to all ambient and loading conditions expected during the life of the unit. f) The design of internally fused capacitor units shall be such that it shall permit upto 40% element failure in series group without passing more than 10% over voltage on other healthy units. g) Each capacitors units shall be mounted so that it can be easily removed from the racks and replaced without removing other units, de-assembling any portion of the rack. PROTECTIVE FUSES: The capacitor unit shall be provided with either internal or external fuses as per standard practice of the manufacturer. CAPACITOR UNITS WITH INTERNAL FUSES: The internal fuses shall conform to IEC: 593/IS:12762 and the Bidder shall furnish type test certificates for compliance with IEC/IS
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6.
6.1
a)
b) c)
The design of the internal fuse shall be same that residues from fuse operation(s) shall not cause deterioration of the impregnating fluid. The fuse assembly shall be distinct and separate from element packs and so constructed that operation of fuse indoor worst condition does not affect the other healthy elements. The fuses shall not melt or deteriorate when subjected to inrush currents, which occur during the life of the bank. The design of the fuse shall be such that it shall isolate only the faulty element and the operation of the fuse shall not affect the other healthy element.
6.2
CAPACITOR UNIT WITH EXTERNAL FUSES: a) The external fuses shall be of current limiting (HRC) type. The fuse system shall in any event be designed to ensure that the energy released into faulty capacitor units is less than the value that will cause rupture or bursting of the container. The fuses shall conform to IEC:549/IS:9402 and Bidder shall furnish type test certificate for compliance with IEC/IS. b) The characteristics of the fuse shall be such that it shall isolate the faulty unit only and prevent it from mechanical destruction due to internal faults. The capacitor unit together with external fuses shall be arranged in the bank by providing adequate clearance between the body of the capacitor units of a phase and the line terminal or the common bus for the units of the other phases to obviate the possibility of occurrence of bird faults. The fuse shall isolate the faulty capacitor unit only and the healthy capacitor units shall not be affected in anyway be the isolation of faulty unit. The fuses shall not melt or deteriorate when subjected to inrush currents, which occur during the life of the bank. The external distance between two metal ends of the fuse shall comply with specified creepage distance (i.e., the length of the insulating part of the fuse shall be such that the specified creepage distance is achieved).
c) d)
7.
The selection of fuse to be done in such a manner that characteristic of fuse shall match suitably with over current withstand characteristic of associated capacitor unit. f) The capacitor bank and protection shall be such that failure of one unit (i.e one external fuse operation) does not cause tripping of the bank. The bidder shall furnish detailed calculations in evidence of above alongwith the Bid. MOUNTING RACKS a) The mounting racks shall be hot dip galvanised steel sections. Each end of the rack shall have provision to receive incoming line connection. b) The racks shall be complete with rack insulators, foundation bolts or any other hardware etc. for assembly into complete bank. The height of the racks of capacitor banks shall be such that for making electrical connections with other equipment, proper electrical clearances are maintained. The capacitor bank along with its mounting racks and series reactor and null CT shall be suitable for installation on the plinth and the enclosure shall be suitably fenced.
e)
c)
d)
8. 8.1
TESTS Type Test: The equipment should be offered type test. Test reports should not more then seven years old reckoned from date of bid opening in respect of all the tests carried out in accredited laboratories (based on ISO/IEC) by a reputed accreditatic body or witnessed by HVPN or
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another electric power utility and be submitted by the successful bidder to HVPNL for approval as schedule given in Bar Chart. i) Thermal Stability Test ii) Capacitor Loss tangent measurement at elevated temperature iii) AC Voltage Test between terminal and containers iv) Lightening impulse voltage test between terminal and containers v) Short circuit discharge test 8.2 8.3 ROUTINE TESTS: As per quality assurance program (QAP). Acceptance & Routine Test: The following acceptance tests as stipulated in the relevant IS: 13925 (PART-I) 1998 shall be carried out by the Supplier in presence of HVPNL representative, unless dispensed with in writing by the HVPNL. i) Visual examination ii) Measurement of capacitance iii) Voltage test between terminals iv) AC Voltage test between terminal container v) Test of discharge device vi) Capacitor Loss tangent measurement at elevated temperature vii) Ceiling test SERIES REACTORS: The series reactor of small size is required for limiting the inrush current. The series reactor shall be outdoor type, 50Hz, air cooled, air core type and suitable for operation in climatic conditions specified. Series reactors shall be capable of withstanding the specified short circuit currents. The percentage series reactance shall preferably be 0.2%. The series reactors shall conform to type tests and shall be subjected to routine tests as per IS. TESTS Type Test: The equipment should be offered type test. Test reports should not more then seven years old reckoned from date of bid opening in respect of all the tests carried out in accredited laboratories (based on ISO/IEC) by a reputed accreditatic body or witnessed by HVPN or another electric power utility and be submitted by the successful bidder to HVPNL for approval as schedule given in Bar Chart. i) Temperature Rise Test ii) Impulse voltage withstand test Routine Tests As per quality assurance program (QAP). Acceptance Tests The following acceptance tests as stipulated in the relevant IS: 5553 (PART-III) 1970 shall be carried out by the Supplier in presence of HVPNL representative, unless dispensed with in writing by the HVPNL. i) Measurement of winding resistance ii) Measurement of current and impedance iii) Separate source voltage withstand test
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9. 9.1
9.2 9.3 9.4 10. 10.1
10.2 10.3
iv) Induced over voltage withstand test or impulse voltage withstand test v) Measurement of insulation resistance 11. TECHNICAL PARAMETERS OF CAPACITORS,SERIES REACTORS & NCT. Sr. No a. b. ITEM SPECIFICATION 33 5.43+5.43 (separated by Isolators as per arrangement shown in drg.) 38 7200+7200 External/ Internal fuse
11.1(a) CAPACITOR for S/Stn. where 2 No. bays are available.
Nominal system voltage (kV) MVAR Capacitor required at (MVAR) nominal system voltage Rated voltage of the (kV) Capacitor Bank Rated output of Cap. Bank (KVAR) at rated voltage Protection of capacitor units Type of connection Rating of Cap. Units with KVAR internal fuse Power loss (tan delta) including loss in the fuse
c. d. e. f. g. h.
7.3 KV 200 Not to exceed 0.2 W per KVAR subject to tolerance as per applicable standards. Max. permissible overloads with reference to voltage current and reactive output shall conform to applicable standards. Un-grounded Not less than 100 times rated current.
i.
Permissible overloads
j. k. l.
Type of grounding Capacity to receive inrush current Temperature category
The capacitors shall be suitable for maximum ambient temperature of 50 deg. C. Adequate care should be taken to protect the capacitors from direct sun radiation on account of outdoor installations. Note: The capacitor bank shall be capable of running either half unit or full unit based on requirement of load. These shall be controlled by single breaker but two isolators. Series reactors shall be arranged accordingly. The maximum bay space available for two part capacitor bank shall be equivalent to 11400 mm (indicative sketch attached at Annexure-1). Special requirement of protection, if any, for two part operation of capacitor bank shall be brought out by the bidder. For single part capacitor unit the bay space available is 5700mm. 11.1(b) CAPACITOR for S/Stn. where 1 No. bay is available. Sr. No a. b. ITEM Nominal system voltage SPECIFICATION (kV) 33 10.872
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MVAR Capacitor required (MVAR)
c. d. e. f. g.
at nominal system voltage Rated voltage of the (kV) Capacitor Bank Rated output of Cap. Bank (KVAR) at rated voltage Protection of capacitor units Type of connection Rating of Cap. Units with KVAR internal fuse Power loss (tan delta) including loss in the fuse
38 14400 External/ Internal Fuse 7.3 KV 400 Not to exceed 0.2 W per KVAR subject to tolerance as per applicable standards. Max. permissible overloads with reference to voltage current and reactive output shall conform to applicable standards. Un-grounded Not less than 100 times rated current. The capacitors shall be suitable for maximum ambient temperature of 50 deg. C. Adequate care should be taken to protect the capacitors from direct sun radiation on account of outdoor installations. Specification
h.
i.
Permissible overloads
j. k.
Type of grounding Capacity to receive inrush current Temperature category
l.
11.2
36 Air core 0.2% of capacitor bank rating to be connected on neutral end d. Insulation levels Impulse withstand 170 voltage /power frequency with stand 70 voltage e. Short-time withstand capacity and 16 times of 130% rated current of duration capacitor bank for 3 seconds. f. Linear characteristic Upto 1.5 pu. g. Continuous rating 130% of rated current of capacitor bank. Note: For 100 MVA, 220/33kV T/F Capacitor bank of capacity 2x10.872 MVAR to be installed per bay. 11.3 NEUTRAL CURRENT T/F (4.7) Highest system voltage 36 kV Rated voltage 33 kV
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SERIES REACTORS Sr. Item No. a. Rated voltage b. Type c. Rating of series reactors
Reference standard Ratio Rated VA Burden Core-I Core-II Accuracy class Core-I Core-II i)Accuracy limit factor Core-I ii) Instrument security factor Core-II Creepage distance Minimum insulation voltage
IS-2705 To be suitably designed by the bidder as per actual requirement 15 15 5P 1 Not less than 10 Not exceeding 5 900 15 kV
12.0 CAPACITOR LOSSES The capacitor shall be of low loss type. The losses in watts for each capacitor unit including losses in fuses and discharge resistors forming integral part of the capacitors along with losses for series reactor shall be guaranteed. If the test figures of capacitor losses exceed 0.18 W/KVAR, the capacitors will be liable for rejection. Total losses shall be complied as below: 6*(W*n+losses in series reactor) where n is number of capacitor units per phase of star connection and W is the total loss in a capacitor unit. 13.0 DOCUMENTATION The successful bidder shall submit four sets of drawings for HVPNL approval. NOTE: All above drawings should be a minimum space (14x10cm) for stamping the approval of drawings by HVPNL.
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SECTION-6 CHAPTER-13 TECHNICAL SPECIFICATION FOR 11 KV SHUNT CAPACITORS 1. SCOPE The specification covers the design. Manufacture, testing at manufacturers works before despatch, supply and delivery F.O.R. Destination of the following equipment: i) Capacitor banks complete with capacitor units provided with external fuses and internal discharge resistors, mounting racks arrangement, bus bar and connecting material, Post insulators and other accessories etc. ii) Residual voltage transformer. iii) 11 KV, 400/630 Amps. Line cum earth switch. iv) Pedestal /structure of above equipment. v) Terminal connectors for above equipment. PARTICULARS OF THE SYSTEM The capacitor banks & RVT are required for use on 11 KV, 3 Phase, 3 wire , AC 50 Hz 2.5 Hz solidly earthed system. Normally where 11 KV winding of power transformers are star connected, the neutral shall be solidly grounded. The maximum short circuit level at the S/Stn is 18.4 KA, auxiliary supply available will be single phase 230 + 10%, 415 Volt + 10%, 3 phase AC & 220 Volt 10% DC. STANDARDS The capacitor units/banks shall conform to IS:13925/Part-I/1998 (with latest edition) RVT to ISS-3156 & L&E Switch to ISS-9921 or their respective IECs. All other equipment shall also comply generally with requirement of the latest editions of the relevant Indian Standards. Deviations from these standard Specifications, if any, should be clearly brought out in the tender and furnished. SERVICE CONDITIONS: As per section-1 Vol-II. TROPICAL TREATMENT AND PAINT All corrodible parts & surfaces shall be of such material and shall be provided with such paints or to other protective finish that no part of the installed equipment shall be injuriously affected by the atmospheric moisture and heat. INSTRUCTION PLATE AND MARKING All name plates, instruction plates, warning signs and any other marking what-so-ever in the equipment and its parts and accessories shall be English/Hindi using idioms, words and meanings in current use in India. In order to facilitate sorting and erection at site, every part of the plant and equipment, shall be suitably marked, these marking shall correspond to similar marks on the assembly drawings. EARTHING All metallic parts not meant to be connected to live circuits shall be earthed. All earthing connections shall be of the bolt and clamp type secured with lock nuts. RATING OF EQUIPMENT The rating of equipment and other particulars such as nominal system voltage, one minute power frequency withstand voltage, standard impulse withstand voltage and rating of banks/unit in KVAR, is as under: (a) Upto20MVA Base T/F i) Nominal system voltage 11kV a) Rated voltage of Capacitor Bank. 12.65kV ii) b) Rated output of Capacitor Bank at rated 3000KVAR +6000KVAR voltage.
-1-
2.
3.
4. 5.
6.
7.
8.0
iii) iv) v) vi) vii)
viii) ix) x)
185sq.mm/300 sq.mm 2 No. (one for each Capacitor bank) Note: -Both the Capacitor Banks i.e.3000 KVAR and 6000 KVAR will be controlled by single 11 KV VCB. (b) For 25/31.5MVA 66/11KV T/F Capacitor bank 2x6.804 MVAR i) Nominal system voltage 11kV 12.65kV9000 KVAR ii) c) Rated voltage of Capacitor Bank. d) Rated output of Capacitor Bank at rated voltage. iii) Connection of Capacitor Bank Single Star iv) Rating of capacitor unit with external fuses. 7.3 kV200 KVAR v) No. of units per bank with external fuses 45 Nos. vi) Capacitor KVAR available at Nominal system 6804 KVAR voltage (without series reactor) Insulation level. vii) c) Impulse withstand voltage 75 kV (Peak) 28 kV (rms) d) Power frequency withstand voltage. 630A viii) Line & earth-switch for each 9000KVAR Bank 400sq.mm XLPE Cable for each 9000KVAR Bank ix) 8.1 8.2 Series reactor for 31.5 MVA, 66/11 KV Transformers (Capacitor Bank 2x6.804 MVAR) SERIES REACTORS Sr. Item Specification No. a. Rated voltage (KV) 11 b. Type Air Core c. Rating of series reactors 0.2% of capacitor bank rating to be connected on neutral end d. Insulation levels Impulse withstand 75 voltage KV(p)/power frequency with 28 stand voltage KV(rms) e. Short-time withstand capacity and 16 times of 130% rated current of duration capacitor bank for 3 seconds. f. Linear characteristic Upto 1.5 pu. g. Continuous rating 130% of rated current of capacitor bank. (i) Type of capacitors The capacitors shall be of unit type suitable for outdoor installations having high dielectric strength special attention shall be paid in design of the capacitors to avoid any stresses due to expansion or contraction caused by the large variation of ambient temperature at site which may range from 2.50C to 500C. Scope of supply of capacitor banks shall include capacitor units/Residual voltage Transformer, 11kv Isolator with earth switch and all necessary supporting framework pedestals, bus bar connections, fuses connecting clamps. Terminal connector & accessories etc, required to complete/commission the bank. Each capacitor unit shall be self contained out-door type, with a rating as specified in clause 8
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Connection of Capacitor Bank Rating of capacitor unit with external fuses. No. of units per bank with external fuses Capacitor KVAR available at Nominal system voltage (without series reactor) Insulation level. a) Impulse withstand voltage b) Power frequency withstand voltage. Line & earth-switch for 3000/6000KVAR Bank XLPE Cable for 3000/6000KVAR Bank RVT
Single Star 7.3 kV200 KVAR 15+30Nos. 2268KVAR+4536KVAR
75 kV (Peak) 28 kV (rms) 400/630A
9.
above. The capacitors shall be rated tom operate at 500C upper limit of temperature category as per table 1 under clause 4.1 of IS-13925/Part-I/1998 or any other standard applicable. The capacitor shall be designed to withstand a continuous 10% over voltage and each unit shall satisfactorily operate at 130% of rated KVAR including factor of over-voltage, harmonic current and manufacturing tolerance. The bidders will furnish calculations to satisfy the above aspect. ii) Type of Dielectric/paper used The bidder shall only quote for non-PCB type impregnent a sper international norm. 10. PHYSICAL ARRANGEMENT OF BANK Each bank shall be connected in single star, neutral connected through a Residual voltage transformer. The no. of parallel units in each series group should be large enough so that failure of any one unit will not create an over-voltage of more than 10% on the remaining units in parallel with it. Detailed calculations regarding the voltage impressed upon the remaining parallel unit when one or more units get out of order in series group shall be attached with the bid. The bidder shall provide fully dimensioned general layout showing arrangement of capacitor units, spacing, stacks and steps, with his bid. The dimension of each unit shall also be shown. The bidder shall state total number of capacitor unit per bank. Number of series groups per phase, & number of units in a parallel group shall be included in the said general layout. MOUNTING RACK ASSY. AND MOUNTING STRUCTURE FOR CAPACITOR BANK The mounting racks and pedestals shall be of galvanised steel members with all galvanising carried out after completion of cutting, drilling and punching. Mounting racks shall be complete with rack insulators, Hardware etc. for assembly into complete banks. The height of mounting structure for Capacitor Banks shall be such that the min. clearance from live part to ground will be about 2.5 Meters. BUS BAR MATERIAL Suitable bus bar arrangement shall be proposed by the bidder and requisite quantity of bus bar material shall be provided for the bank. The normal current rating and the short time current rating of the bus may be specified. All the interconnecting material necessary for interconnecting the units series parallel combination shall be supplied. A warning instruction as DISCHARGE CAPACITORS BEFORE HANDLING shall be prominently marked in red. FUSES: Each capacitor unit shall be individually protected by explosion type fuse of suitable rating and interrupting capacity so that a faulty capacitor unit shall be disconnected by fuse. The fuse shall be satisfactory for operation under the ambient condition. The fuse shall have sufficient strength to withstand the mechanical stresses associated with their location. The following requirement for external type fuse shall be considered while selecting the right size of fuse: a) Ability to withstand the max. discharge current from a healthy capacitor. b) The fuse shall be capable of handling fault so as to avoid mechanical damage to adjacent unit. c) Discrimination between fuse protecting the faulty capacitor unit and those protecting healthy capacitor units. d) The operated fuse shall have visual indication so that it can be detected during periodic inspection. BUSHING: Bushings shall be of porcelain and shall be jointed to the case by solder sealing or other method which ensure an adequate permanent seal. Leads shall be brought out through one piece porcelain bushing solder sealed to the case cover. Before final sealing the entire
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11.
12.
13.
14.
assembly shall be vacuum impregnated with dielectric suitable for operation application from 2.50 C to 500 C ambient temperature. 15. CONTAINER: The container shall be made from sheet steel of thickness not less than 2mm (14 SWG). The out-side of the capacitor containers and other structures should have smooth and tidy look and should be coated with weather proof, corrosion-resistant paint of grey shade. The sheet container shall be suitably insulated from capacitor elements. Sufficient wall insulation shall be provided. LOSSES: The capacitor shall be of low loss type. The losses in watts for each capacitor unit including losses in fuses and discharge resistors forming integral part of the capacitors along with losses for series reactor shall be guaranteed. If the test figures of capacitor losses exceed 0.18W/KVAR, the capacitors will be liable for rejection. DISCHARGE DEVICE: Each capacitor unit shall be complete with suitable built in discharge resistors of adequate thermal rating suitable for discharging the residual voltage to 50 Volts or less, within 5 minutes (preferably less than 5 minutes) after disconnection from the supply. The recommendations of the bidder shall however, be fully detailed out in the bid. TERMINAL CONNECTORS The terminal connectors suitable for horizontal and vertical mounting and cable glands shall be included in the scope of supply, wherever required. RESIDUAL VOLTAGE TRANSFORMER The residual voltage transformer for the neutral voltage displacement relay shall be out-door type naturally cooled, with a ratio of (11000/3)/(110/3) 190 Volt with VA burden of 100 and accuracy class 3 as per IS:3156. it shall have primary connected in star and secondary in open delta to energise neutral voltage displacement relay and to discharge capacitor bank to voltage not exceeding 50 Volt in less than 5 minutes. All the type tests report(not more than seven years old) are required to be submitted along with the bid in case already conducted. Otherwise all the type tests will have to be carried out free of cost in the presence of HVPNLs representative at the time of inspection. 11kV 400/630 AMPS. LINE-CUM EARTH SWITCH The Isolator with earth switch shall be manually operated. Isolator should be provided with ON and OFF indicators, arrangement for mechanical interlock and padlocking. Isolator should be provided with auxiliary switches for their remote position indication on the control panel. The Isolator will be strictly as per IS-9921. The supporting structures are also required to be supplied for Isolator, the rate may be quoted separately. All the type tests report (not more than seven years old) are required to be submitted along with bid in case already conducted. Otherwise all the type tests will have to be carried out free of cost in the presence of HVPNLs representative at the time of inspection. FITTINGS AND ACCESSORIES Any fitting or accessories which might have not been mentioned in the Specification but which are usual or necessary for optimal performance of the equipment are to be provided by the Contractor without extra cost. All equipment must be complete in all respect, whether mentioned in the Specification or not. GUARANTEED DATA AND OTHER TECHNICAL PARTICULARS Guaranteed and other Technical particulars of capacitor bank, Capacitor Unit fuses, 11kV L&E switch & residual voltage transformer should be given in the form of Guaranteed Technical Particulars (Vol-III). Any other particular considered by the contractor may also be given in addition to those listed in the Appendices. TESTS AND INSPECTION No material shall be dsepatched without inspection and testing. The inspection may be carried out by the employer at any stage of manufacture. The bidder shall grant free access
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16.
17.
18.
19.
20.
20.a
21.
22.
to the employers representative at all (reasonable times during the manufacture of equipments) covered by the Specification. Inspection and acceptance of any equipment under this Specification by the employer, shall not relieve the contractor of his obligation of furnishing equipment in accordance with the Specification and shall not prevent subsequent rejection, if the equipment is found to be defective. The contractor shall keep the employer informed in advance, about the manufacturing programme. The contractor shall furnish to the employer works certificates at the time of giving an inspection call for inspection. 22.1 TYPE TESTS The equipment should be offered type test. Test reports should not more then seven years old reckoned from date of bid opening in respect of all the tests carried out in accredited laboratories (based on ISO/IEC) by a reputed accreditatic body or witnessed by HVPN or another electric power utility and be submitted by the successful bidder to HVPNL for approval as schedule given in Bar Chart. i) Thermal Stability test. ii) Partial discharge test. iii) Self-healing test. iv) Impulse voltage test between terminals and container. v) Capacitor discharge test. vi) Endurance test. The remaining type test report as per ISS-13925/IEC-871 shall be submitted by the successful bidder within three months from the date of placement of order. These type test reports shall be from Govt./Govt. approved test house OR from reputed Lab Abroad and shall not be more than seven years old, reckoned from the date of placement of order. The failure to do so will be considered as a breach of contract. ROUTINE TESTS AND ACCEPTANCE TESTS All routine and acceptance tests as specified in relevant ISS/IEC of respective equipment shall be carried out by the Contractor in the presence of employers representative without any additional payment. ENDURANCE TESTING OF CAPACITOR UNIT The endurance test as per the procedure given in IEC-871-2 shall be got conducted at CPRI Bangalore test laboratory to ensure that the capacitor will withstand the service conditions with a high degree of reliability. Test charges if any be quoted in the bid. In case this test has already been got conducted on similar rating of units from Govt./Govt. approved testing house OR from reputed Lab Abroad, copies of test report shall be submitted by bidder along with their bid. The employer reserves the right to carry out this test at Govt. test agency on one or more units, if felt necessary. DRAWINGS The bidder shall furnish one set of following drgs. along with their bid to check the stability of their equipment: 1. Out line general arrangement drg. of capacitor bank with detailed dimension of Capacitor Bank/Unit and structure with complete bill of material. 2. Electrical Layout drg. of Capacitor Bank showing spacing of each equipment. 3. Outline arrangement drawing of Capacitor Unit with detail dimensions. 4. Outline general arrangement drawing of 11kV RVT and of 11kV L&E Switch. 5. Terminal connector drawings for Capacitor Bank, RVT & L&E Switch. The successful bidder shall, within four weeks of placement of order, submit five sets of final versions of all the above said drawings for employers approval. The employer shall communicate his comments/approval on drawings to the contractor within a period of 4 weeks. The contractor shall, if necessary, modify the drawings and re-submit five copies of the modified drawings for employers approval, within one week from the date of employers comments. After receipt of employers approval the contractor shall, within two weeks submit
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22.2
22.3
23.
20 prints along with reproducible of the approved drawings and descriptive literatures on capacitor & all allied equipments covered by the Specification for employers use. 23.1 The manufacturing of the equipments shall be strictly in accordance with the approved drawings and no deviation shall be permitted without written approval of the employer. Approval of drawings by employer shall not relieve the contractor of any of his responsibility and liability for ensuring correctness and correct interpretation of the drawings for meeting the requirement of the latest version of applicable standard of engineering, design and workmanship and latest revision of relevant standards at the time of supply an employer shall have the power to reject any work or material which in his judgment is not in accordance there-with.
23.2
24.
DEPARTURE FROM SPECIFICATION Should the bidder wish to depart from the provisions of the Specification either on account of manufacturing practice or any other reasons, he should draw attention to the proposed points of departure in hisbid and submit such full information, drawing and Specification so that the merits of his proposal may be fully understood. The Specification shall be held binding unless the departure have been fully recorded as required above. PERFORMANCE The bidder shall submit details of similar static shunt capacitor banks and associated equipment supplied by them which are in operation for the last three years along with certificate from their customers in support of the satisfactory manufacture and operation of the static shunt capacitor bank and associated equipment.
25.
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SECTION 6 CHAPTER - 14 TECHNICAL SPECIFICATION FOR OUTDOOR MARSHALLING KIOSKS FOR SUBSTATION WITHOUT AUTOMATION
LIST OF CONTENTS
CLAUSE NO 1.0 2.0 3.0 4.0 5.0 6.0 7.0 DESCRIPTION SCOPE WORKMANSHIP AND MATERIAL PRINCIPAL PARAMETERS TESTS INSPECTION DOCUMENTATION PACKING AND FORWARDING PAGE NO. 2 2 2 7 7 8 9
C:\Documents and Settings\XENWB\Desktop\G-11 Website\Final Technical G-11- Pkg B 06.09.11\SECTION-6\Chapter-14 MK.Doc
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1.0
1.1
SCOPE :
This specification covers the manufacture and supply of 250 Terminals Marshalling Kiosks complete with all fittings for out door installations in Haryana State as per schedule of requirement and generally conforming to the Specifications laid down in the following pages.
1.2
It is not the intent to specify herein complete / all details of the design and construction of equipment. However, the equipment shall conform in all respects to high standards of engineering, design and workmanship and shall be capable of performing in continuous commercial operation up to the contractors guarantee acceptable to the employer. The equipment offered shall be complete in all aspects necessary for its effective and trouble free operation. All similar parts particularly movable ones shall be interchangeable.
2.0
WORKMANSHIP AND MATERIAL :

All materials used in the construction of marshalling kiosks, terminal connector blocks & other accessories/fitments shall be of the best quality obtainable of their respective kind and the whole work shall be of highest class and well finished.
3.0
PRINCIPAL PARAMETERS :
The Marshalling Kiosks covered in this Specification shall meet the Technical requirements listed hereunder: -
3.1
DESCRIPTION OF MARSHALLING KIOSK :

The marshalling kiosk to be suitable for pedestal mounting shall be made of sheet steel. The side panels and rear panels constituting three sides for the kiosk and its internal equipment mounting panel shall be fabricated with atleast 12SWG sheet steel whereas the doors and the roof in the form of a detachable canopy 1250 * 675 mm shall be made of 12 SWG sheet steel. The canopy shall be suitably fixed with the main cubicle with nut & bolts packed with gasket so as to provide no opening to inside and shall be sufficiently projected in all sides to prevent splash of rainwater to the inside of the marshalling kiosk. The Marshalling Kiosk excluding canopy will be 1400mm (height) * 1200mm (width) * 550mm (depth) complete with double door in front provided with pad-locking facility in the door handle. The doors of the Marshalling Kiosk will be hinged by means of die-cast hinges, each of which is split into two identical members, one fixed to the doorframe and the other to the door. A minimum of two sets of hinges will be provided on each side of the door. The hinge assembly shall be smoothly finished without any sharp corner and
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2-
should be small and compact yet with sufficient rigidity to withstand the weight of the door and to withstand the shocks due to swings of the door. The hinges should comprise of a locating pin on one die-cast body and a free hole on the other die-cast member. The inside edge of the doors shall be provided with 10mm thick synthetic rubber gasket. Further stiffener should be provided suitably in order to provide sufficient structural rigidity to the doors. One of the doors shall carry danger plate and other shall carry the label indicating the number of terminals provided, make and HVPNL PO reference for easy identification of equipment in our stores/field. The Marshalling Kiosk shall be bolted on the 550 mm high angle-iron frame work made of 40x40x5 mm MS angle braced (lengthwise) by 40x5 mm MS flat (depth-wise). The bottom of the kiosk will be fitted with 1000mm*225mm removable blank cable glands supporting plate to be drilled at site for fixing cable gland. The inside edges of Gland Plate shall be provided with 10 mm thick one side adhesive Synthetic Rubber Gasket with Nuts & Bolts. Overall tolerance in Dimensions shall be + 5%. The Marshalling Kiosk should be equipped with 1No. tubular space heater of atleast 60Watt 240VAC with toggle ON/OFF switch, 1No. 15A 3-pin socket with ON/OFF switch, 1No.Illuminating lamp with Lamp Holder and ON/OFF Switch complete with respective rewireable fuses and links. The said accessories shall be of reputed make. The switches, fuses and links will be located on the equipment mounting panel. The tubular space heater will be located at centre at the bottom of Marshalling Kiosk and shall have watt loss per unit surface of heater low enough to keep surface temperature well below visible heat. The Marshalling Kiosk shall be equipped with 3 No. earth test links made of tinned copper for CT circuits. The kiosk shall be provided with 2 studs on the main frame (one on each side) to effectively earth the body of the kiosk. THE MARSHALLING SHALL BE DUST, WATER AND VERMIN PROOF. THESE ASPECTS MAY BE CAREFULLY CONSIDERED DETAILS TO BY THE BIDDERS THEM MAY AND BE
NECESSARY
CONSTRUCTIONAL
ACHIEVE
HIGHLIGHTED IN THE BID.
3.2
METAL TREATMENT AND PAINTING :

The raw material used in the construction of Marshalling Kiosk and its fitments/accessories will be best of its kind, free from rust, cracks and flaws. The sheet steel employed for fabrication of Marshalling Kiosk shall be properly degreased and treated (chemically) to remove rust, scale and foreign adhering matter. A suitable high
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luster rust resisting primer shall be applied on the sheet steel which will be followed by application of an undercoat suitable to serve as base for finishing coat. The finishing coat on the exterior will be light Grey to shade 631 of IS:5 and interior will be glossy white and duly baked to give good adherence and finish. THE BIDDER MAY DETAIL OUT THEIR TECHNIQUE/METHOD OF METAL TREATMENT AND PAINTING IN THEIR BIDS.
3.3
TERMINAL BLOCK CONNECTORS :

Terminal block connectors built from cells of moulded dielectric virtually unbreakable (Malemine) having 5mm dia brass studs with two (terminals) studs per way are to be provided. The block moulding will shield the terminals requiring no end barrier or adjacent block to complete the insulation. The terminal block will be suitable for mounting on the standard rail in the normal right angles to the rail position. The terminal connector will conform to the following details: i) ii) Current and voltage rating Capacity 30 Amps, 660 VAC/900 VDC Up to three ring-tongue crimped copper wires of 6mm2 cross-sectional area. iii) Material for: a) Body Cells of moulded dielectric virtually unbreakable (Malemine). b) The channel on which terminal MS dully hot dip galvanised. blocks are to be fixed. c) d) e) Terminal studs and nuts Connecting Link Washer Tin coated Brass. Tin plated copper to IS-1897. Brass plain nickel plated washer (1 No. per stud). f) Spring Washer Spring steel (1 No. per stud)
Electroplated. g) iv)a) Star washer/teeth washer MS plated (1 No. per stud)
Terminal connectors should be Type Tested. Terminal Connectors for CT, PT & CVT shall have provision of splitting facilities and shorting links for measurement of CT currents without opening the CT and isolation of PT & CVT circuits. Terminal connectors used for CT, PT, CVT and AC Supply shall be suitable for Copper Control Cables having cross sectional area 4Sq.mm. For
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DC Supply, the terminal connectors shall be suitable for Copper Control Cables having cross sectional area 6Sq.mm. For control and interlocking circuits, the terminal connectors shall be suitable for Copper Control Cables having cross sectional area 2.5Sq.mm. Further, fuses & links of suitable rating shall be provided for 3 Phase 4 Wire AC Supply & 220 V DC Supply at TB-2. Out of total nos. of given terminals of the Marshalling Kiosks, terminal blocks for the 1st row TB-1 and 10th row TB-10 as per sketch shown at page 6 & 7 under clause 3.4 will be of splitting type 1st row TB-1 for measuring the CT current (without opening the CT secondary) and 10th row TB-10 PT/CVT circuits for providing isolation. 2nd row TB-2 to 9th row TB-9 will be of stud type. In 2nd row TB-2, Stud Type Terminal Connectors suitable for Copper Control Cables of 4Sq.mm & 6Sq.mm are to be provided as shown at page 6 & 7 under Cl. 3.4. In 3rd row TB-3 to 9th row TB-9 Terminal Connectors suitable for Copper Control Cables of 2.5Sq.mm cross sectional area. b) Terminal identification carrier The terminal block is to be complete with terminal identification carrier (see clause-3.4 for identification
numbers). v) Covers A clear nylon cover should be provided which can be clipped to the sides of the Terminal Block.
3.4
DISTRIBUTION OF TERMINALS AND THEIR IDENTIFICATION NUMBERS:

The total number of terminal in the Marshalling Kiosk will be distributed in ten rows. Terminal block connector rows shall be adequately spaced and in no case less than 100 mm apart center to center of the terminal block so as to permit convenient access to terminations. Labels in the form of plastic/steel plates carrying numerals for terminal identification shall be so mounted as to cause no interference with regard to access to terminal nuts. The numerals marked from top to bottom in ascending order starting from left-hand side as viewed from the front of Marshalling Kiosk and a progressively increasing from left-hand-side to right-hand-side in 250 terminals Marshalling Kiosks respectively.
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A)
250 Terminals Marshalling Kiosk (For 132kV Sub-Stations):

TB-1 1 2 3 TB-2 26 27 28
16Nos. TBs of 4Sq.mm
TB-9 201 202 203
TB-10 226 227 228
41 42 23 24 25 50
9 Nos. TBs of 6Sq.mm
223 224 225
248 249 250
4.0
4.1
TEST
Following tests shall be carried out at the manufacturers works after complete assembly of marshalling kiosks and the test reports of such tests supplied in quadruplicate for approval of the CE/MM, HVPNL, Panchkula before effecting despatch of the equipment:-
i)
Checking and verification of the dimensions, gauge of the sheet steel, angle-iron frame work, terminal block connector and its components etc. viz-a-viz the respective approved drawings(s).
ii) iii) iv)
Checking wiring of circuits and their continuity. One minute applied voltage tests for illumination/heater wiring in the marshalling kiosks. Insulation resistance of complete wiring, circuit by circuit, with the lamp/heater in the marshalling kiosks. mounted
5.0
i)
INSPECTION :
The Employer shall have access at all times to the works and all other places of manufacture, where the marshalling kiosks are being manufactured and the contractor shall provide Employer representative all facilities for unrestricted inspection of the works, raw materials, manufacture of all the accessories and for conducting necessary tests as detailed therein.
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ii)
The successful contractor shall keep the employer informed in advance of the time starting and of the progress of manufacture of equipment in its various stages and shall give prior notice of at least 15 days for inspection of material, so that arrangements could be made for inspection.
iii)
No. material shall be despatched from its point of manufacture unless the material has been satisfactorily inspected and tested.
iv)
The acceptance of any quality of the equipment shall in no way relieve the successful contractor of his responsibility for meeting all the requirements of this Specification and shall not prevent subsequent rejection if such material is later found to be defective.
6.0 6.1
DOCUMENTATION :
All drawings shall conform to international standards organisation (ISO) À' series of drawing sheet/Indian Standards Specification IS:11065. All drawings shall be in ink and suitable for microfilming / digitization / scanning, etc for archive purposes. If drawings are computerized than all drawings shall be nicely printed. All dimensions and data shall be in S.I.Units.
6.2
LIST OF DRAWINGS AND DOCUMENTS :

In addition to any other drawings which the bidder may like to enclose to explain the merits of his proposal. The following drawing shall be enclosed with the bid: -
i)
Dimensional drawing of the kiosk highlighting constructional features of the hinges and the junction of canopy with the cubical.
ii)
Dimensional drawing of the terminal connector block highlighting the material of various components forming it the label carrier and details of its arrangement in 10 rows.
iii)
Dimensional drawing showing the disposition of terminals in 10 rows as viewed from the front of the Marshalling Kiosk with its doors open and terminal identification numerals assigned to them.
iv) v) a) b) v)
Dimensional drawing showing top view with gland plate & side view of cubical. Bill of material for all accessories mounted in MK. Description of Item, Make, Type & QTY. of material provided. Voltage & current rating Catalogue of terminal connectors installed in Marshalling Kiosks for reference.
NOTE:-All above drawings should bear a minimum space (14X10cm) for stamping the approval of drawings by the employer.
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6.3
The successful bidder/contractor shall submit four sets of final versions of complete and correct equipment drawings for employers approval alongwith bid in a sealed envelope. The employer shall communicate his comments/approval on the drawings to the bidder/contractor within 21 days from the date of issue of LOI. The submission of complete and correct readable drawings for approval is the responsibility of the bidder/contractor. The contractor shall, if so required by the employer, modify the drawings and resubmit four copies of the modified drawings for employers approval within two weeks from the date of employers comments. Then, the employer shall approve the revised drawings within two weeks from the date of its receipt.
6.4
The manufacturing of the equipment shall be strictly in accordance with the approved drawings and no deviation shall be permitted without the written approval of the employer. All manufacturing and fabrication work in connection with the equipment prior to the approval of the drawing shall be at the bidder/contractor's risk.
6.5
The successful bidder/contractor shall also supply one set of nicely bound documents comprising all the approved drawings & instruction manual containing handling, installation, testing and commissioning of equipment at the time of despatch of material to the consignee with each equipment for our field staff without which the supply will not be considered as complete supply. In addition, 1 sets of such bound manuals and final approved drawings shall be supplied for reference & record in design office alongwith one good quality soft copy on a suitable media of approved drawings and instruction manuals, if computerized.
6.6
Approval of drawings / work by Employer shall not relieve the bidder/contractor of his responsibility and liability for ensuring correctness and correct interpretation of the latest revision of applicable standards, rules and codes of practices. The equipment shall conform in all respects to high standards of engineering, design, workmanship and latest revisions of relevant standards at the time of ordering and employer shall have the power to reject any work or material which in his judgement is not in full accordance therewith.
7.0 7.1
PACKING AND FORWARDING :

The marshalling kiosks shall be securely packed to avoid scratches on the sheet steel & transit damage to various components constituting the marshalling kiosks. The bidder/contractor shall be responsible for any damage to the equipment during transit due to improper & inadequate packing. The easily damageable material shall be carefully packed & marked with the appropriate symbols.
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SECTION-7 TECHNICAL SPECIFICATION FOR SWITCHYARD ERECTION GENERAL This section covers the Technical requirements of various ancillary items and general switchyard erection practices. All ancillary items under the contractors scope of supply shall conform to the type tests and routine tests as per the relevant standards. STRING INSULATORS & HARDWARE GENERAL The insulators for suspension and tension strings shall conform to IS:731, long rod insulator shall conform to IEC-433(1980) and composite long rod insulator shall confirm to various standard mentioned in the specifications. Insulator Hardware shall conform to IS:2486. CONSTRUCTIONAL FEATURES Suspension and tension insulator shall be wet process porcelain with ball and socket connections. Insulator shall be interchangeable and shall be suitable for forming either suspension or strings. Each insulator shall have rated strength marking on porcelain printed and applied before firing. Porcelain used in insulator manufacture shall be homogeneous, free from Laminations, cavities and other flaws or imperfections that might affect the mechanical or dielectric quality and shall be thoroughly vitrified, tough and impervious to moisture. Glazing of the porcelain shall be uniform brown colour, free from blisters, burrs and other similar defects. When operating at normal rated voltage there shall be no electric discharge between conductor and insulator which would cause corrosion or injury to conductor or insulator by the formation of substances due to chemical action. No radio interferences shall be caused when operating at normal rated voltage. The design of the insulator shall be such that stresses due to expansion and contraction in any part of the insulator shall not lead to deterioration. All ferrous parts shall be hot dip galvanised in accordance with the latest edition of IS:2629. the zinc used for galvanising shall be of grade Zn-99.5 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 deposits and blisters. Bidder shall make available data on all the essential features of design including the method of assembly of discs and metal parts, number of discs per insulators, the manner in which mechanical stresses are transmitted through discs 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 Insulator Hardware shall conform to the requirements stipulated for clamps and connectors. All Hardware shall be designed for tensile load with a factor of safety 2. Insulator Hardware shall be of forged steel. Malleable cast iron shall not be accepted except for insulator disc cap. The surface of Hardware must be clean, smooth, without cuts, abrasion or projections. No part shall be subjected to excessive localized pressure. The metal parts shall not produce any noise-generating corona under operating conditions. The tension insulator string shall be designed for the required tensile load Earth wire tension clamp shall be designed for the required tensile load with a factor of safety two (2). The tension insulator string assembly shall be supplied along with suitable turnbuckle at the rate of one turnbuckle per string. All Hardware shall be bolted type. TESTS In accordance with the requirements stipulated in section1 and section2, the suspension and tension strings, insulator discs and Hardware shall be conform to type tests as per relevant IS/IEC and shall be subjected to the following acceptance tests and routine tests. ACCEPTANCE TESTS FOR DISC INSULATOR Visual Examination (IS 2486-1971) Part 1. Verification of Dimensions : Cl no. 10.5 IS:731-1971 Temperature cycle test: Cl no. 10.6 IS:731-1971 Puncture Test: Cl no. 10.10 IS:731-1971 Galvanising Test: CI no. 10.12 IS:731-1971 Mechanical performance test : IEC:575-1977 Cl.4 Test on locking device for ball and socket coupling IEC:372(2)-1976. Porosity test Cl no. 10.11 IS:7311-971. ACCEPTANCE TEST ON HARDWARE FITTING Visual Examination: CI. 5. 10 IS:2486 (Part-1). Verification of Dimensions :CI. 5.8 IS:2486 (part-I)-1971. Galvanizing/Electroplating tests : CI. 5.9 IS:2486 (Part-I)-1971 Slip strength test :CI 5.4 of IS:2486 (Part-I).
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1.0
1.1 1.1.1
1.2
1.3
1.3.1
1.3.2
1.3.3
1.3.4 a) b)
c)
d)
e)
1.4 1.4.1
1.4.2
Shore hardness test for the Elasto-meters (if applicable as per the value guaranteed by the Bidder). Mechanical strength test for each component. The load shall be so supplied that the component is stressed in the same way as it would be in actual service and the procedure as given in 13.1 (g) above should be followed. Test on locking devices for ball and socket coupling : IEC:372(2) 1976. ROUTINE TEST ON DISC INSULATOR/ LONG ROAD INSULATOR Visual inspection :Cl. No. 10.13 IS:731-1971. Mechanical Routine Test : Cl. No. 10.14 IS:731-1971. Electrical Routine Test: Cl. No. 10.15 IS:731-1971. ROUTINE TEST OF HARWARE FITTINGS Visual examination :Cl. 5.10 of IS-2486(I). Mechanical strength test: Cl. 5.10 of IS-2486 (I). Samples taken from the zinc ingot shall be chemically analyzed as per IS:209 - 1966. The purity of zinc shall not be less than 99.5%. Chemical Analysis, mechanical hardness tests and magnetic particle inspection for malleable casting: The chemical analysis, hardness tests and magnetic particle inspection for malleable castings will be as per the internationally recognised 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 HVPNL in Quality Assurance Program. 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. CHEMICAL ANALYSIS, 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 recognised procedures for these tests. The sampling will be based on heat number and heat treatment batch. PARAMETERS DISC INSULATORS a) Type of insulators : Anti Fog type b) Size of insulator units (mm) : 280 x 145 for 12000 kg. 255 x 145 for 9000/4500 kg. c) Electro mechanical strength : 12000/ 9000/ 4500 kg for Twin/ single conductor. d) Creepage distance of individual insulator units : Markings on porcelain shall be (minimum and as required to meet total creepage printed and applied before firing. distance).e) Markings. INSULATOR STRING 220 kV 132 kV 66 kV 33 kV 11 kV Power frequency withstand 460 kV (rms) 275 kV 140 kV 75 kV 28 kV (rms) voltage of the complete string with (rms) (rms) (rms) arcing horns (dry & wet) Lightning impulse withstand 1050 kV 650 kV 325 kV 170 kV 75 kV voltage of the complete string with corona control rings (+ and peaks) Power frequency puncture 1.3 times actual wet flashover voltage of the unit. withstand voltage for a string insulator unit. RIV level of the complete string 1000 micro volts with CC rings at 1.1 U/-3 (max) Total creepage distance of the ---------------- 25 mm/kV -----------------complete insulator string (mm) Total no. of discs per strings. 15 S/T 10 S/T 6 S/T 3 S/T 2 S/T 14 S/S 9 S/S 5 S/S 3 S/S 2 S/S Technical Description of Composite Long Rod Insulators Details of Composite Long Rod Insulators The insulators of the strings shall consist of composite long rod insulators for a three phase, 50 Hz, effectively earthed 220kV sub-station application in a very heavy polluted environment. Couplings shall be ball and socket type. Bidder shall quote such composite insulators which have proven use under foggy/humid operational conditions in polluted industrial environment combined with smoke and dust particles. The Bidder shall furnish evidence in the form of certification from the power utilities that the similar type of
-2-
1.4.3 1.4.3.1
S.No
1 1 2
1 2
1 2
1 2
1 2
1.4.3.2
1.4.3.3
1.4.3.4
1.4.3.5
1.4.3.6
product supplied to them had been performing satisfactory. The Bidder shall also submit certified test report for an accelerated ageing test of 5000 hours such as that described in Appendix-C of IEC-61109. Insulators shall have sheds of the open aerodynamic profile without any under ribs with good selfcleaning properties. Insulator shed profile, spacing projection etc. shall be strictly in accordance with the recommendation of IEC-60815. The size of long rod insulator, minimum creepage distance, the number to be used in different type of strings, their electromechanical strength and mechanical strength of insulator string alongwith hardware fittings shall be as follows: Type of *Size of Min. No. of ElectroMechanical String Composite Creepage individual Mechanical Strength of Insulator Distance Units per Strength of Insulator String (Core dia x (mm) String Insulator Unit along with Nominal (Nos.) (kN) Hardware Fittings length) (mm) (kN) 2 3 4 5 6 7 FOR 220kV AC yard of substations with AAC Tarantula/ACSR Zebra Conductor Single 20x2030 7595 1x1 90 90 Suspension Single 20x2175 7595 1x1 90 90 Tension FOR 132kV AC yard of substations with AAC Tarantula/ACSR Zebra Conductor Single 20x1305 4495 1x1 90 90 Suspension Single 20x1450 4495 1x1 90 90 Tension FOR 66kV AC yard of substations with AAC Tarantula/ACSR Zebra Conductor Single 20x725 2248 1x1 90 90 Suspension Single 20x870 2248 1x1 90 90 Tension FOR 33kV AC yard of substations with AAC Tarantula/ACSR Zebra Conductor Single 20x435 1124 1x1 90 90 Suspension Single 20x435 1124 1x1 90 90 Tension FOR 11kV AC yard of substations with AAC Tarantula/ACSR Zebra Conductor Single 20x290 750 1x1 90 90 Suspension Single 20x290 750 1x1 90 90 Tension Note: *The core dia of composite insulators mentioned at column No.3 is minimum requirement. The bidder shall offer composite long rod insulators of suitable core dia to meet specified E&M strength requirements. For offered core dia, the bidder shall submit documentary evidence of past supplies & satisfactory operation of the same for minimum period of three years. However, the overall string length shall be within the limits specified in the drawing. Pin and Cap Pin and cap shall be designed to transmit the mechanical stress and develop uniform mechanical strength in the insulator. The cap shall be circular with the inner and outer surfaces concentric of such design that it will not yield or distort under load conditions. The design shall be such as to permit easy removal of replacement of either insulator units or fittings under the live line conditions. Ball and Socket Designation The dimensions of the Ball and Socket shall be of 16mm designation for 90kN Insulator in accordance with the standard dimensions stated in IEC:120/ IS:2486 (Part-II). Dimensional Tolerance of Composite Insulators The tolerances on all dimensions e.g. diameter, length and creepage distance shall be allowed as follows: (0.04d+1.5) mm when d300 mm. (0.025d+6) mm when d>300 mm. Where, d being the dimensions in millimeters for diameter, length or creepage distance as the case may be. However, no negative tolerance shall be applicable to creepage distance. Interchangeability The composite long rod insulators inclusive of the ball & socket connection shall be standard design suitable for use with the hardware fittings of any make conforming to relevant IEC standards. Corona and RIV Performance
-3-
1.4.3.7
1.4.3.8 i)
ii)
iii)
iv)
1.4.3.9
All surfaces shall be clean, smooth, without cuts, abrasions or projections. No part shall be subjected to excessive localized pressure. The insulator and metal parts shall be so designed and manufactured that it shall avoid local corona formation and shall not generate any radio interference beyond specified limit under the operating conditions. Maintenance The long rod insulators offered shall be suitable for employment of hot line maintenance technique so that usual hot line operation can be carried out with ease, speed and safety. All insulators shall be designed to facilitate cleaning and insulators shall have the minimum practical number of sheds and grooves. All grooves shall be so proportioned that any dust deposit can be removed without difficulty either by wiping with a cloth or by remote washing under live line condition. Materials Core It shall be a glass-fiber reinforced (FRP rod) epoxy resin rod of high strength. Glass fibers and resin shall be optimized. The rod shall be electrical grade corrosion resistant (ECR), boron free glass and shall exhibit both high electrical integrity and high resistance to acid corrosion. Housing & Weather sheds The FRP rod shall be covered by a seamless sheath of a silicone rubber compound of a thickness of minimum 3mm. The housing & weather sheds should have silicon content of minimum 30% by weight. It should protect the FRP rod against environmental influences, external pollution and humidity. It shall be extruded or directly molded on the core. The interface between the housing and the core must be uniform and without voids. The strength of the bond shall be greater than the tearing strength of the polymer. The manufacturer shall follow non-destructive technique (N.D.T.) to check the quality of jointing of the housing interface with the core. The technique being followed with detailed procedure and sampling shall be furnished along with the bid. The details for this shall be finalized during detailed engineering and finalization of MQP. The weather sheds of the insulators shall be of alternate shed profile. The weather sheds shall be vulcanized to the sheath (extrusion process) or molded as part of the sheath (injection moulding process) and free from imperfections. The vulcanization for extrusion process shall be at high temperature and for injection moulding shall be at high temperature & high pressure. Any seams / burrs protruding axially along the insulator, resulting from the injection moulding process shall be removed completely without causing any damage to the housing. The track resistance of housing and shed material shall be class 1A4.5 according to IEC60587. The strength of the weather shed to sheath interface shall be greater than the tearing strength of the polymer. The composite insulator shall be capable of high pressure washing. End Fittings End fittings transmit the mechanical load to the core. They shall be made of malleable cast iron spheroidal graphite or forged steel. They shall be connected to the rod by means of a controlled compression technique. The manufacturer shall have in-process Acoustic emission arrangement or some other arrangement to ensure that there is no damage to the core during crimping. This verification shall be in-process and done on each insulator. The gap between fitting and sheath shall be sealed by a flexible silicone rubber compound. The system of attachment of end fitting to the rod shall provide superior sealing performance between housing and metal connection. The sealing must be humidity proof and durable with time. Grading Rings Grading rings shall be used at both ends of each composite insulator unit for reducing the voltage gradient on and within the insulator and to reduce radio and TV noise to acceptable levels. The size and placement of the metallic grading rings shall be designed to eliminate dry band arcing/corona cutting/ exceeding of permissible electrical stress of material. The bidder shall furnish calculations along with the proposed placement and design of corona ring in support of the above. Grading rings shall be capable of installation and removal with hot line tools without disassembling any other part of the insulator assembly. The supply of grading rings shall be in the scope of the composite insulator supplier. Workmanship All the materials shall be of latest design and conform to the best modern practices adopted in the extra high voltage field. Bidders shall offer only such insulators as are guaranteed by him to be satisfactory and suitable for transmission lines specified and will give continued good service. The design, manufacturing process and material control at various stages shall be such as to give maximum working load, highest mobility, best resistance to corrosion, good finish and elimination of sharp edges and corners to limit corona and radio interference. 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. The core shall be sound and free of cracks and voids that may adversely affect the insulators. Weather sheds shall be uniform in quality. They shall be clean, sound, smooth and free from gross defects and excessive flashing at parting lines. End fittings shall be free from cracks, seams, shrinks, air holes and rough edges. End fittings should be effectively, sealed to prevent moisture ingress, effectiveness of sealing system must be
-4-
1.4.3.10
a) b) c) d)
e) f) g) h)
supported by test documents. All surfaces of the metal parts shall be perfectly smooth with the projecting points or irregularities which may cause corona. All load bearing surfaces shall be smooth and uniform so as to distribute the loading stresses uniformly. All ferrous parts shall be hot dip galvanized to give a minimum average coating of zinc equivalent to 600 gm/sq.m. and shall be in accordance with the requirement of ISO:1461 (E) and shall satisfy the tests mentioned in ISO:1460 (E). The zinc used for galvanizing shall be of purity of 99.95%. The zinc coating shall be uniform, adherent, smooth, reasonably bright continuous and free from imperfections such as flux, ash rust stains, bulky white deposits and blisters. The galvanized metal parts shall be guaranteed to withstand at least six successive dips each lasting for one (1) minute duration under the standard preece test. The galvanizing shall be carried out only after any machining. Equipment Marking Each composite long rod unit shall be legibly and indelibly marked with the trade mark of the manufacturer, name of HVPNL and month & year of manufacture. The guaranteed combined mechanical and electrical strength shall be indicated in kilo Newton followed by the word kN to facilitate easy identification and to ensure proper use. One 10 mm thick ring or 20 mm thick spot of suitable quality of paint shall be marked on the cap/end fitting of each composite long rod of particular strength for easy identification of the type of insulator. The paint shall not have any deteriorating effect on the insulator performance. Following codes shall be used as identification mark : For 90 kN long rod unit : Orange Bid Drawings The Bidder shall furnish full description and illustration of the material offered. The Bidder shall furnish along with the bid the outline drawing (6 copies) of each insulator unit including a cross sectional view of the long rod insulator unit. The drawing shall include but not limited to the following information : Long rod diameter and ball to ball spacing with manufacturing tolerances Minimum Creepage distance with positive tolerance Protected creepage distance Eccentricity of the long rod unit Axial run out Radial run out Unit mechanical and electrical characteristics Size and weight of ball and socket parts Weight of composite long rod units Materials Identification mark Manufacturer's catalogue number After placement of award, the Supplier shall submit full dimensioned insulator drawings containing all the details as given in Clause No. 3.2 above, in four (4) copies to Employer for approval. After getting approval from Employer and successful completion of all the type tests, the Supplier shall submit 20 more copies of the same drawing to the Employer for further distribution and field use at Employer's end. After placement of award the Supplier shall also submit fully dimensioned insulator crate drawing for different type of insulators. After placement of award, the Supplier shall submit full dimensioned manufacturing drawing of composite long rod insulator unit in six (6) copies to the Employer for reference and record. Tests and Standards Type Tests The following type tests shall be conducted on long rod units, components, materials or complete strings: On the complete composite Long Rod Insulator String with Hardware Fittings Power frequency voltage withstand test with corona control IEC:383-1993/ rings/grading ring and arcing horns under wet condition Annexure A Switching surge voltage withstand test under wet condition IEC:383-1993 Impulse voltage withstand test under dry condition IEC:383-1993 Corona and RIV test under dry condition Annexure-A Mechanical Strength test Annexure-A Vibration test Annexure-A Salt-fog pollution withstand test Annexure-A On Composite Insulator Units Tests on interfaces and connections of metal fittings (Tests to be IEC: 61109 performed on the same samples in the sequence given below) i) Dry power frequency voltage test ii) Sudden load release test iii) Thermal mechanical test
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1.4.3.11
(a) (b) (c) (d) (e) (f) (g) (a)
(b)
(c) (d) (e)
(f) (g) (h) (i) (j)
a) b) c) d) d) e)
f)
a) b)
a) b) c) d)
iv) Water immersion test v) Steep front impulse voltage test vi) Dry power frequency voltage test Assembled core load time test IEC: 61109 i) Determination of the average failing load of the core of the assembled unit ii) Control of the slope of the strength time curve of the insulator Brittle fracture resistance test Annexure-A Test of housing, Tracking and erosion test IEC: 61109 Tests for the core material IEC:61109 i) Dye penetration test ii) Water diffusion test Flammability test IEC:61109 Recovery of Hydrophobicity test Annexure-A Mechanical Load Time test and test of tightness between end firings IEC:61109 and insulator housing Silicone content test Annexure-A High Pressure washing test Annexure-A All the type test given in Clause No. 4.1.1 shall be conducted on Single I suspension, Double tension, Double I suspension & Quadruple tension insulator string along with hardware fittings. All the type tests given in Clause No. 4.1.1 (a) to (e) shall also be conducted on Single 'I' Pilot suspension & Single tension insulator string along with hardware fittings. Acceptance Tests: For Composite Long Rod Insulators Verification of dimensions IEC : 61109 Galvanising test IEC : 60383 Verification of locking system IEC : 60383 Verification of tightness of interface between end fittings and IEC : 61109 insulator housing and of specified mechanical load Recovery of Hydrophobicity Annexure-A Tests on interfaces and connections of metal fittings (Tests to be IEC: 61109 performed on the same samples in the sequence given below i) Dry power frequency voltage test ii) Sudden load release test iii) Thermal mechanical test iv) Water immersion test v) Steep front impulse voltage test vi) Dry power frequency voltage test Silicone content test Annexure-A The test 4.2.1.(e) shall be carried out in case total quantity of insulators of a particular rating exceeds 5000 nos. The test 4.2.1.(f) shall be done against each lot or against every 5000 nos. of insulators whichever is less. In the event of failure of the sample to satisfy the acceptance test(s) specified in 4.2 above, the retest procedure shall be as per clause 7.6 of IEC 61109. Routine Tests For Composite Long Rod Insulator Units Visual Inspection As per IEC:61109 Mechanical routine test As per IEC:61109 Tests During Manufacture On all components as applicable Chemical analysis of zinc used for galvanising As per Annexure-A Chemical analysis, mechanical, metallographic test and magnetic As per Annexure-A particle inspection for malleable castings. Chemical analysis hardness tests and magnetic particle inspection for As per Annexure-A forgings Tracking and erosion test on insulating material IEC 60587 Testing Expenses Testing charges for the type test specified shall be indicated separately in the prescribed schedule. Bidder shall indicate unit type test charges for all type tests covered under Clause 4.1.1 and 4.1.2 separately, in the relevant schedule of Prices as applicable. Charges for each type tests shall be separately indicated. For Type Tests which involves the tests on the complete insulator string with hardware fitting, the Contractor of hardware fittings shall supply the necessary number of sets of hardware fittings at the place of testing free of cost. In case of failure in any type test the supplier whose material has failed is either required to modify the design of the material & successfully carryout all the type tests as has been detailed out in
-6-
a) b) c) d)
1.4.3.12
Clause 4.1 of this specifications or to repeat that particular type test at least three times successfully at his own expenses. In case of failure of the complete string in any type test, the manufacturer whose product has failed in the test shall get the test repeated at his cost. The Supplier whose material has not failed in the test shall be required to supply the requisite quantity of material (that is insulator or hardware fittings as the case may be) required for repeat testing at the place of testing and the cost of supply shall be borne by the Supplier whose material has failed in testing. Bidder shall indicate the laboratories in which they propose to conduct the type tests. They shall ensure that adequate facilities are available in the laboratory and the tests can be completed in these laboratories within the time schedule guaranteed by them in the appropriate schedule. The entire cost of testing for acceptance and routine tests and tests during manufacture specified herein shall be treated as included in the quoted Ex-works/CIF Price. In case of failure in any type test, if repeat type tests are required to be conducted, then all the expenses for deputation of Inspector/ Employer's representative shall be deducted from the contract price. Also if on receipt of the Bidder's notice of testing, the Employer's representative does not find the material or test setup / equipments to be ready for testing, the expenses incurred by the Employer for redeputation shall be deducted from contract price. The Bidder shall intimate the Employer about carrying out of the type tests along with detailed testing programme at least 2 week in advance (in case of testing in India) and at least 6 weeks advance (in case of testing abroad) of the scheduled date of testing during which the Employer will arrange to depute his representative to be present at the time of carrying out the tests. Sample Batch for Type Testing The Bidder shall offer material for sample selection for type testing only after getting Quality Assurance Programme approved by the Employer. The Bidder shall offer at least three times the quantity of materials required for conducting all the type tests for sample selection. The sample for type testing will be manufactured strictly in accordance with the Quality Assurance Programme approved by the Employer. Before sample selection for type testing, the Supplier shall be required to conduct all the acceptance tests successfully in presence of Employer's representative. Schedule of Testing The Bidder has to indicate the schedule of following activities in their bids : Submission of drawing for approval. Submission of Quality Assurance Programme for approval. Offering of material for sample selection for type tests. Type testing. Additional Tests The Employer reserves the right of having at his own expenses any other test(s) of reasonable nature carried out at Supplier's premises, at site, or in any other place in addition to the aforesaid type, acceptance and routine tests to satisfy himself that the material comply with the Specifications. The Employer also reserves the right to conduct all the tests mentioned in this specification at his own expense on the samples drawn from the site at Supplier's premises or at any other test centre. In case of evidence of non compliance, it shall be binding on the part of the Supplier to prove the compliance of the items to the technical specifications by repeat tests or correction of deficiencies or replacement of defective items, all without any extra cost to the Employer. Guarantee The Supplier of insulators shall guarantee overall satisfactory performance of the insulators. Test Reports Copies of type test reports shall be furnished in at least six (6) copies along with one original. One copy shall be returned duly certified by the Employer only after which the commercial production of the concerned material shall start. Copies of acceptance test reports shall be furnished in at least six (6) copies. One copy shall be returned duly certified by the Employer, only after which the material shall be dispatched. Record of routine test reports shall be maintained by the Supplier at his works for periodic inspection by the Employers representative. Test certificates of test during manufacture shall be maintained by the Supplier. These shall be produced for verification as and when desired by the Employer. Inspection The Employers representative shall at all times be entitled to have access to the works and all places of manufacture, where insulator, and its component parts shall be manufactured and the representatives shall have full facilities for unrestricted inspection of the Suppliers and subSuppliers works, raw materials, manufacture of the material and for conducting necessary test as detailed herein. The material for final inspection shall be offered by the Supplier only under packed condition as detailed in clause No.4.13 of the specification. The Employer shall select samples at random from the packed lot for carrying out acceptance tests. The lot should be homogeneous and should contain insulators manufactured in 3-4 consecutive weeks. The Supplier shall keep the Employer informed in advance of the time of starting and the progress of manufacture of material in their various stages so that arrangements could be made for inspection.
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1.4.3.13
1.4.3.14
Sl. No. 1. 2. 3. 4.
5.
6. 7. 8. 9. 10. 11. 12.
No material shall be dispatched from its point of manufacture before it has been satisfactorily inspected and tested unless the inspection is waived off by the Employer in writing. In the latter case also the material shall be dispatched only after satisfactory testing for all tests specified herein have been completed. The acceptance of any quantity of material shall be no way relieve the Supplier of his responsibility for meeting all the requirements of the specification and shall not prevent subsequent rejection, if such material are later found to be defective. Packing and Marking All insulators shall be packed in suitable PVC/ plastic tubes/any other suitable packing along with temporary wrap-on shields/shrouds for each insulator unit. The packing shall provide protection against rodent. The shields/shrouds shall be for protection during transport and for preventing bird pecking during erection. Further, the shields/shrouds shall be made of opaque, weather proof material of adequate strength and shall be colour coded. The shields/shrouds shall have smaller diameter than the insulator to stay in place against winds & weather and shall be designed so as to leave only the end fittings exposed for attachment of insulator to tower and line hardware until line construction is complete. The shield/shroud shall have suitable pull off loop for easy detachment just prior to charging of the line without causing any damage to the insulator. The bidder/Supplier shall furnish detailed design of the packing and shield/shroud along with attachment and detachment procedure in this regard. For marine transportation, crates shall be palleted. The packing shall be of sufficient strength to withstand rough handling during transit, storage at site and subsequent handling in the field. Suitable cushioning, protective padding, or dunnage or spacers shall be provided to prevent damage or deformation during transit and handling. The Supplier shall guarantee the adequacy of the packing and shall be responsible for any loss or damage during transportation, handling, storage and installation due to improper packing. All packing cases shall be marked legibly and correctly so as to ensure safe arrival at their destination and to avoid the possibility of goods being lost or wrongly dispatched on account of faulty packing and faulty or illegible markings. Each case/crate shall have all the markings stenciled on it in indelible ink. Standards The insulator strings and its components shall conform to the following Indian/International Standards which shall mean latest revision, with amendments/changes adopted and published, unless specifically stated otherwise in the Specification. In the event of supply of insulators conforming to standards other than specified, the Supplier shall confirm in his bid that these standards are equivalent or better to those specified. In case of award, salient features of comparison between the standards proposed by the Supplier and those specified in this document will be provided by the Supplier to establish equivalence. Indian Title International Standard Standard IS:209-1992 Specification for zinc BS:3436 IS:406-1991 Method of Chemical Analysis of Slab Zinc BS:3436 IS:731-1991 Porcelain insulators for overhead Power lines with a BS:137- (I&II) IEC:60383 nominal voltage greater than 1000 V IS:2071 Part Methods of High Voltage Testing IEC:60060-1 (I)- 1993 (Part(II)1991 Part(III)1991 IS:2486 Specification for Insulator fittings for Overhead Power Part- I-1993 Lines with a nominal voltage greater than 1000V Part- II-1989 General Requirements and Tests Dimensional BS:3288 Requirements IEC:60120 Part-III-1991 Locking Devices IEC:60372 IS:2629Recommended Practice for Hot, Dip Galvanisation for ISO-1461 (E) 1990 iron and steel IS:2633Testing of Uniformity of Coating of zinc coated articles 1992 IS:3188Dimensions for Disc Insulators IEC:60305 1988 IS:6745Determination of Weight of Zinc Coating on Zinc coated BS:433-1969 ISO:14601990 iron and steel articles 1973 IS:8263Methods of RI Test of HV insulators IEC:60437,NEMA Publn 1990 No.07/1964/ CISPR IS:8269Methods for Switching Impulse test on HV insulators IEC:60506 1990 Thermal Mechanical Performance test and mechanical IEC: 60575
-8-
13. 14.
15. 16.
17. 1.4.3.15 a.
b.
c.
d.
e.
1.4.3.16
performance test on string insulator units Salt Fog Pollution Voltage Withstand Test IEC:60507 Composite insulators for A.C. Overhead lines with IEC 61109 nominal voltage greater than 1000V Definitions, test methods and acceptance criteria Guide for the selection of insulators in respect of IEC:60815 polluted conditions Tests on insulators of Ceramic material or glass or IEC:60383 glass for overhead lines with a nominal voltage greater than 1000V Characteristics of string insulator units of the long rod IEC : 60433 type Tests on Complete Strings with Hardware Fittings Annexure-A Corona Extinction Voltage Test (Dry) The sample assembly when subjected to power frequency voltage shall have a corona extinction voltage as per ISS/IEC applied 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 : 383. RIV Test (Dry) Under the conditions as specified in Corona Extinction Voltage Test (Dry)(a) above, the insulator string along with complete hardware fittings shall have a radio interference voltage level below 1000 micro volts at one MHz when subjected to 50 Hz AC voltage as per ISS/IEC applied line to ground under dry condition. The test procedure shall be in accordance with IS:8263 /IEC : 60437. Mechanical Strength Test The complete insulator string along with its hardware fitting excluding arcing horn, corona control ring, grading ring and suspension assembly/dead end assembly 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 disassemble 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. Vibration Test The suspension string shall be tested in suspension mode, and tension string in tension mode itself in laboratory span of minimum 30 metres. In the case of suspension string, a load equal to 600 kg shall be applied along the axis of the suspension string by means of turn buckle. The insulator string along with hardware fittings and the sub-conductors each tensioned at 43 kN shall be secured with clamps. The system shall be suitable to maintain constant tension on each sub-conductors throughout the duration of the test. Vibration dampers shall not be used on the test span. All the sub-conductors shall be vertically vibrated simultaneously at one of the resonance frequencies of the insulators string (more than 10 Hz) by means of vibration inducing equipment. The peak to peak displacement in mm of vibration at the antinode point, nearest to the string, shall be measured and 1.8 the same shall not be less than 1000/f where f is the frequency of vibration in cycles/sec. The insulator string shall be vibrated for not less than 10 million cycles without any failure. After the test the insulators shall be examined for looseness of pins and cap or any crack in the cement. The hardware shall be examined for looseness, fatigue failure and mechanical strength test. There shall be no deterioration of properties of hardware components and insulators after the vibration test. The insulators shall be subjected to the Mechanical performance test followed by mechanical strength test as per relevant standards. Salt-fog pollution withstand test This test shall be carried out in accordance with IEC : 60507. The salinity level for composite long rod insulators shall be 160 Kg/m3 NACL. Composite Long rod Insulator Units Brittle Fracture Resistance Test Assembled core load time test with container that contains1n-HNO3 concentric acid that is applied at the naked rod. The rod should be held at 80% of SML for the duration of the test. The rod should not fail within the 96 hour test duration Recovery of Hydrophobicity Test The surface of selected samples shall be cleaned with isopropyl alcohol. Allow the surface to dry and spray with water. Record the HC classification. Dry the sample surface.
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1.4.4 1.4.4.1 1.4.4.2 1.4.4.3
1.4.4.4 1.4.4.5 1.4.4.6 1.4.4.7
1.4.4.8
1.4.4.9
1.4.4.10
1.4.4.11
Treat the surface with corona discharges to destroy the hydrophobicity. This can be done utilizing a high frequency corona tester, Holding the electrode approximately 3mm from the sample surface, slowly move the electrode over an area approximately 1 x 1. Continue treating this area for 2 3 minutes, operating the tester at maximum output. Immediately after the corona treatment, spray the surface with water and record the HC classification. The surface should be hydrophilic, with an HC value of 6 or 7. If not, dry the surface and repeat the corona treatment for a longer time until an HC of 6 or 7 is obtained. Dry the sample surface. Allow the sample to recover and repeat the hydrophobicity measurement at several time intervals. Silicone rubber should recover to HC 1 HC 2 within 24 to 48 hours, depending on the material and the intensity of the corona treatment. Silicone content test Minimum content of silicone as guaranteed by supplier shall be verified through FT-IR spectroscopy & TGA analysis or any other suitable method mutually agreed between Employer & Supplier in Quality Assurance Programme. High Pressure washing test The test is to be carried out at 3800 kPa with nozzles of 6 mm diameter at a distance of 3m from nozzles to the insulator, followed by a dry power frequency voltage test as per IEC 61109. Tests on All components (As applicable) Chemical Analysis of Zinc used for Galvanizing Samples taken from the zinc ingot shall be chemically analysed as per IS:209-1979. The purity of zinc shall not be less than 99.95%. Tests for Forgings The chemical analysis hardness tests and magnetic particle inspection for forgings, will be as per the internationally recognised procedures for these tests. The sampling will be based on heat number and heat treatment batch. The details regarding test will be as discussed and mutually agreed to by the Supplier and Employer in Quality Assurance Programme. Tests on Castings The chemical analysis, mechanical and metallographic tests and magnetic, particle inspection for castings will be as per the internationally recognised procedures for these tests. The samplings will be based on heat number and heat treatment batch. The details regarding test will be as discussed and mutually agreed to by the Supplier and Employer in Quality Assurance Programme. WEDGE CONNECTOR Wedge connector should be FIRED-ON or powder actuated only The power booster should be colour coded for proper installation of wedge connectors Wedge connector members- taperd C shaped spring member and wedge should be made from a special Aluminium alloy of high ductility and electrical conductivity. When Installed, it will provide a tenable electrical and mechanical connection for solid or stranded conductor combinations including ACSR conductor The dimensions for the wedge shall be manufactured to close tolerance to ensure repeatability and reliability of the connection. All sharp edges and burrs shall be removed. The wedges shall be burnished to achieve optimum surface roughness for electrical contact. The wedge connector shall meet the current cycle test requirements as per ANSI C119.4-1998 Class AA. When connected as specified samples shall indicate electrical stability for terminated connectors. The resistance of connection, when measured as specified shall be stable through out test. The sample shall be tested to 500on/off current cycle with the control conductor raised between 0 0 175 C to 180 C above ambient. The wedge connector shall meet the mechanical requirements as per ANSI C119.4-1998 Class-3, minimum tension. When tested as specified or 5% of the rated cable strength of the weaker conductor. The Wedge connector shall meet the following thermal shock/salt spray test:a) Hours at 1500C b) 15 minutes at 0C water, immediately from the oven c) 30 minutes at 1500C d) 20.75 hours at room temperature Salt spray corrosion, samples shall be subjected to a 30 day salt spray corrosion test. Each daily exposure shall consist of :a) 15 hours in 5% salt spray atmosphere b) 1 hour in drying over at 1000C c) 8 hours at room temperature During installation, the wedge of wedge shall be driven inside the C member at high velocity between the run & tap conductor so as to spread the C member to ensure high retentive force on the conductors. A locking tab, formed balance on the tool should prevent the wedge from loosening once it has been driven into position
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1.4.4.12
1.4.4.13 2.0 2.1 2.1.1
2.1.2
2.1.3
a) b) c)
d) e) f) g) h) i) j)
a) b) c) d) e) 2.1.4
2.1.5 2.1.6
Note: 2.1.7 2.1.8
2.1.9
The wedge terminal shall have back up conductor cleaning capability during application. The wedge terminals should ensure stable & low contact resistance under varying load conditions & the thermal cycling effects. An oxide inhibiting compound placed in the wedge & C member groove of Wedge Terminals. CONDUCTOR AAC TARANTULA CONDUCTOR DETAILS OF CONDUCTOR SCOPE This specification provides for design, manufacture, engineering, inspection, stage testing and testing before dispatch, packing and delivery at site of All Aluminium conductor specified herein for its satisfactory operation on various Transmission lines and substations of the State. AAC Tarantula conductor is to be used as power conductor on single circuit and double circuit transmission lines and sub-stations of the HVPNL. STANDARDS The power conductor shall conform to the following Indian Standards, which shall mean latest revision, amendments/changes adopted and published, unless otherwise specified herein before. Sr ISS Title No 1. IS: 398 Part I to Specification for Aluminium conductors for overhead Transmission V (As relevant) purpose. 2. IS : 1778 Reels and Drums for Bare conductors 3. IS : 1841 EC grade Aluminium rod produced by rolling 4. IS : 5484 EC grace Aluminium rod produced by continuous casting and rolling PRINCIPAL PARAMETERS The detail of conductor are tabulated below Stranding and wire diameter 37/5.23 mm Al. Code name AAC TARANTULA Number of strands per layer of aluminium Wire Central 1 1st Aluminium layer 6 12 2nd Aluminium layer 18 3rd Aluminium layer Total Sectional area of aluminium (Sq. mm) 795.6 mm2 Overall diameter (mm) 36.61mm Approximate weight (kg/km) 2198 kg/km Calculated max. d.c. resistance at 20 Deg. C (ohm/km) 0.03656 Minimum UTS (kN) of conductor 11,600 kg. Modulus of Elasticity 0.5976x106 kg/cm2 Coefficient of linear expansion (per Deg.C) 23X10-6 The details of aluminium strand are as follows: Minimum breaking load of strand before stranding (kN) Minimum breaking load of strand after stranding (kN) 3.08 Maximum D.C resistance of strand of 20 Deg. C (ohm/km) 1.350 Diameter mm (Standard/Max/Min) 5.23/5.28/5.18 Mass (Kg/Km) 59.40 GENERAL TECHNICAL REQUIREMENT The ACC Tarantula conductor shall be suitable for being installed directly in air supported on suspension insulator strings or anchored through tension insulator strings at the power cross arms of single circuit and double circuit transmission line towers. The conductor shall therefore be suitable for satisfactory operation under the tropical climatic conditions listed under the Annexure III of Section 1. Physical constants of materials Physical constants for Hard-drawn Aluminium Resistivity The resistivity of aluminium depends upon its purity and its physical condition. For the purpose of 2 o this specification the maximum value permitted is 0.028264 mm /m at 20 C and this value has been used for calculation of the maximum permissible value of resistance. It is not intended to check the resistivity from the measured values of resistance. Density At a temperature of 20oC the density of hard drawn aluminium has been taken as 2.703 g/cm3. Constant-Mass Temperature Co-efficient of Resistance At a temperature of 20o C the constant mass temperature co-efficient of resistance of hard drawn aluminium measured between two potential points rigidly fixed to the wire, the metal being allowed to expand freely, has been taken as 0.004 per degree Celsius. Co-efficient of Linear Expansion The co-efficient of linear expansion of hard-drawn aluminium at 0oC has been taken as 23.0x10-6
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2.1.10
2.1.11
2.1.12
2.1.13 2.1.13.1 Note:
2.1.14
Note:
2.1.15
Note:
2.2 2.2.1 2.2.2 a)
per deg. C. This value holds good for all practical purposes over the range of temperatures from 0o C to highest safe operating temperature. Materials The conductor shall be manufactured from EC grade aluminium rods suitably hard-drawn on wire drawing machines. The aluminium rods used shall comply with IS:1841-1978 and IS:5484. The mechanical and electrical properties of aluminium wire shall comply with the requirements given in relevant standard. The aluminium wire shall be manufactured from not less than 99.5% pure electrolytic aluminium rods of E.C. Grade. Freedom from Defects The wires shall be smooth and free from all imperfections such as spills, spilts, slag inclusion, die marks, scratches, fittings, blow-holes, projections, looseness, overlapping of strands, chipping of aluminium layers etc. and all such other defects which may hamper the mechanical and electrical properties of the conductor. Special care should be taken to keep away dirt, grit etc. during stranding. Wire Sizes Nominal Size The aluminium for the stranded conductor covered by this standard shall have diameters specified in clauses 2.1.3 Tolerances on normal size Aluminium Wires A tolerance of + 1% is permitted on the nominal diameter of AAC conductor. In order to maintain the circularity of the wires the tolerance allowed in 2.1.13.1 shall apply to both the measurement at right angles taken at the same cross-section as per clause 2.2 of IS:398 (PartII) (Second Revision with latest Amendments). Joints in wires Aluminium wires No joints shall be permitted in the aluminium wires in the outermost layer of the ACSR conductor. Joints in the inner layers are permitted, in addition to those made in the base rod or wire before final drawing, but no two such joints shall be less than 15 metres apart in the complete stranded conductor. Such joints shall be made by cold pressure butt-welding. Joints are not permitted in the outermost layer of the conductor in order to ensure a smooth conductor finish and reduce radio interference levels and corona losses on the extra high voltage lines. Stranding The wires used in the construction of all aluminium conductor shall, before stranding, satisfy all the relevant requirements of this specification. The lay ratio of the different layers shall be within the limits given in the table below LAY RATIO OF ALL ALUMINIUM CONDUCTOR No. of Lay Ratios for Aluminium Wires wires Al. Outside Layer Layer Immediately Innermost Layer of conductor with beneath out side layer three Aluminium Wire Layers Min. Max. Min. Max. Min. Max. 37 11.25 14 14 21 18 21 For the purpose of calculation, the mean lay ration shall be taken as the arithmetic mean of the relevant minimum and maximum values given in this table In all constructions, the successive layers shall have opposite directions of lay, the outermost layer being right-handed. The wires in each layer shall be evenly and closely stranded. The lay ratio of any aluminium layer shall not be greater than the lay ratio of the aluminium layer immediately beneath it. Standard Length The standard length of the conductor shall be 500 meters. A tolerance of +5% on the standard length shall be permitted. All lengths outside this limit of tolerance shall be treated as random lengths. Random lengths will be accepted provided no length is less than 70% of the standard length specified and the total quantity of such random lengths shall not be more than 5% of the total quantity ordered. Supplier shall also indicate the maximum single length above the standard length, he can manufacture, in the guaranteed technical particulars. The conductor shall be supplied in standard drum length of manufacturer as per actual requirement. ACSR MOOSE/ ZEBRA CONDUCTOR DETAILS OF CONDUCTOR The conductor shall conform to IS:398(Part V)-1982 except where otherwise specified herein. The details of the conductor are tabulated below: Moose Zebra Stranding and wire diameter 54/3.53mm AL+7/3.53mm 54/3.18mm AL+7/3.18mm steel steel
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b)
c) d) e) f) g) h) 2.2.3 i) ii) iii) 2.2.4 i) ii) iii)
3.0
3.1 a) b) c) d) e) f) g) Note: 3.2 a) b) c) d) 3.3
Number of strands 1 core 1 6 1st Layer 6 2nd Layer 12 12 3rd Layer 18 18 4th Layer 24 24 428.9 mm2 Sectional area of Aluminium 528.5 mm2 484.50 mm2 Total sectional area 597 mm2 Overall diameter 31.77mm 28.62 mm Approximate weight 1998 kg/km 1621 kg/km Calculated DC resistance at 0.05595 ohm/km 0.06868 ohm/km 20 degree C Minimum UTS 159.60 KN 130.32 KN The details of aluminium strand are as follow: Minimum breaking load of 1.57 kN 1.29 kN strand before stranding Minimum breaking load of 1.49 kN 1.23 kN strand after stranding 3.651 ohms/KM Maximum D.C resistance of 2.954 ohms/KM strand at 200C The details of steel strand are as follows: Minimum breaking load of 12.86 kN 10.43 kN strand before stranding Minimum breaking load of 12.22 kN 9.95 kN strand after stranding Minimum no. of twist to be 18-before stranding 18-before stranding with stood in torsion test 16-after stranding 16-after stranding when tested on a gauge length of 100 times diameter of wire Tests The type, acceptance and routine tests and tests during manufacture, shall be carried out on the conductor. For the purpose of this clause: Type tests shall mean those tests, which are to be carried out to prove the process of manufacture and general conformity of the material to this specification. These tests shall be carried out on samples prior to commencement of commercial production against the order. The supplier shall indicate his schedule for carrying out these tests in the activity schedule. Acceptance tests shall mean those tests, which are to be carried out on samples taken from each lot offered for pre-dispatch inspection, for the purposes of acceptance of that lot. Routine tests shall mean those tests which are to be carried out on each strand/spool/length of the conductor to check requirements which are likely to vary during production. Tests during manufacture shall mean those tests, which are to be carried out during the process of manufacture and end inspection by the Supplier to ensure the desired quality of the end product to be supplied by him. Samples for individual wires for tests shall be taken before stranding from not less than ten percent of the spools in the case of aluminium wires. If samples are taken after stranding, they shall be obtained by cutting 1.2 metres from the outer end of the finished conductor from not more than ten percent of the finished reels. The standards and norms to which these tests will be carried out are listed against them. For type and acceptance tests, the acceptance values shall be the values guaranteed by the Supplier in the Performa for Guaranteed Technical Particulars, furnished in the Annexure-II or the acceptance value specified in this specification, whichever is more stringent for that particular test. Acceptance Tests Visual and dimensional check Visual check for joints, scratches etc. and lengths of conductor. Dimensional check on aluminium strands Check for lay ratios of various layers Breaking load test on aluminium strands Wrap test on aluminium strands DC resistance test on aluminium strands All the above tests shall be carried out on aluminium strands after stranding only. Routine Tests Check to ensure that the joints are as per specification Check that there are no cuts, etc. on the strands. Check that drums are as per specifications. All acceptance tests are mentioned in Clause 6.2 above shall be carried out on each coil. Testing Expenses
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3.4
3.5
3.6
3.7
3.8
4.0
The testing charges for the type tests specified shall be indicated separately in the prescribed schedule. The supplier shall indicate the type test charges for each type test separately. In case of failure in any type, the supplier is either required to modify the design of the material or repeat the particular type test three times successfully at his own expenses. The decision of the Purchaser in this regard shall be final binding. Suppliers shall indicate the laboratories in which they propose to conduct the type tests. They shall ensure that the tests can be completed in these laboratories within the time schedule guaranteed by them in the appropriate schedule. The entire cost of testing for the acceptance and routine tests and tests during manufacture specified herein shall be treated as included in the quoted unit price of conductor, except for the expenses of the inspector/Purchasers representative. Additional Tests The Purchaser reserves the right of having at his own expenses any other test(s) of reasonable nature carried out at Suppliers premises, at site, or in any other place in addition to the aforesaid type, acceptance and routine test, to satisfy himself that the material comply with the specifications. Sample Batch for testing Samples shall be obtained by cutting 2mtrs. length from the outer end of the finished conductor from minimum 10% of the finished drums offered for inspection. The Supplier is required to carry out all the acceptance tests successfully in the presence of Purchasers representative before dispatch. Test Reports Copies of type test reports shall be furnished in at least six(6) copies alongwith one original. One copy shall be returned duly certified by the Purchaser only after which the material will be dispatched. Record of routine test reports shall be maintained by the supplier at his works for periodic inspection by the Purchasers representative. Test Certificates of tests conducted during manufacture shall be maintained by the supplier. These shall be produced for verification as and when desired by the Purchaser. Test Facilities The following additional test facilities shall be available at Suppliers works Calibration of various testing and measuring equipment including tensile testing machine, resistance measurement facilities, burette, thermometer, barometer etc. Standard resistance for calibration of resistance bridges. Finished conductor shall be checked for length verification and surface finish on separate rewinding machine at reduced speed (variable from 8 to 16 meters per minute). The rewinding facilities shall have appropriate clutch system and shall be free from vibrations, jerks etc. with transverse layering facilities. INSPECTION The Purchasers representative shall, at all times, be entitled to have access to the works and all places of manufacture where conductor shall be manufactured and the representative shall have full facilities for unrestricted inspection of the Suppliers works, raw materials and process of manufacture and conducting necessary tests as detailed herein. The Supplier shall keep the Purchaser informed in advance of the time of starting and of the progress of manufacture of conductor in its various stages so that arrangements can be made for inspection. No material shall be dispatched from its point of manufacture before it has been satisfactorily inspected and tests, unless the inspection is waived off by the Purchaser in writing. In the later case also, the conductor shall be dispatched only after satisfactory testing for all tests specified herein has been completed and approved by the Purchaser. The acceptance of any quantity of material shall in no way relieve the Supplier of any of his responsibilities for meeting all requirements of the specification, and shall not prevent subsequent rejection if such material is later found to be defective. At least 10% of the total number of drums subject to minimum of two in any lot put up for inspection shall be selected at random to ascertain the length of conductor by the following method. At the works of the manufacture of the conductor, the conductor shall be transferred from one drum to another at the same time measuring its length with the help of a graduated pulley & Cyclometer. The difference in the average length thus obtained and as declared by the Supplier in the packing list shall be applied to all the drums if the conductor is found short during checking. DOCUMENTATION Six sets of type test reports, duly approved by the Purchaser shall be submitted by the Supplier for distribution, before commencement of supply. Adequate copies of acceptance and routine test certificates, duly approved by the Purchaser shall accompany the dispatched consignment. Approval of drawing/work by Purchaser shall not relieve the Supplier of his responsibility and liability for ensuring correctness and correct interpretation of the latest revision of applicable standards, rules and codes of practices. The material shall conform in all respects to high standards of engineering, design, workmanship and latest revisions of relevant standards at the time of ordering
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5.0
a) b) c) d) e) f) g) h)
and Purchaser shall have the power to reject any work or material which in his judgement is not in full accordance therewith. PACKING & FORWARDING The conductor shall be supplied in non-returnable, strong wooden drums provided with lagging of adequate strength capable of withstanding displacement during transit, storage and subsequent handling and stringing operation in the field. The drums shall generally conform to IS: 1778-1980 except otherwise specified hereinafter. The drums shall be suitable for wheel mounting and for jetting off the conductor under a minimum controlled tension of the order of 5 kN. The Supplier shall submit the proposed drum drawings alongwith the bid. However, the same shall be in line with the requirements as stated herein. After placement of the Letter of Award, the Supplier shall submit four copies of fully dimensioned drawing of the drum he wishes to supply , for Purchasers approval before taking up manufacturing of Conductor. After getting approval from the Purchaser, the Supplier shall submit 30 more copies of the approved drawing to Purchaser for further distribution and field use at Purchasers end. All wooden components shall be manufactured out of seasoned soft wood free from defects that may materially weaken the component parts of the drums. Preservative treatment for anti-termite /anti fungus (Aldrime /Aldruse) shall be applied to the entire drum with preservatives of a quality which is not harmful to the conductor. The flanges shall be of two/three ply construction with each ply at right angles to the other and nailed together. The nails shall be driven from the inside face flange, punched and then clenched on the other face. The tolerance in thickness of each ply shall be +3 mm only. There shall be at least 3 nails per plank of ply with maximum nail spacing of 75mm. Where a slot is cut in the flange to receive the inner end of the conductor, the entrance shall be in line with the periphery of the barrel. The wooden battens used for making the barrel of the conductor shall be of segmental type. These shall be nailed to the barrel supports with at least two nails. The battens shall be closely butted and shall provide a round barrel with smooth external surface. The edges of the battens shall be rounded or chamfered to avoid damage to the conductor. Barrel studs shall be used for construction of drums. The flanges shall be holed and the barrel supports slotted to receive them. The barrel studs shall be threaded over a length on either end, sufficient to accommodate washers, spindle plates and nuts for fixing flanges at the required spacing. The Barrel studs should be tack-welded with the nuts after tightening. Normally, the nuts on the studs shall stand proud of the flanges. All the nails used on the inner surface of the flanges and the drum barrel shall be countersunk. The ends of barrel shall generally be flushed with top of the nuts. The inner check of the flanges and drum barrel surface shall be painted with a bitumen based paint. Before reeling, card board of double corrugated or thick bituminized waterproof bamboo paper shall be secured to the drum barrel and inside of flanges or the drum by means of a suitable commercial adhesive material. The paper should be dried before use. Medium grade Kraft paper shall be used in between the layers of the conductor. After reeling the conductor, the exposed surface of the outer layer of conductor shall be wrapped with think polythene sheet across the flanges to preserve the conductor from dirt, grit and damage during transportation and handling and also to prevent ingress of rain water during storage/transport. A minimum space of 125mm shall be provided between the inner surface of the external protective layer and outer layer of the conductor. Each batten shall be securely nailed across grains as far as possible to the flange edges with at least 2 nails per end. The length of the nails shall not be less than twice the thickness of the battens. The nail shall not protrude above the general surface and shall not have exposed sharp edges or allow the battens to be released due to corrosion. Outside the protective layer, there shall be a minimum of two binders consisting of hoop iron/galvanized steel wire. Each protective layer shall have two recess to accommodate the binders. The conductor ends shall be properly sealed and secured with the help of U-nails on one side of the flanges. The conductor shall be hinged by use of galvanized steel wire/aluminium wire at three locations at least 75mm apart or more covered with PVC adhesive tape so as to avoid loosening of conductor layers in transit and handling. Only one length of conductor shall be wound on each drum. Marking Each drum shall have the following information stenciled on it in indelible ink alongwith other essential data: Purchase order number Name and address of consignee Manufactures name and address Drum Number Size of conductor Length of conductor in meters Gross weight of drum with conductor Weight of empty drum with lagging
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i) 6.0 6.1
Arrow marking for unwinding GALVANISED STEEL EARTHWIRE DETAILS OF EARTHWIRE 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. The details of the earthing are tabulated below: Stranding and wire diameter 7/2.50 mm steel 7/3.15 mm steel 7/3.66 mm steel Number of strands Steel core 1 1 1 Outer steel layer 6 6 6 54.55 mm2 73.65 mm2 Total sectional area 35.30 mm2 Overall diameter 7.50 mm 9.45 mm 10.98 mm Approximate weight 271 kg/km 428 kg/km 583 kg/km Calculated DC resistance at 5.56 /km 3.375 /km 2.5 /km 200C Minimum ultimate tensile 36 KN 57 KN 68.4 KN strength Direction of lay of outer layer Right hand Right hand Right hand WORKMANSHIP All steel strands shall be smooth, uniform and free of all imperfections, such as spills and splits, die marks, scratches, abrasions and kinks after drawing and also after stranding. The finished material shall have minimum brittleness, as it will be subjected to appreciable vibration while in use. The steel strands shall be hot dip galvanised and shall have a 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 strands specified and coated with zinc, the finished strands shall be of uniform quality and have the same properties and characteristics in ASTM designation B498-74. The steel strands shall be performed and post formed in order to prevent spreading of strands while cutting of composite earth wire. Care shall be taken to avoid damage to galvanization during pre forming and post forming operation. To avoid susceptibility towards wet storage stains (white rust), the finished material shall be provided with a protective coating of boiled linseed oil. 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. TOLERANCES The manufacturing tolerances 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 Dia. Maximum Dia. Minimum Dia. Earth wire 7/2.50 2.50 mm 2.56 mm 2.47 mm 7/3.15 3.15 mm 3.20 mm 3.10 mm 7/3.66 3.66 mm 3.75 mm 3.57 mm Lay length Earth Wire Standard Maximum Minimum 7/2.50 113 mm 135 mm 90 mm 7/3.15 160 mm 175 mm 145 mm 7/3.66 181 mm 198 mm 165 mm MATERIALS STEEL The steel wire strands shall be drawn from high carbon steel rod and shall conform to the following requirements as to the chemical composition: Element %Composition 7/2.50 mm steel 7/3.15 mm steel 7/3.66 mm steel Carbon 0.55 Max. 0.55 Max. 0.55 Max. Manganese 0.4 to 0.9 0.4 to 0.9 0.4 to 0.9 Phosphorus 0.040 Max. 0.040 Max. 0.04 Max. Sulphur 0.040 Max. 0.040 Max. 0.04 Max. Silicon 0.15 to 0.35 0.15 to 0.35 0.15 to 0.35 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. STANDARD LENGTH
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a) b)
c) d) e) f) g) h) 6.2 6.2.1 6.2.2 6.2.3
6.2.4
6.2.5 6.3
6.4
6.5 6.5.1
6.5.2
6.5.3
The earth wire shall be supplied in standard drum length of manufacturer as per actual requirement. 6.6 TESTS In accordance with the requirements stipulated in Section1 and Section2, earth wire shall conform to type tests as per relevant IS/IEC and shall be subjected to the following acceptance tests and routine tests: ACCEPTANCE TESTS Visual check for joints, scratches etc. and length ) of Earth wire. Dimensional check ) Galvanising test ) Lay length check ) Torsion test ) Elongation test ) Wrap test ) DC resistance test ) IS:398 (Part III) 1976 Breaking load test ) Chemical analysis of steel ) ROUTINE TESTS Check that there are no cuts, fins etc. on the strands. Check for correctness of stranding. TESTS DURING MANUFACTURING Chemical analysis of zinc used for galvanising. ) Chemical analysis of steel ) MARSHALLING KIOSK PRINCIPAL PARAMETERS The Marshalling Kiosk shall be suitably fixed so as to provide no opening to inside and shall be sufficiently projected to prevent splash of rainwater to the inside of the Marshalling Kiosk. The Marshalling Kiosk will be 1400 mm (height) 1200 mm (width) and 550 mm (depth) complete with double door in front provided with pad-locking facility in the door handle. The Marshalling Kiosk shall be bolted on the 550 mm high angle-iron frame work made of 35x35x6 mm MS angle braced lengthwise by 35x6 mm MS Flat. The Marshalling Kiosk shall be equipped with 3 No. earth test links made of tinned copper for CT circuits. TERMINAL BLOCK CONNECTORS Terminal block shall conform to requirements given in Section 2(GTR). The terminal connector will conform to the following details: Current & Voltage 30 Amps, 660VAC/900 VDC Ratings 2 Capacity up to three ring-tongue crimped copper wires of 4mm , cross sectional area. disconnecting type terminal blocks for CTs and PTs Terminal connectors for CT/PTs shall have provision of disconnecting and shortening links for measurement of CT currents without opening the CTs and isolation of PT circuits. DISTRIBUTION OF TERMINALS AND THEIR IDENTIFICATION NUMBERS The no. of terminals required shall be as follows: 220kV-300, 132kV-250 & 66kV-200. The total number of terminals in the Marshalling Kiosk will be distributed in ten rows. Terminal block connector rows shall be adequately spaced and in no case less than 100 mm apart center of the terminal block so as to permit convenient access to terminations. Labels in the form of plastic/steel plates carrying numerals for terminal identification shall be so mounted as to cause no interference with regard to access to terminal nuts. The numerals marked from top to bottom in ascending order starting from left-hand side as viewed from the front of the Marshalling Kiosk and a progressively increasing from left hand side to right hand side. The numbering of Terminals and their arrangement in a 200, 250 and 300 terminals Marshalling Kiosks shall be as per sketch enclosed (Drg. No. C/ENG/HSEB/MB). EARTHING CONDUCTORS 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. CONSTRUCTIONAL FEATURES GALVANISED STEEL Steel conductors above ground level shall be galvanised according to IS:2629. The minimum weight of the zinc coating shall be 610 gm/sq.m. and minimum thickness shall be 85 microns.
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6.6.1
a) b) c) d) e) f) g) h) i) j)
6.6.2
a) b)
6.7 6.7.1
6.8
i.) ii.) iii.)
6.9
6.10 6.10.1
6.11 6.11.1
6.11.2
6.12 6.12.1 6.13
6.14
6.14.1 6.14.2
a) b)
7.0
7.1 7.1.1 7.1.2
a) b) c) d) 7.2 a) b) c)
d)
e) f) g) h) 7.3 7.3.1 7.3.2
7.3.3 7.3.4
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 discolored 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. TESTS Galvanised steel shall be subjected to four one minute dips in copper sulphate solution as per IS:2633. SPACERS GENERAL Spacers shall conform to IS-10162. CONSTRUCTIONAL FEATURES No magnetic material shall be used in fabrication of spacers except for GI Bolts and nuts. Spacer design shall be made to take care of fixing and removing during installation and maintenance. The design of the spacers shall be such that the conductor does not come in contact with any sharp edge. TESTS In accordance with requirements stipulated in Section1 and Section2, each type of spacer shall conform to type tests as per relevant IS/IEC and shall be subjected to the following, acceptance tests and routine tests in addition to those specified in IS/IEC: ACCEPTANCE TEST The acceptance tests shall be as per IS:10162 (latest revision). ROUTINE TEST Visual Examination Dimensional verification. EARTHING The earthing shall be in accordance with requirements given hereunder. The earthmat design shall be done by the contractor as per IEEE 80. The earthmat shall be connected to the existing earthmat in case of substations where earthmat is already laid. GENERAL Exact location of earthing connections shall be designed to suit the site conditions. Neutral points of system 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. Code of practice for Earthing IS:3043. Code of practice for the protection of building and allied structures against lightning IS:2309. Indian Electricity Rules 1956 with latest amendments. National Electricity Safety Code IEEE-80. DETAILS OF EARTHING SYSTEM ITEM SIZE MATERIAL Main Earthing Conductor 40 mm dia MS Rod Mild Steel Conductor above ground & 75x12 mm GS Flat Galvanised Steel earthing leads (for equipment) Conductor above ground & 75x12 mm GS Flat Galvanised Steel earthing leads (for columns & aux. Structures) Earthing of indoor LT panels, 50x6 mm GS Flat Galvanised Steel control panels marshalling boxes, MOM boxes, junction boxes & lightning panels etc. Rod electrode 40 mm dia, 3000 mm Mild Steel Pipe electrode upto water level 100 mm dia CI pipe with 13 CI mm thickness Earthing for motors flat 25x3 mm steel Galvanised Earthing conductor along 50x6 mm GS Flat Mild Steel painted with Red outdoor cable trenches primer Oxide EARTHING CONDUCTOR LAYOUT Earthing conductors in outdoor areas shall be buried at least 600 mm below finished grade level unless stated otherwise. Wherever earthing conductors cross cable trenches, underground service ducts, pipes, tunnels, railway tracks etc. It shall be laid minimum 300 mm below them and shall be re-routed in case it fouls with equipment/structure foundations Tap-connections from the earthing grid to the equipment/structure to be earthed, shall be terminated on the earthing terminals of equipment/structure. Earthing conductors or leads along their run on cable trench, ladder columns, beams, walls etc. shall
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7.3.5
7.3.6 7.3.7 7.4 7.4.1
7.4.2
7.4.3
7.4.4 7.4.5 7.4.6
7.4.8 7.4.9 7.4.10 7.4.11 7.4.12
7.4.13
7.5 7.5.1
7.5.2
7.5.3 7.5.4 7.5.5
7.5.6 7.5.7 7.6
7.7 7.7.1
be supported by suitable welding/cleating at intervals of 750 mm. Wherever it passage through walls, floors etc., galvanised iron sleeves shall be provided for the passage of the conductor and both ends of the sleeves shall be sealed to prevent the passage of water through the sleeves. 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 temperature is encountered at some location, the earthing conductor shall be laid minimum 1500 mm away from such location. Earthing conductor crossing the road shall be laid 300 mm below road or at a greater depth to suit the site conditions. Earthing conductor embedded in the concrete shall have approximately 50 mm concrete cover. EQUIPMENT AND STRUCTURE EARTHING Earthing pads shall be provided by the Contractor of the apparatus/equipment at accessible position. The connection between earthing pads and the earthing grid shall be made by short and direct earthing leads 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 engineer. Whether specifically shown in drgs. or not, steel/structure 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. Metallic pipes, conduits and cable tray sections for cable installation shall be bonded to ensure electrical continuity and connected to earthing conductors at regular. Apart from intermediate connections, beginning points shall also be connected to earthing system. Metallic conduits shall not be used as earth continuity conductor. A separate earthing conductor shall be provided for earthing lighting fixtures, receptacles, switches, junction boxes, lighting conduits etc. 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. Light poles, junction boxes on the poles, cable and cable boxes/glands, lockout switches etc. shall be connected to the earthing conductor running along with the supply cable which in turn shall be connected to earthing grid conductor at a minimum two points whether specifically shown or not. Railway tracks within switchyard area shall be earthed at a spacing of 30 mm and also by both the ends. Earthing conductor shall be buried 500 mm inside the switchyard fence. Every alternate post of the fence and gates shall be connected to earthing loop by one lead. Flexible earthing connectors shall be provided for the moving parts. All lighting panels, junction boxes, receptables fixtures, conduits etc. shall be grounded in compliance with the provision of I.E. rules. A continuous ground conductor of 16 SWG GI wire shall be run all along each conduit run and bonded at every 600 mm by not less than two turns of the same size of wires. The conductor shall be connected to each panel ground bus. All junction boxes, receptacles, lighting fixtures etc. shall be connected to this 16 SWG ground conductor. 50 mm x 6 mm MS flat shall run on the top tier and along the cable trenches and the same shall be welded to each of the racks. Further this flat shall be earthed at both the ends at an interval of 30m. The MS flat shall be finally painted with two coats of Red Oxide primer and coats of post office and red enamel paint. JOINTING 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. Connection between equipment earthing lead and main earthing conductors and between main earthing conductors shall be welded/brazed type. For rust protections, the welds should be treated with red lead and afterwards thickly coated with bitumen compound to prevent corrosion. Steel to copper connections shall be brazed type and shall be treated to prevent moisture ingression. Resistance of the joint shall not be more than the resistance of the equivalent length of the conductor. All ground connections shall be made by electric arc welding. All welded joints shall be allowed to cool down gradually to atmospheric before putting any load on it. Artificial cooling shall not be allowed. Bending of large rod/thick conductor shall be done preferably by gas heating. All arc welding with large dia. Conductors shall be done with low hydrogen content electrodes. 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 cable shall be earthed at switchgear end only. SPECIFIC REQUIREMENT FOR EARTHING SYSTEMS Each earthing lead from the neutral of the power transformer shall be directly connected to one pipe electrode in independent treated earth pit up to water level which in turn, shall be buried in cement
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7.7.2 7.7.3 7.7.4
7.7.5 7.7.6 7.7.7 7.8 7.8.1 7.8.2 7.8.3
7.8.4 7.8.5 8. 8.1 8.2 a) b) c) d) e) 9.
10. 10.1
10.2 11. 11.1
11.2 12. 12.1.1 12.1.2 12.1.3 12.1.4 12.1.5
concrete pit with a cast iron cover hinged to a cast iron frame to have an access to the joints. One directly driven three meter MS Rod of 40 mm dia electrode shall also be provided on each neutral. In one substation minimum four number of independent pipe electrodes up to water level shall be provided at least one each at every neutral point of all transformer. All the pipe electrodes and rod electrodes shall be connected to the station main earth grid. Earthing terminal of each lightning arrester shall be directly connected to two rod electrode which in turn, shall be connected to station earthing grid. Capacitor voltage transformer , PT and down conductors of tower with peak etc. shall be directly connected to rod electrode which in turn, shall be connected to station earthing grid. Auxiliary earthing mat comprising of closely spaced (300mm x 300mm) conductors of 40 mm dia rod shall be provided at depth of 300 mm from ground level below the operating handles of the MOM Boxes of Isolators in area of 1.5m x 1.5m. MOM Boxes shall be directly connected to the auxiliary earthing mat. The auxiliary earthing mat shall be connected to main earth mat. Earthing of each Post Insulator base of Isolator and support Insulators of circuit Breakers is required to be connected with earthing strip. The earthing strips are required to be connected at the top of support structure on both sides and not at bottom. Insulating strings in the gantry beam are required to be connected at the base with common strip. SPECIFIC REQUIREMENTS FOR LIGHTNING PROTECTION SYSTEM Conductors of the lightning protection system shall not be connected with the conductors of the safety earthing above ground level. Down conductors shall be cleated on the structures at 2000 mm interval. Connection between each down conductor and rod electrodes shall be made via test joint located approximately 1500 mm above ground level. The bidders shall include the cost of test links in the erection price component of respective equipment/structure and no extra payment shall be made for the same. Lightning conductors shall not pass through or run inside G.I. conduits. All metallic structures within a vicinity of 2000 mm in air and 5000 mm below ground shall be bounded to the conductors of lightning protection system. MAIN BUS BARS The brief description of the bus switching scheme, bus bar layout and equipment connection already adopted are indicated in the SLDs enclosed with Section 1. The bidder shall furnish supporting calculations for the bus bars/conductors to show adequacy of design parameters for: Cantilever strength of Post Insulators. Short circuit forces and spacer location for each span of ACSR conductor stringing. Earthing design calculations. Direct stroke lightning protection. Ampacity calculations. BAY EQUIPMENT # The disposition of various bay equipment is shown in single line diagrams and standard section drawing/layout drawing enclosed with Section 1. LIGHTNING PROTECTION Direct stroke lightning protection (DSLP) shall be provided in the switchyard by shield wires. The layout drawings enclosed indicate arrangement. The final arrangement shall be decided after approval of the DSLP calculations. Rezvik method of lightning protection shall be followed. Any additional expenditure resulting from change of layout if required shall be to the firms account. The lightning protection system shall not be in direct contact with underground metallic service ducts and cables. TERMINAL POINTS The terminal points for the scope of work of switchyard are given below: LINE FEEDERS The transmission line shall terminate on line side gantry structure. The supply and erection of tension insulator string for line termination and tension clamps for earthwire are included in the scope of the bidder. Lightning protection down conductor at this end, tap offs and jumper connections from this dead end to all equipment in the switchyard are in Contractors scope. EQUIPMENT ERECTION NOTES All support insulators, circuit Breaker interrupters and other fragile equipment shall preferably be handled with cranes having suitable booms and handling capacity. The slings shall be of sufficient length to avoid any damage to insulator due to excessive swing, scratching by sling ropes etc. Handling equipment, sling ropes etc. should be tested periodically before erection for strength. Bending of compressed air piping should be done by a bending machine and through cold bending only. Bending shall be such inner diameter of pipe is not reduced. 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. Hacksaw shall not be used.
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12.1.6 12.1.7 12.2
13 (A) a)
b)
Muslin or leather cloth shall be used for cleaning the inside and outside of hollow insulators. All the equipment, instruments and auxiliaries required for testing and commissioning of equipment shall be arranged at site by the contractor. STORAGE 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/HVPNL shall be strictly adhered to. WIRING DIAGRAM AND CABLE SCHEDULES FOR TURNKEY PROJECTS At 400kV & 220kV Sub-Stations, Armoured Copper Control Cables with 350TB or more (depends upon control circuit termination) & 300TB MK resp. and at 132/66kV Sub-Stations Unarmoured Copper Control Cables with 250TB/200TB MKs are used. All cables from each equipment installed in a bay shall be routed through BMK to Control Room (for S/Stns without SAS). However, for 33kV voltage level MKs are not provided and Unarmoured Copper Control Cables from each equipment installed in a bay shall be routed directly to Control Room(for S/Stns without SAS). Further, Control cables shall be routed directly from equipments to AC kiosks for S/Stns. with SAS except for 400kV S/Stns. where cables shall be routed through BMKs to AC Kiosks. Voltage level for 400kV is designated by AA, 220kV is designated by A, 132kV is designated by B, 66kV is designated by C, 33kV is designated by D and 11kV is designated by E. As per standard practice in HVPNL, following sizes of copper control cables are being used for 400/220/132/66/33kV voltage levels:3CX2.5Sq.mm, 7CX2.5Sq.mm, 10CX2.5Sq.mm, 16CX2.5Sq.mm, 4CX4Sq.mm, 2CX4Sq.mm, 2CX6Sq.mm and 7CX4Sq.mm and routed as under:-
Sr. No.
Size of Cables (Cores X Sq.mm) 7CX4 & 4CX4 4CX4 & 2CX4 7CX4 & 4CX4 4CX4 & 2CX4 4CX4 & 2CX4 2CX4 2CX4 4CX4 & 2CX4 2CX6 16CX2.5 or 10CX2.5
1. 2. 3. 4. 5. 6. 7. 8.
MK TB No. TB-1 TB-1 TB-1 TB-1 TB-1 TB-2 TB-2 TB-3
Equipment Circuits to be used
9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23.
16CX2.5 or 10CX2.5 16CX2.5 or 10CX2.5 10CX2.5 or 7CX2.5 10CX2.5 or 7CX2.5 or 3CX2.5 16CX2.5 or 10CX2.5 3CX2.5 16CX2.5 or 10CX2.5 3CX2.5 16CX2.5 or 10CX2.5 3CX2.5 16CX2.5 or 10CX2.5 3CX2.5 3CX2.5 4CX4 4CX4
TB-3 TB-4 TB-5 TB-6 TB-6 TB-7 TB-7 TB-8 TB-8 TB-9 TB-9 TB-10 TB-10
For 220kV CT Circuit (from Top) From MK to C&R Panel For 132/66kV CT circuits (From Top). From MK to C&R Panel For 33kV CT circuit Directly to C&R Panel. For 220/132/66kV NCT Circuit (Bottom TBs). For 33kV NCT circuit Directly to C&R Panel. For 230VAC Supply (From Top). (3-Phase 4wire & 1-Phase) For 220VDC Supply (From Bottom). From top, CB Trip Circuit (DC Supply-1/Auto Reclose / Remote Close / Remote Tip-1/ Prot. Trip-I / Remote Trip-II / Prot. Trip-II/ Post-Pre Close Sup. TC-I / Post-Pre Close Sup. TC-II / DC Supply-II) etc. For CB Alarm Circuit including spring charge indications (After CB Trip Circuits) For all CB N/C Contacts (Semaphore / Auto Trip / Trip Alarm / Close Indication / Digital Status), etc. For all CB N/O Contacts (Semaphore / Open Indication / Digital Status), etc. For 33kV VCB Tripping Circuit, Alarms and Indication For Bus Isolator-A N/C Contacts (From Top) For Bus IsolatorB N/C Contacts (From Middle) For Bus Isolator-A Electrical Interlocking Coil (Bottom). For Bus Isolator-A N/O Contacts (From Top) For Bus IsolatorB N/O Contacts (From Middle) For Bus Isolator-B Electrical Interlocking Coil (Bottom). For Line Isolator N/C Contacts (From Top) For Earth Switch N/C Contacts (From Middle) For Line Isolator Electrical Interlocking Coil (Bottom). For Line Isolator N/O Contacts (From Top) For Earth Switch N/O Contacts (From Middle) For Earth Switch Electrical Interlocking Coil (Bottom). For 33kV Isolators / Line &Earth Switch semaphore. In case of Bus Coupler Bay PT Circuits (From Top) In case of Line Bay with 3No. CVTs CVT Circuits (From Top)
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24.
3CX2.5 2CX4
TB-10 TB-10
25.
3CX2.5 TB-10 16CX2.5 or 10CX2.5 or TB-10 7CX2.5
KCVT Supply for Electrical Interlocking (From Bottom) In case of Line Bay with 1No. CVT CVT Circuits and KCVT Supply for Electrical Interlocking (From Bottom) In case of T/F Bay T/F Tripping Contacts (From Top) T/F Alarm Circuits (After trip Circuits)
1. 2. 3. 4. 5. c)
NOTE:In case of transformer and Bus Coupler bays, TB No. 8 & 9 of MK will remain spare since L&E does not exist. In case, all CB alarm wires do not get accommodated on Bottom part of TB-3 of MK then shift all CB alarm wires on Bottom part of TB-5 of MK. In case of 33kV Bays suitable Terminal Junction Box shall be erected near CTs and wires from CT will be taken to JB & then to Control Room. Suitable rating of fuses & links shall be provided for AC & DC Supply by firm. 10% spare capacity of cores shall be kept spare in each size of cables used for each circuit and intermixing of cables is not allowed for wiring. As per HVPNL standard practice cable marking be done as given below and Cable ferrule Numbering shall start from equipment and the numbers will continue in sequential order for outgoing cables to Control Room for same equipment. MK TB Purpose Cable Numbering No. TB-1 CT/NCT Circuit Starting from 401 TB-2 For AC AC Supply for Adj. MK / ACDB -801 AC Supply for C&R Panel from ACDB -802 TB-2 For DC DC Supply for Adj. MK / DCDB -101 DC Supply for C&R Panel from DCDB -102 The Cable No. from MK to TB-2 For AC Supply to 501 Control Room in next sequential CB order 5XX. TB-3 For CB trip 502 Circuits. TB-3 For CB Alarms 503 TB-4 N/C Contacts of 504 CB TB-5 N/O Contact of 505 CB TB-8 & 9 N/C and N/O 601 The Cable No. from MK to Contacts of Line Control Room in next sequential Isolator. order 6XX. TB-8 Electrical 602 Interlocking Coil of Line Isolator. TB-6 & 7 N/C and N/O 603 Contacts of Bus Isolator-A TB-8 Electrical 604 Interlocking Coil of Bus Isolator-A TB-6 & 7 N/C and N/O 605 Contacts of Bus Isolator-B TB-8 Electrical 606 Interlocking Coil of Bus Isolator-B TB-8 & 9 N/C and N/O 301 Contacts of Earth Switch TB-8 Electrical 302 Interlocking Coil of Earth Switch TB-10 KCVT Supply for 303 Interlocking TB-10 For AC Supply 701 The Cable No. from MK to
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TB-10 TB-10 TB-10
for T/F For T/F Trip Circuits For T/F Alarms For PT/CVT Circuits
702 703 Starting from 201
Control Room in next sequential order 7XX.
1. 2.
3. i) ii) iii) iv) d)
1. 2. 3. 4. 5.
13.(B) 13.1 13.2
13.3 13.4 13.5 13.6
13.7 13.7.1
13.7.2 13.7.3
NOTE:Incase of Isolators / L&E Switch the cable numbering for AC & DC supply shall be in continuation to the numberings marked above. Each cable number is to be followed by respective bay number and same method of cable numbering is to be followed for 400kV, 220kV,132kV, 66kV and 33kV bays. Example:- In case of 132kV Bay with Bay No. B-10; cable numbering for AC supply to Circuit Breaker be done as2C X 4mm2 C.No.501B10 Where, 2C X 4mm2 is Size of Cable. 501 is cable number. B is Voltage level. 10 is bay number. Cable termination shall be done as described below. At MK, LHS of each TBs shall have respective equipment cable ferrule no. / MK TB No. and RHS shall have MK TB No./ C&R Panel cable ferrule no. At Each Equipment, LHS of TBs shall have MK TB No./Equipment ferrule no. At C&R Panel, LHS of TBs shall have respective MK TB No./ C&R panel ferrule no. In Wiring Diagram, single line Diagram shall have complete TB details of all equipment installed in a bay with cable core ferrule no. as per approved drawings has to be provided. Electrical Interlocking Scheme for Double Bus-Bar sub-stations The main requirement of Electrical Interlocking Scheme for grid sub-stations having Double BusBar sub-stations is as under:The Isolator shall not operate unless the circuit breaker is locked in open position. The earthing switch shall close only when the line Isolator is open and line is OFF. The line Isolator shall close only when the corresponding Circuit Breaker is open. The Bus Isolator of Bus Coupler Bay shall operate only when the Bus Coupler Circuit Breaker is open. When one Bus Isolator of any bay excepting the Bus Coupler is closed, the other shall close only when the Bus Coupler Circuit Breaker & its both the Isolators are closed. A typical Interlocking Scheme satisfying the above requirement is shown in figure 1 enclosed. Further, Electrical Interlocking Scheme for Single Bus-Bar sub-stations be prepared in this pattern accordingly. These schemes shall be provided in respective wiring diagrams and interlinking be shown in MK. Note:CS/WD as per above shall be prepared by the bidder after award of contract and submitted in 5sets for consideration and approval to the purchaser. CABLE TAGS AND MARKERS Each cable and conduit run shall be tagged with numbers that appear in the cable and conduit schedule. 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 circular shape for control cables. Location of cables laid directly underground shall be clearly indicated with cable marker made of galvanised iron plate. Location of underground cable joints shall be indicated with cable marker with an additional inscription Cable Joints. The marker shall project 150mm 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. 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 every twenty meters (20 m) in cable tray/trench runs. Cable tags shall be provided inside the switchgear, motor control centers, control and relay panels etc., wherever required for cable identification, where a number of cables enter together through a gland plate. CABLE SUPPORTS AND CABLE TRAY MOUNTING ARRANGEMENTS The contractor shall provide embedded steel insert on concrete floors/walls to secure supports for by welding to these inserts or available building steel structures, for the purpose of casting in the control room. The supports shall be fabricated from standard structural steel members. 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 an
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13.8 13.8.1 13.8.2
13.8.3 13.8.4
13.8.5
13.8.6
13.8.7 13.8.8 13.8.9 13.8.10
13.8.11
13.8.12 13.8.13 13.8.14 13.8.15 14. 14.1
14.2 14.3 15. 15.1
15.2
15.3
15.4
interval of 1000 mm (as per drg. attached). CABLE TERMINATION AND CONNECTIONS The termination and connection of cables shall be done strictly in accordance with cable and termination kit manufacturers instructions, drawing and/or as directed by the HVPNL. 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. Supply of all consumable material shall be included in the scope of the contractor. The equipment will be generally provided with un-drilled 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. Control cable cores entering control panels /switchgear /MCC / miscellaneous panels shall be neatly bunched, clamped and tied with nylon strap or PVC perforated strap to keep them in position. The contractor shall tag/ferrule control cable cores at all terminations, as instructed by the HVPNL. 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 no. as well Spare cores shall be similarly tagged with cable numbers and coiled up. All cable entry points shall be sealed and made vermin and dust proof. Unused openings shall be effectively closed. Double compression type tinned/nickel plated brass cable glands shall be provided by the contractor for all power and control cables to provide dust and weather proof terminations. The cable glands shall be tested as per BS:6121. They shall comprise of heavy duty brass casting, machine finished and tinned to avoid corrosion and oxidation. Rubber components used in cable glands shall be neoprene and of tested quality. The cable glands shall be of approved make. The cable gland shall also be tested for dust proof and weather proof termination. The test procedure has to be discussed and agreed to between the HVPNL and cable glands manufacturer. If the cable and box or the 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 HVPNL. Crimping tool shall be of approved design and make. Cable lugs shall be tinned copper solderless crimping type conforming to IS:8309 and 8394. The cable lugs shall be of approved make. Solderless crimping of terminals shall be done by using corrosion inhibitory compound. The cable lugs shall suit the type of terminals provided. DIRECTLY BURIED CABLES The contractor shall construct the cable trenches required 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 soil conditions prevailing at site, before quoting the unit rates. The power and control cable between LT station, Control room, shall be laid in the buried cable trenches. Further, for lighting purposes also, buried cable trench can be used in the outdoor area. 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. INSTALLATION OF CABLES Cabling shall be on cable racks, in built-up trenches, vertical shafts, excavated trenches for direct burial, pulled through pipes, and conduits laid in concrete ducts, run bare and clamped on wall/ceiling/steel structures etc. as shown in the drawings in detailed engineering stage. Where specific cable layouts are not shown on drawings, contractor shall route these as directed by the HVPNL. The contractor shall fabricate and install mounting arrangements for the support and installation of all the cables on angles at 1000 mm spacing in the trenches, as shown in the drawing enclosed with Specification. These mounting structures/cable racks shall be fabricated from structural steel members (channels, angles and flats) of the required size. The fabrication, welding and erection of these structures shall conform to the relevant clauses of Section STR, in addition to the Specifications given herein. Cable racks and supports shall be painted after installation with two coats of metal primer (comprising of red oxide 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. All welding works inclusive of the consumables required for Specifications given herein. All inter pole cables (power & control) for all equipment shall be laid in cable trenches/Gl conduit pipes of NB 50/100 mm diameter, class medium as per IS 4736 which shall be buried in the ground at a depth of 250 mm. The interpole cabling piping of Breakers shall be laid in cable trenches. The scope shall include all labour,material, equipment for transporting, laying, burying etc. including required bends and seals.
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15.5
15.6
15.7
15.8
15.9
15.10
15.11
15.12 15.13
15.14
15.15 15.16 15.17 15.18 15.19 15.20 15.21
15.22
15.23
15.24 15.25
15.26
Cable 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 floor shall be provided. In all these cases necessary bending radius as recommended by the cable Contractor shall be maintained. Cabling in the control room shall be done on ladder type cable trays. Cables from the equipment to trench shall run in GI conduits. Necessary conduits of adequate sizes and length shall be supplied and installed by the contractor. Flexible conduit should be used between fixed conduit/cable trays (perforated type) and equipment terminal boxes, where vibration is anticipated. The flexible conduit shall be as per the relevant IS. Power and control cables shall be laid in separate tiers. The order of laying of various cables shall be as follows, for cables other than directly buried: Power Cable on top tiers. Control instrumentation and others service cables in bottom tiers. Single core cables in trefoil formation shall be laid with a distance of three times the diameter of cable between trefoil centerlines. All power cables shall be laid with a minimum center-to-center distance equal to twice the diameter of the cable. Trefoil clamps for single core cable shall be pressure die cast Aluminium (LM-6), Nylon or fibre glass and shall include necessary fixing GI nuts, bolts, washers etc. These are required at every 2 meter of cable runs. The cost of supply and erecting these clamps shall be made on the unit rate basis. Power and control cable shall be securely fixed to the trays/supports with self locking type nylon ties with deinterlocking facility at every 5 meter interval for horizontal run Vertical and inclined cable runs shall be secured with 25 mm wide and 2 mm thick Aluminium strip clamps at 2 m. Cables shall not be bent below the minimum permissible limit. The permissible limits are as follows: Table of cable and Minimum bending radius voltage grade Power cable 12 D. Control cable 10 D. D is overall diameter of cable. The cables are to be laid in single layers on racks and are to be routed through culvert whenever there is road crossing. In each cable run some extra length shall be kept at a suitable point to enable one (for LT cables)/two (for HT cables) straight through joints to be made in case the cable develop fault at later date. 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 HVPNL. If straight through joints are unavoidable, the contractor shall use the straight through joints kit of reputed make. Control cable terminations inside equipment enclosures shall have sufficient lengths so that changing of termination blocks can be done without requiring any splicing. Metal screen and armour of the cable shall be bonded to the earthing system of the station, wherever required by the HVPNL. Rollers shall be used at intervals of about two meters while pulling cables. All due care shall be taken during unreeling, laying and termination of cable to avoid damage due to twist, kinks, sharp bends etc. Cable ends shall be kept sealed to prevent damage. Inspection on receipt, unloading and handling of cables shall generally be in accordance with IS:1255 and other Indian Standard Codes of practices. Wherever cable pass through wall openings or other partitions, 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. Contractor shall remove the RCC/Steel trench covers 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 sometime. Contractor shall furnish three 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. Contractor shall paint the tray identification number on each run of trays at an interval of 10 m. 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 HVPNL. 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 HVPNL, i.e. the contractor shall be paid for installation and removal of the damaged cable. 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.
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15.26.a 15.26.b 15.26.c 15.26.d
15.27 15.27.1 15.27.2
15.28 15.28.1
15.28.2
15.28.3 15.28.4
15.28.5 15.28.6 15.28.7 15.28.8 15.28.9
15.28.10
15.28.11
15.28.12 15.28.13
15.28.14 15.28.15 15.28.16 15.28.17 15.28.18
15.28.19
15.28.20
Separate racks/trays will be utilised for different voltage levels from switchyard to control room. All the cable trenches will be constructed as per standard HVPNL design as far as electrical portion is concerned. The GI pipe duly lugged at both ends and by providing bends/elbows or trenches will be provided/constructed from equipment to trenches. Provision for accommodation of cables of future bays (All bays position marked on the drawing whether shown dotted or not to be included for future provision in main the trench size) are to be made in the main trenches. TESTS ON CABLE TRAYS Test for galvanising (Acceptance test) to be done as per relevant standard. DEFLECTION TEST (TYPE TEST) A 2.5 meter straight section of all widths cable trays be simply supported at two ends a uniform distributed load of 76 kg meter shall be applied along the length of the tray. A maximum deflection at the mid span shall not exceed 7 mm. CONDUITS, PIPES AND DUCT INSTALLATION 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 engineering drawing. The size of the conduit/pipe shall be selected on the basis of 40% fill criterion. 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 edges. Anticorrosive paint shall be applied at all field threaded portions. 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. 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. Conduit installation shall be permanently connected to earth by means of a special approved type of earthing clamps. GI pull of adequate size shall be laid in all conduits before installation. Each conduit run shall be painted with its designation as indicated on the drawing such that it can be identified at each end. Embedded conduits shall have a minimum concrete cover of 50 mm. Conduit run sleeves shall be provided with the bushings at each end. 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. When embedded conduits turn upwards from a slab or fill, the termination dimensions shown on the drawings, 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. All conduits/pipes shall have their ends closed by caps until cable are pulled. 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. For underground runs, contractor shall excavate and back fill as necessary. 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, check nuts, male and female bushings (brass or galvanised steel), caps, square headed male plugs, nipples, gland sealing fittings, pull boxes, conduit terminal boxes, gaskets and box covers, saddle terminal boxes, and all steel supporting work shall be supplied by the contractor. All unarmoured cable shall run within the conduits from lighting panels to lighting fixtures, receptacles etc. Size of conduit for lighting shall be selected as per the table given in the attached drawings. 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 100 mm 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 brickwork by grouting or by nylon rawl plugs. Wooden plug inserted in the masonry or concrete for conduit support is not acceptable. 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 and in no case shall be less than 38 mm.
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15.28.21 Where conduits are along with cable trays, they shall be clamped to supporting steel at an interval of 600 mm. 15.28.22 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. 15.28.23 Conduit shall be installed in such a way as to ensure against trouble from trapped condensation. 15.28.24 Conduit shall be kept, wherever possible, at least 300 mm away from hot pipes, heating devices etc. when it is evident that such proximity may reduce the service life if cables. 15.28.25 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. 15.28.26 For long conduit run, pull boxes shall be provided at suitable intervals to facilitate wiring. 15.28.27 Conduit shall be securely fastened to junction boxes or cabinets, each with a lock nut inside and outside the box. 15.28.28 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 lead for exposed conduit. 15.28.29 Field bends shall have a minimum radius of four (4) times the conduit diameter. All bends shall be free of kinds, indentations of flattened surfaces. Heat shall not be applied in making any conduit bend. Separate bends may be used for this purpose. 15.28.30 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. 15.28.31 After installation, the conduits shall be thoroughly cleaned by compressed air before pulling in the wire. 15.28.32 Lighting fixtures shall not be suspended directly from the junction box in the main conduit run. 16. ILLUMINATION SYSTEM 16.1.1 The scope of work comprises of design, engineering, testing, supply, installation, testing and commissioning of various lighting fixtures complete with lamps, supports and accessories, lighting panels, lighting complete with distribution boxes, galvanised rigid steel conduits, lighting wires, G.I. Earthwire receptacles, switchboards, switches, junction boxes, pull out boxes complete with accessories, lighting transformer & Street steel light poles as per IS: 2713-1980 (Part-II). The details of area to be illuminated are given below: Control Room Building. Switch Yard area. Roads and streets. 16.1.2 The minimum lux levels to be maintained in the different areas shall be as per following: Sr. No. Area Lux. Level i) Switchyard 50 lux on power transformer and 20 lux on other equipment. ii) Street/Road 20 lux. Bidder shall submit detailed for reaching the above LUX levels. 16.1.3 Any material, wire, conduits, accessories etc. not specifically mentioned or specified but required for installation of lighting fixtures are included in the scope of contractor. All lighting fixtures & accessories shall be designed for continuous operation under atmospheric conditions existing at site, without reduction in the life or without any deterioration. The lighting fixtures shall be of Philips or Bajaj or Crompton Greaves of make only. 16.2 TEMPERATURE RISE All lighting fixtures and accessories shall be designed to have a low temperature rise according to 0 the relevant Indian Standards, the design average ambient temperature shall be taken as 50 C. 16.3 LIGHTING FIXTURES 16.3.1 All fixtures shall be designed for minimum glare. 16.3.2 All lighting fixtures shall be complete with lamps a specified and shall be suitably wired up. 16.3.3 All lighting fixtures shall be complete with accessories. Outdoor type fixtures shall be provided with outdoor type weather proof box. 16.3.4 Each lighting fixtures shall be provided with an earthing terminal and all metal parts of the housing shall be constructed so as to ensure earthing continuity throughout the fixture up to the earthing terminal. 16.3.5 The mounting facility and conduit knock-outs for the fixtures shall be suitable for 20 mm conduit entry. 16.3.6 The wire shall be of 1100 V grade and PVC insulated with multi stranded copper conductor. 16.4 TESTS Manufactures type and routine test certificates shall be submitted for the fixtures and accessories. 16.5 SYSTEM DESCRIPTION The lighting system shall comprise of the following: 16.5.1 AC NORMAL LIGHTING All the lights connected to the AC lighting system in different area will be connected to the AC
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16.5.2
16.5.3
16.6 16.6.1 16.6.2
16.6.3
16.6.4 16.6.5
16.6.6
16.6.7 16.6.8
16.6.9 16.6.10 16.6.11
16.6.12
16.6.12.1
i. ii, iii. iv. v. vi. 16.6.12.2 i. ii. iii. iv. v. vi. vii. viii. ix. x. xi. xii.
distribution boards to be supplied. DC EMERGENCY LIGHTING DC emergency in Control room, relay and protection room, office, LT switchgear room, D.C.D.B. room shall be provided to avoid complete darkness in case of complete AC failure. The number of DC emergency lights to be provided shall be calculated on the basis that at least illumination level of at least 30 LUX is achieved when DC emergency lights get switched ON. RECEPTACLES Adequate number of 5A, 15 A, (single phase) and 32 A (3phase) receptacles shall be provided at suitable locations to be mutually during the detailed engineering. ERECTION, TESTING AND COMMISSIONING OF LT PANELS & BATTERY CHARGER The Contractor shall unload, erect, install, test and put into commercial use all electrical equipment included in this Specification. Equipment shall be installed in a neat, workman so that it is level plumb, square and properly aligned and oriented. Tolerance shall be as established in Contractors drawings or as stipulated by HVPNL. No equipment shall be permanently bolted down to foundations until the alignment has been checked and found acceptable by the HVPNL. Contractor shall furnish all supervision, labour tools equipment rigging materials, bolts, wedges, anchors, concrete insert etc. in proper time required to completely install, test and commission the equipment. Manufactures and HVPNLs instructions and recommendations of all equipment. 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 utilised to lift or erect any equipment without prior permission of HVPNL. All switchboards shall be installed in accordance with Indian standards IS:3072 and at HVPNLs instructions. Switchboard panels shall be installed on finished surfaces, concrete or steel stills. Contractor shall be required to install and align any channel sills which from part of foundations. In joining shipping sections of switchboards together adjacent housing of panel section or flanged throat sections shall be bolted together after alignment has been completed. 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. All switchboards shall be made completely vermin proof. 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 blocking materials HVPNL for safe transit of instrument and relays shall be removed after ensuring that panel been completely installed and to further movement of the same should be necessary. Any damage shall be immediately reported to HVPNL. Equipment furnished with finished coats of paint shall be touched by up Contractor if their surface is specified or marred while handling. Foundation work for all switchboard panels will be carried out by Civil Contractor. However, minor modifications shall be carried out by the Contractor at no extra cost. 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. COMMISSIONING CHECK TESTS The Contractor shall carry out the following commissioning check wherever applicable in addition to the other checks and tests recommended by the manufacturers: GENERAL Check nameplate details according to the Specification. Check for physical damage. Check tightness of all bolts, clamps, joints connecting terminals. Check earth connection, Check cleanliness of insulators and bushings. Check all moving parts for proper lubrication. CIRCUIT BREAKERS Check alignment of Breaker truck for free movement. Check correct operation of shutters. Check control wiring for correctness of connections, continuity and IR values. Manual operation of Breaker completely assembled. Power closing/opening operation, manually and electrically. Breaker closing and tripping time. Trip free and anti-pumping operation. IR values, minimum pick up voltage and resistance of coils. Contact resistance. Simultaneous closing of all the three phases. Check electrical and mechanical interlocks provided. Check on spring charging motor, correct operation of limit switches, and timeof charging.
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xiii. 16.2.12.3 i. ii, iii. iv. 16.2.12.4 i. ii, iii. iv. 16.2.12.5 i. ii, iii. iv. 16.2.12.6 i. ii. a) b) iii. iv. v. vi. vii. 16.2.12.6 i. ii, iii. 16.7 16.7.1 16.7.2
16.7.3
16.7.4
All functional checks. CURRENT TRANSFORMERS Megger between winding and winding terminals top body. Polarity test. Ratio identification checking of all ratios on all by primary injection of current. Spare CT cores, if any, to be shorted and earthed. VOLTAGE TRANSFORMER Insulation resistance test. Ratio test on all cores. Polarity test. Line connections as per connection diagram. CUBICLE WIRING Check all switch development. Each wire shall be traced by continuity tests and it should be made sure that the wiring is as per relevant drawing. All interconnection between panels/equipment shall similarly checked. All the wire shall be meggered to earth. Functional check of all control circuit e.g. closing, tripping control, interlock, supervision and alarm circuit. RELAYS Check connections and wiring. Megger all terminal to body. Megger AC to DC terminals. Check operations characteristics by secondary injection. Check minimum pick up voltage of DC coils. Check operation of electrical/mechanical targets. Relays settings. Check CT and VT connections with particular reference to their polarities for directional relays, wherever required. METERS Check calibration by comparing it with a sub-standard. Megger all insulated portions Check CT and VT connections with a particular reference to their polarities for power type meters. ERECTION, TESTING AND COMMISSIONING OF BATTERY BANK The control shall unload, erect, install, test and put into commercial use already electrical equipment included in this Specification. 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 established in Contractors drawings or as stipulated by HVPNL. No equipment shall be permanently bolted down to foundations until the alignment has been checked and found acceptable by the HVPNL. Contractor shall furnish all labour tools equipment rigging materials, bolts, wedges, anchors, concrete inserts etc. in proper time required to completely install, test and commission the equipment. Manufacturers and HVPNLs instructions and recommendations shall be correctly followed in handling, testing and commissioning of Battery Bank.
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SECTION 8
STRUCTURES
1.0 1.1 GENERAL The scope of specification covers fabrication, proto-assembly supply and erection of galvanised steel structure for towers, latticed griders and equipment support structure. Towers, girder & equipment support structures shall be as per HVPN drawing conforming to IS 2062 (latest). The scope shall include all types of bolts, nuts, step bolts, inserts in concrete, gusset plates, equipment mounting bolts, structure Earthing bolts, foundation bolts, spring washers, fixing plates, angles and bolts for structure mounted or ground mounted marshalling boxes (AC/ DC Marshalling box & equipment control cabinet) 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 0.610 kg/m2. One additional nut shall be provided below the base plate which may be used for the purpose of leveling. DESIGN REQUIREMENTS Minimum distance from the hole centre to edge shall be 1.5x bolt diameter. Minimum distance between center to center of holes shall be 2.5x bolt diameter. The minimum bolt diameter shall be 16 mm. In order to facilitate inspection and maintenance, the structures shall be provided with climbing devices. Each tower shall be provided with step bolts not less than 16 mm diameter & 175 mm long spaced not more than 450 mm apart, staggered on faces on 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 on towers with lighting appliances shall be provided with safety guards. 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. Foundation bolts/ studs shall be designed for the loads for which the structures are designed. FABRICATION OF STEEL The Bidder shall bear all the expenditure at all stages on account of loading/ unloading, transportation and other miscellaneous expenses and losses and damages for all materials upto the fabrication yard/ shop and there after to the erection site including all other expenses till the erection of work has been completed and accepted. The unit rates shall be deemed to be inclusive of all such incidental expenses and nothing extra shall be payable on any account in this regard.
2.0 2.1 2.2 2.3
2.4
2.5 3.0 3.1
-1-
3.2
4.0
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 nonstipulation of some particular provision in IS:802. All materials shall be completely shop fabricated with proper connection material and erection marks for ready assembly in field. ASSEMBLY The component parts shall be assembled in such a 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 minimise 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 patten. If the individual components are to be bolted, paralled and tapered drifts shall bed used to align the part so that the bolts can be accurately positioned. ii) Sample towers, beams and equipment support structure shall be trial assembled keeping in view the actual site conditions, before erection in the fabrication shop and shall be inspected and approved by HVPNL before mass fabrication. Necessary match marks shall be made on these components in the shop before disassembly and despatching. BOLTING i) Every bolt shall be provided with a spring 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 galvanised. iii) 2.0% extra nuts and bolts shall be supplied for erection. WELDING The work shall be done as per approved fabrication drawing which clearly indicate various details of joints to be welded, type of weld, length and size of weld, whether shop or site weld. 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 welding due to constructional difficulties. FOUNDATION BOLTS Foundation bolts for the towers and equipment supporting structures and elsewhere shall be embedded in first stage concrete while the foundation is cast. The Bidder shall ensure the proper alignment of these bolts to match the holes in the base plate. The Bidder shall be responsible for the correct alignment and leveling of all steel work on site to ensure that the towers/ structures are plumb. All foundation bolts for lattice structures are to be supplied by the Bidder. All foundation bolts shall be fully galvanised so as to achieve 0.61 kg per Sq.m of Zinc Coating as per specification. STABILITY OF STRUCTURE The Bidder shall be responsible for the stability of the structure art all stages of its erection at site and shall take all necessary measures by the additions of i)
5.0
6.0
7.0 7.1
7.2 7.3 7.4 8.0
-2-
9.0
temporary bracing and guying to ensure adequate resistance to wind and also to loads due to erection equipment and their operations. GROUTING The method of grouting the column bases shall be subject to approval of HVPNL and shall be such as to ensure a complete uniformity of contact over the whole area of the steel base. The Bidder will be fully responsible for the grouting operations. GALVANISING All structure steel works and single pipe supports shall be galvanised after fabrication. Zinc required for galvanising shall have to be arranged by the manufacturer. Purity of zinc to be used shall be 99.5% as per IS:209 (latest). The Bidder shall be required to make arrangement for frequent inspection by the HVPNL as well as continuous inspection by a resident representative of the HVPNL, if so desired for fabrication work. INSPECTION BEFORE DISPATCH Each part of the fabricated steel work shall be inspected and certified by the HVPNL of his authorised representative as satisfactory before it is dispatched to the erection site. Such certificate shall not relieve the Bidder of his responsibility regarding adequacy and completeness of fabrication. TEST CERTIFICATE Copies of all test certificate relating to material procured by the Bidder works shall be forwarded to the HVPNL. ERECTION The Bidder should arrange his own erection plant and equipment, welding set, tools and tackles, scaffolding, trestles equipment etc. and any other accessories and ancillaries required for the work. SAFETY PRECAUTIONS The Bidder 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 erection for structural steel work IS:7205.
10.0 10.1 10.2 10.3
11.0
12.0
13.0
14.0
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G-11/Package-A & B
SECTION-9
CIVIL WORKS 1.0 GENERAL The intent of specification covers the following: Design, Engineering, Construction of all specified Civil Works of the proposed substation covered under the scheme. All Civil Works shall also satisfy the general technical requirements specified in other sections of this specification and as detailed below. All the specified designs shall be carried out to the required service conditions/loads as specified elsewhere in the specifications or implied as per National/International Standards and as specified by manufacturers. All Civil Works shall be carried out as per applicable Indian Laws, latest Standards and Codes. All material shall be of best quality conforming to relevant Indian Standards and Codes. The successful bidder shall furnish all design, (unless otherwise specified), drawings, labour, tools, equipment, material, temporary works, construction plant and machinery, supply fuel, transportation and all other incidental items not shown or specified but are required for complete performance of the works in accordance with approved drawings, specifications and direction of HVPNL. The work shall be carried out according to the design/drawings to be developed by the successful bidder and submit the same for approval of the HVPNL or shall be supplied to the bidder by the HVPNL as detailed in the schedule of quantities. The design/drawing so approved shall become the property of the Nigam and the Nigam shall be free to use these designs/drawings at any of its upcoming/future station. For all structures, buildings, foundations etc. necessary layout and details shall be developed by the bidder keeping in view the functional requirement of the sub-station facilities and providing enough space and access for operation, use and maintenance based on the input provided by the HVPNL. Certain minimum requirements are indicated in this specification for guidance purposes only. However, the bidders shall quote considering all the requirements essential for functional purposes. All the civil works covered under the said scheme shall be constructed under the supervision of experienced degree/diploma holder civil engineers as mentioned under GCC.
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2.0
SOIL DATA For the guidance of the bidders, the general soil data around proposed sub-station is specified below.
Name of station Type of soil Dry/Wet Angle Cohes Bulk of -ion Density internal kg/m2 friction 00 00 00 00 00 00 00 00 Safe allowable B.C (t/m2) at 1.5m depth (F.O.S=2.5) 6.5 . 7.4 Depth of water table from N.S.L
Mund Badhana
RGEC, Sonipat Sector-6, Sonipat Badli Machhrauli Gurnawati Beri
Normal/Silty sand Silt with some sand and kankar Fine sand with some silt Fine sand with some silt Fine sand with some silt Fine sand with some silt Nomal/Silty
1600, 1780 1610, 1800 1570, 1800 1570, 1800 1600, 1780 1560, 1760 1500, 1650 1590, 1750
28 28
Below 6m Below 6m
28 28 28 27 28 28
6.5 6.5 6.7 6.8 6.0 6.5
Below 6m Below 6m Below 6m Below 6m Below 6m Below 6m
Tajpur Bhattu Khurd Aherwan
Mostly silt with some sand and a little kankar Fine sand 1580, with some silt 1760 Mixture of 1500, Clay and Sand 1600 Sand with silt 1680, & some 1870 kankar
28 28 32
00 00 00
7.4 6.0 7.0
Below 6m Below 6m Below 6m
2.1
GENERAL SITE DESCRIPTION The substation sites are generally leveled except Machhrauli and Gurnawati where tibbas and depressions are there. Therefore, to achieve formation level which is generally fixed at a higher level than its surroundings, earth filling/cutting may be required. However, where only new bays are proposed at the existing sub-station(s), the formation level shall be same as that of existing sub-station. The quantities of earth filling/cutting indicated in the BoQ are tentative and may vary based on site contouring and site requirement/surroundings at each substation. The bidders are, therefore, advised to visit each site before quoting.
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2.2
The successful bidder shall use the soil data mentioned above for designing the equipment structure foundations. Minimum depth of foundation in natural ground so designed shall not be less than 1.0 meter excluding lean concrete. SITE PREPARATION The site(s) as available shall be handed over to the selected bidder. Clearing of the site(s) from bushes/trees including its roots shall be carried out by the successful bidder. The HVPNL, if required, shall arrange necessary permission for cutting of trees from the concerned authorities. The bidder/contractor shall hand over the wood of trees to HVPNL. The Contractor shall prepare the `CONTOURS` of land at suitable intervals. The spot levels shall be taken at a distance not more the 5.0M (2.0M where bays are proposed) intervals. The contours at new substations shall extend sufficient distance (approx. 50M) around the land and main road in front of land and any other important existing feature to give a fair idea about topography of the area. On submission of contour plan by the successful bidder and based on the surroundings, drainage condition etc., the HVPNL shall fix the Formation Level(s) of the sub-stations which are generally fixed somewhat higher than the surroundings. The contractor, as per specifications shall carry out the necessary earth cutting/filling in layers, compaction, leveling and dressing to reach the desired formation level. The contractor at his own cost shall make the layout and levels of all structures/buildings as per the general grid of the plot and the Benchmark given by the Executive Engineer/ Civil Works Division. The permanent Benchmark and all the change points shall be established at the proposed site and the same shall be got authenticated before taking any further levels. The contractor shall provide all help including instruments, materials and personnel to the Executive Engineer/Civil Works Division or his representative for checking the detailed layout and shall solely be responsible for the correctness of the layouts and levels.
2.3
3.0
SCOPE This clause covers the design, engineering, supply of labour, material and execution of civil items including dismantling of the existing foundations/structures/roads wherever required, clearing the site, site preparation, supply and compaction of fill material to achieve formation level, foundations, excavation and compaction of backfill for foundation, roads, trenches including trenches below floors in buildings etc., retaining wall complete in all respects.
-3-
3.1
WATER SAMPLE The successful bidder shall arrange water supply connection from Local Govt. (Village Panchyat, Public Health Deptt., Municipal Committee/Council etc.) to meet the construction requirement. HVPNL will facilitate the successful bidder for obtaining connection from the concerned govt. department. In case the water connection from local govt. is not available, the successful bidder shall arrange representative samples of ground water (from the substation land). The collected samples shall be of sufficient quantity and shall be stored in air-tight containers so that chemical analysis of water for use in concrete and curing could be carried out. If the water so tested is found potable/ useful for construction activities, the successful bidder shall provide a bore hole with suitable submersible motor for use at the substation(s). Before start of work, the water sample results and scheme shall be submitted for approval of HVPNL. In case water supply connection and bore are not feasible, the successful bidder shall arrange at his own cost sufficient quantity and good quality water along with required pumping arrangements for construction, curing and other purposes. In all the above mentioned three conditions the successful bidder shall provide underground water storage tank of atleast 10,000ltr. capacity for storage of water. Nothing shall be paid extra on account of obtaining water connection/water supply/provision of tubewell bore for arranging water from any other source. However, in case good quality water is available at existing sub-stations, the same shall be provided to the successful bidder free of cost.
3.2
GENERAL
3.2.1 Material including excavated material unsuitable for founding of foundations shall be removed and replaced by suitable fill material and the same is required to be got approved from the HVPNL. 3.2.2 Fill/Backfill material around foundations or other works shall be free from harmful salts viz. sulphates, chlorides and or any organic/inorganic materials. The Fill/Backfill material should be compacted as described under clause 3.4. 3.3 EXCAVATION AND BACKFILL
3.3.1 Excavation and backfill for foundations shall be in accordance with the relevant IS code and as per approved design/drawings.
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3.3.2 Whenever water table/seepage water is met during excavation, it shall be dewatered and foundation pit shall be maintained dry i.e. free of water during the excavation, concreting and back filling. No extra payment on this count shall be admissible. 3.3.3 When embankments are to be constructed on slopes of 15% or greater, benches or steps with horizontal and vertical faces shall be cut in the original slope prior to placements of embankment material. The vertical faces shall measure not more than 1.0 m in height. 3.3.4 Embankments adjacent to abutments, culverts, retaining walls and similar structures shall be constructed by compacting the material not exceeding 15cm in thickness of loose material before compaction in successive uniform horizontal layers. Each layer shall be compacted as required by means of mechanical tempers approved by the HVPNL. Rocks larger than 10 cm shall not be placed in embankment adjacent to structures. 3.3.5 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 measurements 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. 3.3.6 In case the switchyard area needs leveling & dressing only, to maintain the final formation level as fixed by HVPNL, same shall be done with utmost care and with proper compaction. If the top crest of earth (30 cm depth) is containing harmful salts and organic/inorganic materials, it shall be scraped and disposed off at a place outside substation as directed by Executive Engineer/ Civil Works Division. . 3.4 COMPACTION
3.4.1 The method and equipment used to compact the fill material shall be suitable to achieve the density that will give the allowable soil bearing pressure required for the foundations, roads etc. in each layer of fill material. Each layer of earth embankment when compacted shall be as close to optimum moisture content as practicable. Embankment material that does not contain sufficient moisture to obtain proper compaction shall be wetted. If the material contains 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 rock fills. No compaction shall be carried out in rainy season/during rains. 3.4.2 At all times, the 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.
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3.4.3 The density to which fill materials shall be compacted shall be as per relevant IS and as per direction of HVPNL. 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 Optimum Moisture Content (OMC). The sub-grade for the roads and embankment filling shall be compacted to minimum 95% of the Standard Proctor's density at OMC. 3.5 EARTH WORK FOR ACHIEVING FORMATION GROUND LEVEL (FGL)
3.5.1 To maintain the formation level (FL) as fixed by HVPNL, earth filling/cutting or both filling/cutting may be required. Before earth work is started, the site shall be clear from bushes/trees including roots, existing structures etc. by the successful bidder 3.5.2 In case earth is to be imported (earth filling), the area from where the earth is to be imported should be pre-determined so as to ensure good quality of earth i.e. earth imported should be free from shrubs, ranks, vegetation, grass, brushwood, stone shingle and boulders (longer than 75mm in any direction), organic or any other foreign matter. Earth containing deleterious materials salt peter earth etc. shall not be used for filling. All clods and lumps of earth exceeding 8cm in any direction shall be broken or removed before the earth is used for filling. Imported earth shall be measured for payment as per x-sections based on initial and final levels at the substation. 3.5.3 In case the earth work is required in cutting, the cut earth shall be spread in sub-station areas requiring filling and the surplus earth, if any shall be disposed of to a suitable undisputed place outside the substation. The successful bidder shall be responsible in case some dispute arises on account of disposal of earth at a disputed site. Cutting shall be measured and payment shall be made on actual basis as per x-sections based on initial and final levels at the substation. 3.5.4 In case both cutting of earth (including spreading) & filling (import of earth) are required, each item will be measured separately and payment made on actual basis for both as per x-sections based on initial and final levels at the substation. 3.5.5 The rates for earth filling/cutting and spreading of earth shall include site clearance, laying of earth in layers (as per specification briefly brought out under compaction), dressing, carriage, lead, loading and unloading, watering and compaction with roller including compensation of earth etc. as per specification complete for the substation as a whole, including under roads. 3.5.6 In case only dressing is required for maintaining FGL, nothing shall be paid extra on this account.
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3.5.7 In case earth contains harmful salts, deleterious materials etc. and top layer of 300mm layer requires cutting and disposal only, nothing shall be paid extra on this account. This earth shall be disposed outside substation area and shall not be used for filling anywhere in the substation area. 4.0 4.1 SITE SURFACING SCOPE OF WORK The contractor shall furnish all labour, equipment and materials required for complete performance of the work in accordance with the drawings, Specification and direction of the Executive Engineer/ Civil Works Division. Stone spreading along with cement concrete layer shall be done in areas presently in the scope of the scheme. Stone spreading only shall, however, be provided in the areas (bays) kept for future expansion. 4.2 GENERAL REQUIREMENT
4.2.1 The material required for site surfacing/gravel filling should be free from all types of organic materials and shall be of standard approved quality as directed by the Executive Engineer/ Civil Works Division. 4.2.2 The material to be used for stone filing/site surfacing shall be 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 0-10 (upto 90% retained on sieve) One Test shall be conducted for every 500 cum per source.
b)
Hardness Abrasion Value (IS: 2386 Part-IV) not more than 40% Impact value (IS: 2386 Part-IV) not more than 30% One test per 500 cum with a minimum of one test per source.
4.2.3 The Contractor, after all the structures and equipment have been erected and accepted, shall furnish and install the site surfacing to the lines and grades as shown in the drawing and in accordance with the requirements and direction of the Executive Engineer/Civil Works Division. The site shall be maintained to the lines and grades indicated in the drawing by using 3 ton roller with suitable water sprinklers to form a smooth and compact surface condition which shall match with finished ground level of the switchyard area.
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4.2.4 100mm thick base layer of cement concrete in 1:4:8 (1 cement: 4 fine aggregates conforming to zone-II as per IS:583: 8 coarse aggregate nominal size 20MM) shall be provided in the areas excluding roads, drains, cable trenches as per detailed engineering drawing. 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 1:4:8. A layer of cement slurry of mix 1:4 (1 cement: 4 fine aggregates) shall be laid uniformly over cement concrete layer. The cement consumption for cement slurry shall not be less than 150kg per 100 sq.m. 20mm single size coarse aggregate should be used for base concrete. 4.2.5 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 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. 4.2.6 Areas where the Executive Engineer/Civil Works Division is satisfied that proper filling of the base course material by normal rolling equipment is not possible due to closely laid foundations and structures, the filling of the base course material shall be compacted by hand. Due care shall be exercised to avoid any damage to the foundations, structures, equipments (Cable trench or Cable) during rolling compaction or otherwise. 4.2.7 A final layer of 100mm thick uncrushed/crushed/broken stone of 40mm nominal size (ungraded size) shall be spread uniformly over cement concrete layer after curing is complete. 4.2.8 Generally site surfacing will be restricted upto 2.0m beyond the last structure/equipment foundation. However, depending upon the site requirement, the same shall be carried out as per instructions of Executive Engineer/Civil Works Division. To hold the stone (bajri) wherever required, a toe wall of 115mm thick, 300mm deep (1:4) shall be provided. Top of wall shall be 25mm above top of bajri. All visible portion of toe wall shall be plastered and cement painted. 5.0 SITE DRAINAGE SCOPE Adequate site drainage system shall be provided by the Contractor within the switchyard fencing under the present scope including house building & connection at one or more points to the outfall point located outside the substation boundary wall is in the scope of contractor. Invert level of drainage system at outfall point shall be decided in such a way that the
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water can easily be discharged outside the substation boundary wall. Outfall point shall be got approved from Executive Engineer/Civil Works Division before commencement of construction. The contractor shall obtain rainfall data and design the storm water drainage system including culverts, ditches, drains etc. to accommodate the most intense rainfall that is likely to occur over the catchments area in one hour period on an average of once per ten years. While designing the drainage system following points shall taken care of: 5.1 The surface of the switchyard shall be sloped to prevent pounding of water. Longitudinal slope shall generally be not less than 1 in 1000. However, keeping in view the discharge, the same can be increased to 1:2000. Open surface drains shall be construed in first class brick masonry in 1:4 cement sand mix laid over 100mm thick PCC of 1:4:8 (1cement; 4 coarse aggregates; 8 stone aggregate 20mm nominal size). The side walls shall be plastered with 1:5 cement sand mix The trapezoidal drains, if proposed shall have 300mm bottom width and sides slope of 1 horizontal; 1.5 vertical. For design of lined drain IS: 10430 and for construction of cast-in-situ cement lining IS: 3873 shall be followed. Drain shall be constructed on one/both sides of roads as per site requirement. In the switchyard maximum spacing between two drains shall not be more than 100meter. It will be ensured that no area is left undrained. The side wall(s) of the drains as per site conditions shall be 25mm above the gravel level to prevent spilling gravels. Suitable mild steel grating be provided for drainage of surface water. RCC pipe drains shall be provided in area of switch yard where movement of crane will be necessary in operating phase of the substation. For pipe drains, RCC concrete pipe of class NP3 shall be used. However, for road crossings rail crossings etc., RCC pipes of class NP4 shall be provided. For design of RCC pipes for drains and culverts, IS: 456 and IS: 783 shall be followed. Pipe drains shall be connected through manholes at an interval of max. 30m. Sum pit of suitable size to hold water for 5 minutes discharge has to be constructed within the substation boundary at suitable site as per HVPNLs drawing & directions of Executive Engineer/Civil Works Division.
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5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
5.10
5.11
The drainage scheme and associated drawings shall be developed by the successful bidder and shall be got approved from HVPNL before commencement of work. Two non clog pumps (of reputed make) and of suitable capacity (depending upon maximum discharge and capable of lifting particle size 65mm) shall be provided at sum pit(s) by the contractor without any extra cost. RAINWATER HARVESTING. In addition to drainage of rainwater in accordance with clause 5.0 of section civil of Technical specification, the contractor shall make arrangement for rainwater harvesting also as per drawing supplied by the HVPNL with the bid document. Rainwater harvesting shall not be done if the depth of water table is within 8.0 m from finished ground level. Rainwater harvesting shall be done by providing two numbers recharge structures with bore wells. The recharge structures shall be suitably located within the sub-station. Branch drains from the main drain carrying rainwater from entire switchyard, constructed in accordance with clause 5.0, shall be connected to the recharge structures. The internal diameter of recharge shafts shall be 3.0/4.5 meter as per HVPNL drawing 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 300kg per sq m. Two openings of size 0.7x0.7 meter shall be provided in the RCC cover slab as shown in the drawing. An iron cover made of 5mm thick chequerred plate with hinges shall be provided on the openings. Galvanized M.S. rungs of 20mm diameter at spacing of 300mm shall be provided in the wall of shaft below the opening in the RCC slab to facilitate cleaning of shaft. 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 or as per directions of the Executive Engineer/ Civil Works Division. A 150 mm dia. class 3 PVC pipe conforming to IS 4985-1981 with latest revision shall be lowered in the bore well keeping bail plug towards bottom of bore well. The pipe shall have 1.58 mm holes for 4.0 meter length starting from 1.0 meter from bottom of bore well. Holes of 3.0 mm 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.
5.12
6.0 6.1
6.2
6.3
6.4
6.5
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6.6
Gravel of size 3mm to 6mm shall be filled around 150 dia PVC pipe in the bore well. The shaft shall be filled with 500mm thick layers each from the bottom of shaft with boulders of seize 50mm to 150mm, gravel of size 5mm to 10mm coarse sand having particle size 1.5mm to 2.0 mm and boulders of size not less than 200mm respectively. ROAD, CULVERTS AND PCC PAVEMENT/PARKING: Latest specifications as adopted by HVPNL for construction of roads and pavement shall be followed. Finished top (crest) of roads shall be as per tender drawings & levels shall match with the levels fixed by the HVPNL. SCOPE:
7.0
7.1
This clause covers the supply of labour and material for executing the work for the road & design, engineering, supply of labour and material for providing culverts within the sub station fencing including approach road from main Public/Village road to the sub-station main entry gate(s) as contained in the General Electric layout (GELO)/Civil layout (CLO) or as per requirement of the Sub-Station covered under the said scheme. The rates quoted shall be for constructions of roads as per attached drawings, complete in all respect (except earth filling). Wherever earth cutting is involved no extra payment shall be made for it. However, layout of roads shall be as per General Electric layout (GELO)/Civil layout plan of the Sub-Station. Adequate turning space for vehicles shall be provided and bend radii shall be set accordingly. All substation roads shall be constructed to permit transportation of all heavy equipment. The main road leading to control room/switch yard/colony shall have a minimum 6m width with shoulder on either side (Refer drawing HCD/SK-181). The roads within the sub-station shall be as per General Electric layout (GELO)/Civil layout (CLO) and as per above referred drawing. The shoulders/footpath/side-walk should be provided with pre-cast kerbs on either side of the road. The top edge of the kerbs shall be battered. The kerb stones with top 20cm wide shall be laid with their length running parallel to the road edge, true in line and gradient at a distance of 30cm from the road edge to allow for the channel and shall project about 12.5cm above the latter. The channel stones with top 30cm wide shall be laid in position in camber with finished road surface and with sufficient slope towards the road gully chamber. The joints of kerb and channel stones shall be staggered and shall not be more than 10mm. Wherever specified all joints shall be filled with mortar 1:6 (1 cement: 6 coarse sand) and pointed with mortar 1:2 (1 cement:2 fine sand) which shall be cured for 7 days. The kerb should be painted as per directions of Executive Engineer/ Civil Works Division.
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7.2
7.3
7.4
The necessary drainage openings of specified sizes shall be made through the kerb as per drawings or as directed by the Executive Engineer/ Civil Works Division for connecting to storm water drains. Top of the shoulders/footpath/side-walk shall be provided with 20mm thick precast chequred tiles made in ordinary grey cement without chips laid on bed of 100mm coarse sand, PCC 1:8:16 (100mm thick) and 20mm thick bed of cement coarse sand mortar 1:3 with neat cement slurry between joints as per PWD specifications. 7.5 7.6 Adequate provision shall be made for road drainage. The rate of camber on a cement concrete surfacing shall be 1 in 72 unless otherwise provided. The base sub-grade is to be consolidated with power road roller of 8 Tons to 12 Tons (Roller shall pass a minimum of 5 runs on sub-grade). The roller shall run over the sub-grade till the soil is evenly and densely consolidated and behaves as elastic mass. All undulations in the surface that develop due to rolling shall be made good with quarry spoils and sub grade is re-rolled. The coarse aggregate used shall be crushed or broken stone or any naturally occurring aggregates such as kankar, laterites of suitable quality shall conform to the physical requirements as given below: Los Angeles Abrasion value (Max) 50% (IS: 2386 (Part-IV)) Aggregate Impact Value (Max) 40% (IS: 2386 (Part-IV) or IS: 5640) Flakiness Index (Max) 10% (IS: 2386 (Part-I) The crushed or broken stone shall be hard, durable and free from excess flat, longated, soft and disintegrated particles, the 100mm thick & 75mm thick. Soling aggregates shall conform to following grading respectively.
GRADE SIZE 95 to 45 SIEVE DESIGNATION 125mm 90mm 63mm 45mm 22.4 mm 90mm 63mm 53mm 45mm 22.4mm 13.2 mm 11.2 mm 5.6mm 180 micron % BY WT. PASSING 100 90-100 25-60 0-15 0-5 100 90-100 25-75 0-15 0-5 100 95-100 15-35 0.10
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7.7
7.8
63 to 45
13.2
7.9
The base shall be constructed, to have as nearly as practicable a uniform bearing power throughout its entire width and to conform to the line, grade and cross-section, shown in the drawing enclosed with the document. Where existing road is to be widened every precaution shall be taken to ensure that there would be no differential settlement between the old surface and the newly added strip. The base course shall be extended on either side to at least 15 cm (for switch yard roads) beyond the edge of the concrete pavement. The base course shall be prepared at least 2 days in advance of concreting. The side forms shall be made of metal of approved section having a thickness not less than 5 mm and shall have a depth equal to the specified thickness of the slab. They shall be provided with an efficient locking device to ensure continuity of line and level through joints and with steel pins to hold them in position. Building up of forms shall not be permitted. Flexible or curved forms of proper radius shall be used for curves of 30 meters radius or less. Forms shall not deflect more than 6mm. when tested as a simple beam with a span of 3 meters and a load equal to that which is expected upon them during construction. Forms shall be at least 7.5 cm wide at the base and shall be free from wrap, bends or kinks. The top of the form shall not vary from a 3 meters straight edge by more than 3 mm at any point and the side of the form by more than 6 mm. The base under the form shall be compacted and cut to grade so that the forms, when set, shall be uniformly supported for their entire length and at the specified elevation. Surface found to be below established grade at the form line shall be filled to grade in lifts of 12mm or less and thoroughly re-levelled or tamped Forms shall be set over length presenting 2 days work in advance of the point where concrete is being proposed to be placed and shall be cleaned and oiled prior to the placing of concrete. Forms shall remain in place for at least 12 hours after placing the concrete. If the air temperature is below 100C at any time during 12 hours period from the time the concrete is placed, forms shall not be removed until 30 hours after placing of the concrete. While using the device, care shall be taken not to damage the edge of the concrete or of the form. Forms shall be cleaned for reuse immediately after striking. They shall be handled with care and in no circumstances shall be dropped or struck with heavy hammers to remove adhering concrete. After the base has been approved by the Executive Engineer/Civil Works Division, it shall be sprinkled with water and kept moist to prevent the absorption of water from the concrete. If so required by the Executive Engineer/ Civil Works Division, it shall be saturated with water previous night for not less than 6 hours previous to placing of the concrete. The method of sprinkling of water shall not be such as to form mud or pools of
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7.10
7.11
7.12
7.13
7.14
water. No concrete shall be placed around man-holes for other structures until they have been brought to the required grade and camber. 7.15 The concrete to be placed shall conform to M-20 grade design mix. For small works, nominal mix of 1:1:3 may be used for which specific approval shall be obtained by the successful bidder. The concrete shall be distributed to such depth that when consolidated and finished, the slab thickness obtained is equal at all points and no surface is below the specified level at any point. The un-compacted concrete will be placed keeping the surface slightly higher than the top of the forms; the amount of surcharge depending upon the consistency of the concrete. The concrete shall be deposited on the prepared base for the required width, in such a manner as to require as little re-handling as possible. Concrete shall be placed at the working face as provided in the code. Necessary hand-spreading shall be done with shovels and not with rakes. For large works, concrete shall be compacted by vibrators. However, for small works hand-tamping shall be allowed at the discretion of the Executive Engineer/ Civil Works Division. The slab is laid continuously in strips/alternate between longitudinal joints. Ends of slabs should be painted with bitumen before the intermediate bays are filled in. After belting and as soon as surplus water, if any, has risen to the surface, the pavement shall be given a broom finish, with an approved steel or fibre broom not less than 50cm wide. The broom shall be pulled gently over the surface of the pavement from edge to edge. Adjacent strokes shall be slightly overlapped. Brooming shall be perpendicular to the centre line of the pavement and so executed that the corrugations thus produced will be uniform in character and width, and not more than 1.5mm deep. Brooming shall be completed before the concrete reaches such as stage that the surface is likely to be torn or unduly roughened by the operation. The broomed surface shall be free from porous or rough spots, irregularities depression etc. Immediately after the final set has taken place, the surface of the finished concrete shall be kept covered with moist gunny bags for the first 24 hours. The gunny bags shall then be removed and the grooves in the transverse expansion and contraction joints shall be sealed temporarily. The surface shall then be cured for at least 14 days by pounding to a depth of about 7.5 cm or by covering with not less than 7.5cm layer of wet earth. The earth cover shall be kept wet continuously during the whole curing period. At the expiry of the curing period, the surface shall be cleaned of all earth etc.
7.16
7.17
7.18
7.19
7.20
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7.21
Forms shall not be removed from freshly placed concrete until it has set for at least 24 hours. They shall be so carefully removed and in such a manner that no damage will be done to the edge of the pavement. After the forms have been removed, the ends of all joints shall be cleaned, after which the sides of the slab shall be covered with earth to the level of the top of the slab. The finished concrete road shall not be opened to traffic till after the expiry of 4 weeks and till all the joints have been sealed, as specified above. The expansion joints shall not be more than 20mm. For filling the joints, either pre-moulded or poured types of filers as described below may be used. (a) Sand 60%; asphalt 30%; saw-dust 7%; cement 3%. (b) 80kg of hot bitumen; 1 kg cement; 0.25 cum of coarse sand. Joints should not be sealed while the concrete is still green or when it is damp. The sealing compound shall be heated until it is fluid enough to pour easily into the joint. Rubberized compositions shall not be heated above 1800. Preparation of base, lying of concrete/joints etc. shall conform to the Indian Standard Specifications. Cement concrete paving/parking shall be provided on front, rear & sides, if any of Switch House Building as per drawing No. HCD/SK-172. The concrete blocks shall be of size 46. The blocks shall be casted in situ alternatively but after 48hrs. No gap is to be left between the panels. Top surface be left rough but should be in level. Suitable slope of earth for drainage of rainwater be provided. RCC pipe culverts shall be provided at appropriate location(s) in the roads as per site requirement. The culverts shall be of one or two pipes (750mm i/d) as per situation. The exact location, number and diameter of RCC pipe shall be decided by the Executive Engineer/ Civil Works Division. The design of culvert shall be as per IRC standards for class A loading. The design data, contours and details required for design of culvert shall be submitted by the successful bidder along with the design/drawing to HVPNL for approval. The finished surface shall be uniform and conform to the lines, grades and typical X-section shown in the approved drawing. Bitumen Roads Scope This clause covers the supply of labour and material for executing the work for the road & design, engineering, supply of labour and material for providing culverts within the sub station fencing including approach road
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7.22
7.23
7.24
7.25
7.26
7.27
from main Public/Village road to the sub-station main entry gate(s) as contained in the General Electric layout (GELO)/Civil layout (CLO) or as per requirement of the Sub-Station covered under the said scheme 7.28 The rates quoted shall be for constructions of road as per drawings attached, complete in all respects (except earth filling). Wherever earth cutting is involved no extra payment shall be made for it. However, Layout of roads shall be as per GELO and civil layout plan of the respective SubStation. Adequate turning space for vehicles shall be provided and bend radii shall be set accordingly. All substation roads shall be constructed to permit transportation of all heavy equipment. The main road leading to switch yard shall have a minimum 3.66m. Black topping, with 1.2-m wide shoulder on either side of the road. (Refer enclosed drawing of Road Section - drawing C.001 attached with the tender). Finished top (crest) of roads shall be as per tender drawing & levels fixed by the Employer. Road construction shall be as per IRC standards. Adequate provision shall be made for road drainage. The surface of the formation of sub-base, which shall be 15 cm more on either side of base course shall first be cut to a depth equal to combined depth of sub-base and surface course below proposed finished level (due allowance be made for consolidation). Any ruts or soft yielding patches that appear due to improper drainage conditions or from any other cause etc. be corrected and sub-grade dressed off parallel to finished profile. The base sub-grade is to be consolidated with power road roller of 8 Tons to 12 Tons (Roller shall pass a minimum of 5 runs on sub-grade). All undulations in the surface that develop due to rolling shall be made good with quarry spoils and sub grade is re-rolled. The finished surface shall be uniform and conform to the lines, grades and typical x-section shown in drawing. Inverted choke, 25 mm thickness (compacted) shall be provided over subgrade consisting of screenings predominantly of non-plastic material such as moorum or gravel (other than rounded river borne material). The screening shall conform to the following grading:
7.29
7.30
7.31
7.32 7.33 7.34
7.35
7.36
7.37
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Size of screening 11.2 mm
Sieve Designation 11.2mm 5.60mm 180 micron
Percent by wt. Passing 100 90-100 15-35
Screening material shall be spread uniformly and evenly to proper profile. Immediately after spreading screening rolling shall be done with 8 - 10 tones road roller to achieve compacted thickness. 7.38 Sub-base, base course & soling shall be of the final compacted thickness given in the drawing to the specified lines & cross-section and to be made free of dust and other extraneous materials. The coarse aggregate used shall be crushed or broken stone or any naturally occurring aggregates such as kankar, laterites of suitable quality shall conform to the physical requirements as given below: Los Angeles Abrasion value (Max) 50% (IS: 2386 (Part-IV)) Aggregate Impact Value (Max) 40% (IS: 2386 (Part-IV) or IS: 5640) Flakiness Index (Max) 10% (IS: 2386 (Part-I)
The crushed or broken stone shall be hard, durable and free from excess flat, elongated, soft and disintegrated particles, the 100 mm thick & 75 mm thick. Soling aggregates shall conform to following grading respectively. Grade Size 1. 95 to 45 Sieve Designation 125 mm 90 mm 63 mm 45 mm 22.4 mm 90 mm 63 mm 53 mm 45 mm 22.4 mm Percent by weight passing 100 90 - 100 25 - 60 0 - 15 05 100 90 - 100 25 - 75 0 - 15 0-5
2.
63 to 45
The work shall consist of, crushed aggregates mechanically interlocked by rolling and bonded together with screening as binding material and water where necessary, laid on a properly prepared sub grade/subbase/base and finished in accordance with the requirements and in close conformity with the lines, grades, cross-sections and thickness as per drawings.
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The coarse aggregates shall be spread uniformly and evenly upon the prepared sub-grade/sub-base to proper profile. The thickness of each compacted layer is not more than 100 mm for grading 1 and 75 mm for grading 2 immediately following the spreading of course aggregate rolling shall be started with 8 to 10 tons capacity or tandem or vibratory rollers. Rolling shall be discontinued when the aggregates are partly compacted with sufficient void space in them to permit application of screenings. During rolling slight sprinkling of water may be done. After the coarse aggregate has been rolled, screenings to completely fill the interstices shall be applied gradually over the surface. These shall not be damp or wet at the time of application. Dry rolling shall be done while screenings are being spread so that vibrations of the roller cause them to settle down into voids of coarse aggregates. The spreading, rolling and brooming of screenings shall be carried out in such lengths, which could be completed in one-day operation. The sprinkling, sweeping and rolling shall be continued with additional screenings applied as necessary until the course aggregates has been thoroughly keyed. The compacted water bound macadam course shall be allowed to completely dry and set before next permanent course is laid over it . The binding material used as filler material be of following grade or of the grade of screenings used in inverted choke. Size 13.2 mm Sieve Designation 13.2 mm 11.2 mm 5.6 mm 180 micron Percent by weight passing 100 95 - 100 15 - 35 0-10
7.39
RCC pipe culverts wherever required shall be provided at appropriate location on sub-station approach road. The culverts shall be of one or two pipes of minimum internal diameter 600mm as per site requirements. The exact location, number and diameter of pipe shall be decided by Engineerin-charge. The design of culvert as per site requirements shall be based on IRC standards and shall be got approved by successful bidder before execution. TRANSFORMER FOUNDATION TRANSFORMER FOUNDATION (100 MVA): The transformer foundation plinth for placing the transformer shall be of RCC having minimum Grade M-20 laid on base concrete (1:4:8) of
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8.0 8.1
minimum thickness 100mm. Foundation shall be designed for the equipment load requirements of transformer including impact load equivalent to 15% of total transformer load including oil etc. or total Jacking Load whichever is more. The top of plinth i.e. top of rail level shall match with height of tractor-trailer used for transporting the transformer (minimum 750-mm from top of road). The plinth shall extend upto edge of road for perfect movement from trailer to plinth and vice-versa. Suitable arrangement for shifting the transformer from trailer like jacking etc. wherever required shall be made in plinth and in front of plinth on the road. The space between the tract rails of the transformer plinth if any, shall be suitably filled with compacted sand and 50-mm thick PCC of grade 1:2:4 laid on 75-mm thick base concrete (1:5:10) placed over compacted earth filling. The top of PCC shall be minimum 300-mm above the formation level of switchyard. Adequate drainage outlets shall be provided and necessary slopes given to drain off rain water/oil. The deep beam/wall having rails at top shall be of minimum thickness as 300 mm and suitably restrained at ends by beam/ wall of same thickness. The rails shall be fresh, first quality 52-kg/meter medium manganese steel as per Indian railway specification T-12-64 and its subsequent revisions. Suitable arrangement shall be made to maintain the rail gauge. Suitable foundations shall be provided for all auxiliary equipment of the transformer like radiators, fan supports etc. as required. The work of Transformer foundation shall be taken in hand only after approval of transfer equipment drawing and the transformer plinth foundation shall match the equipment drawing. For NIFPES fire fighting system, the successful bidder shall develop design & foundation drawings as per manufacturer layout drawing as approved by Design (electrical) wing of HVPNL and submit the same for approval of HVPNL. 8.2 Drawing No. HCD/TS-1140 attached with the bid document shall be follow by the successful bidder for construction of 20/25, 16/20, 10/16MVA Transformer. However, changes required if any shall have to be made by the successful bidder without any extra cost. Before execution the contractor shall get such changes approved from HVPNL. PARTICULAR SPECIFICATION The cable trench to transformer shall be as per trench layout plan. The cables leading to various components of transformer shall pass through GI pipes supported suitably in transformer pit.
8.3
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9.0 9.1
FIRE PROTECTION WALLS GENERAL Fire protection wall for 100MVA transformer shall be constructed as per drawing no. HCD/TS-1106 supplied with the bid document.
10.0
CABLE & PIPE TRENCHES SCOPE
10.1
The contractor, as per drawing attached with the bid document shall construct various sizes of cable trenches proposed in the switch yard and inside the switch house building to carry the control cables etc. The layout and size of cable trenches shall be as approved by the HVPNL and detailed in the GELO.
10.2 Trenches shall be reinforced cement concrete of M-20 grade concrete. MS angle 50x50x6mm welded with MS flat 50x6mm 75mm long @1 meter c/c to hold the angle shall be provided on top of the trench walls for protection of the edges. 10.3 RCC cable trenches and precast removable RCC covers enclosed by suitable MS angles for edge protection in respect of switch yard trenches (with lifting arrangement) shall be designed to withstand self weight of top slab + concentrated load of 150kg at center of span on each panel. 6mm thick chequred plates with lifting arrangement the bottom of which shall be welded with MS Angle 65x65x6 mm for holding the plates shall be provided over the indoor cable trenches. Medium weight channels (ISMC) of 75x40mm shall be provided @ 600mm across the indoor cable trenches to support the chequred plates. The length of chequred plates shall be 600mm except at the ends/bends. The cables shall be placed on hard wood supported on steel racks of MS Angles 50x50x6 (grouted in the RCC walls) spaced 1.0-m c/c. The ends of the horizontal MS angles should be fixed with suitable angle (by welding at 900) to hold the cables. All the racks (MS angles, flats etc.) shall be galvanized (conforming to IS 2629-1985 and IS 4759-1968 and withstand tests as per IS 2633-1986). The galvanizing shall be done after fabrication work is complete. However for touch-ups of damaged spots, cold galvanizing be done with paints/sprays such as ZINKOTE -20 Zinc rich paint or Zinc metal spray after cleaning the damaged spots of rust, oil, grease, dirt, moisture, water etc.
10.4
10.5
10.6
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10.7
The top of trenches shall be kept at least 25mm above the gravel level. The top of cable trench shall be such that the surface rain water does not enter the trench. All metal parts inside the trench shall be connected to the earthing system. Trench wall shall not foul with the foundations. Cable trenches shall be blocked at the ends (if required for future extensions) with brick masonry 1:6 in cement sand mortar and this brick masonry work shall be plastered from both sides with cement sand mortar 1:4.
10.8 10.9
10.10 The trench bed shall have a slope of 1/500 along the run & 1/250 perpendicular to the run. In case straight length exceeds 30m, suitable expansion joint shall be provided at appropriate space. The expansion joint shall run through vertical wall and base of trench. All expansion joints shall be provided with approved quality PVC water stops of approx. 230x5 mm size. 10.11 Suitable box culvert (Single span or multi spans) shall be provided for any road crossing. The box culvert shall extend 1.5 m on each side of road and shall have 230-mm wide, 500mm high brick parapet wall at ends. If required, the bed of trench on both sides of culvert shall have to be lowered in slope, in 1.5 m length to meet the bed of culvert. 10.12 Necessary sumps shall be provided at suitable places as per direction of EIC and each sump shall be provided with pumps of 1 HP capacity with all accessories shall be supplied for pumping out water collected in the cable trenches. Cable trenches shall not be used as storm water drains. Man hole shall be provided at interval of not more than 30 meters. This clause shall be applicable as per site requirement. 11.0 FOUNDATION FOR RCC CONSTRUCTION (GENERAL) 11.1 Work covered under this clause comprises the design, engineering, supply and construction of foundations and other RCC constructions for switchyard structures, equipment supports, trenches, drains, jacking pad, crane hoisting, pulling block, control cables, bus supports, transformers marshalling kiosks, auxiliary equipment system buildings or for any other equipment or service and any other foundation required to complete the work. This clause is as well applicable to other RCC constructions. In case of overlapping of foundations in switchyard area, deeper foundation shall be constructed first. The foundations resting on filled up soil, the fill material under foundation/trenches shall be such that the maximum pressure from the footing transferred through fill material will not exceed the allowable soil bearing pressure of original undistributed soil.
11.2
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11.3
In case earth filling is involved due to high fixation of formation level, all foundation shall rest below virgin ground level and the minimum depth excluding lean concrete of all foundations below virgin ground level shall not be less than 1000mm. All the properties of concrete regarding its strength under compression, tension, shear, punching and bond strength etc. as well as workmanship will conform to IS: 456. The concrete used as lean concrete or base concrete under the structure/equipment/trench/Walls etc. foundations shall be minimum 150/100 mm thick (1:4:8) as mentioned on the drawings. The successful bidder shall also use above mentioned thickness and grade of lean concrete for equipments foundation designed. The aggregate size shall be 20mm nominal for 100mm thickness and 40mm nominal for thickness more than 100mm. Base concrete shall be well compacted. The top surface of base concrete shall be leveled before placing the reinforcement. During excavation if excavation exceeds than the required depth or if any loose pocket of earth is met below the base then the loose earth shall be removed or excavation depth be increased till normal hard soil is met as per satisfaction of Executive Engineer/Civil Works Division. This extra depth shall be filled with lean concrete. No extra shall be payable an account of this extra excavation and lean concrete. If the site is sloppy, the foundation height will be adjusted to maintain the exact level of the top of structures to compensate such slopes. The Switch Yard foundations shall be 100mm above the finished ground level or as per the manufacturers design. The plinth level of the control room building shall be minimum 500mm above the finished ground level. Based on the general topography of the surrounding area, HVPNL shall, fix the plinth level of building. 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 or pile foundation may be required based on soil/sub-soil conditions and superimposed loads. The cement concrete used for foundation shall be of grade M-20 (irrespective of any grade mentioned on the drawings). The mix-design (conforming to IS-Standards) shall be done prior to start of work, as per specifications, got approved from HVPNL and shall be used for the construction, provided there is no change in the source and the quality of materials. The source of materials shall be intimated to the HVPNL and shall be ensured that Mix design is with the materials from intimated source only and it is not changed during construction. In case source of material changes or quality of
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11.4
11.5
11.6
11.7
11.8
11.9
11.10 The Coarse aggregate used shall be of 20 mm graded or two types of single size aggregate mixed in some fixed ratio to have graded 20mm aggregate. The Coarse aggregate shall conform to IS 383. 11.11 Grading of Fine aggregate shall conform to Zone-II of Table - 4 of IS: 383 and shall be free from deleterious materials. 11.12 The environmental exposure condition considered for mix design shall be MILD. 11.13 For Mix-design, the degree of quality control shall be considered as FAIR. 11.14 The Water cement ratio shall be minimum 0.50 and maximum 0.55. 11.15 The minimum slump shall be 25mm and maximum 75mm. 11.16 For Volumetric use of ingredients for concrete mix, the contractor shall intimate the size of measuring boxes along with the Mix-design. 11.17 Ordinary Portland Cement (OPC) of Grade 43 conforming to IS: 8112 manufactured by major cement manufacturer shall be used. 11.18 The water used for preparing concrete and for curing purpose shall be fresh, clean and free from oil, acids and alkalis, organic materials or suspended or other deleterious substances. Saltish or brackish water shall not be used. Water used for construction & curing etc. shall be conforming to requirements of IS: 456 Clause 5.4. Contractor shall arrange at his own cost sufficient quantity and good quality water for construction and curing and other purposes. In case good quality water is available at existing sub-stations, it can be used by the successful contractor free of cost (also refer clause 3.1). 11.19 No admixtures shall be used except water proofing cement additives conforming to IS 2645 with the approval of the HVPNL. 11.20 Reinforcement steel (including TMT) Bars manufactured by main producers or their authorized re-rollers in India or abroad shall be used and certificates in this regard shall be submitted by the Contractor to the entire satisfaction of the HVPNL. The steel used shall conform to IS: 1786 for deformed and cold twisted bars. Required grade of steel shall be Fe415. All reinforcement shall be clean and free from loose mill scale, dust, loose rust and coats of paint, oil or other coating, which may destroy or reduce bond with concrete. Reinforcement bars should be fresh. Bidder shall supply, fabricate and place reinforcement to shapes and dimensions as indicated on the drawings or as required to carry out the intent of
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drawings and specifications. Adequate nos. of chairs, spacers of required size shall be provided to ensure the proper placement of reinforcement. The reinforcement bars crossing one another should be tied together at every intersection with two strands of annealed steel wires 0.9 to 1.6 mm thick twisted and tied to make the skeleton of the steel work rigid so that the reinforcement does not get displaced during concrete placement. All the reinforcement steel should be placed/ stacked at site store on raised (at least 0.5 meter from near surroundings) pucca/brick platform or reinforcement steel should be placed on MS/GI sheets. The reinforcement steel after stacking should be covered with Tarpaulin to avoid corrosion. Immediately before concreting (portion of reinforcement to be embedded in concrete) shall be painted with cement slurry after removing any rust/corrosion/any other foreign material. Overlaps in more than 30% of bars will not be allowed at a section. Fabricated Reinforcement bars shall be placed in position as shown in the drawing or as directed by Executive Engineer/Civil Works Division. 11.21 The bars crossing one another shall be tied together at every intersection with two strands of annealed steel wires 0.9 to 1.6mm dia. twisted and tied to make the skeleton of steel work rigid so that reinforcement does not get displaced during placement of concrete. 11.22 Two types of steel shall not be used. 11.23 All the foundation bolts used for equipment foundations & for main gantry tower foundations shall be galvanized. 11.24 The foundation bolts shall be embedded in concrete during concreting and no grout holes shall be left for this purpose. 11.25 Excavation shall extend minimum 150 mm around foundation (from RCC portion and not from lean concrete). 11.26 Proper shuttering & shoring shall be provided to support the excavated earth face to avoid falling of earth. No extra charges shall be admissible for the removal of fallen earth in the pit, once excavated. 12.0 12.1 MIXING, PLACING AND COMPACTION OF CONCRETE The concrete shall be mixed in a mechanical mixer. The mixer shall comply with IS: 1791 & 12119. The mixer shall be fitted with water measuring devices. Mixing shall be continued until there is uniform distribution of material and the mix is uniform in colour and consistency. If there is segregation after unloading from mixer, the concrete should be re-mixed, but in no case the mixing shall be done close to the foundation, or place of work but in case it
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12.2
is not possible the concrete may be mixed at the nearest convenient place. From mixer, concrete shall be put on pucca platform or steel troughs, which shall be leak proof to avoid any loss of water/slurry. The concrete shall be transported from the place of mixing to the place of final deposit as rapidly as practicable, which shall prevent the segregation before any setting commences. 12.3 Proper shuttering shall be used for the construction of all type of PCC/RCC works. Shuttering shall be rigidly tightened so that there are no distortions in the shape. Shuttering shall be made sufficiently strong to with stand all the loads and vibrations. Vibrators shall be used to ensure thorough compaction. After the shuttering has been removed, if the concrete surface is found to be slightly damaged, same shall be repaired with rich cement sand mortar to the satisfaction of the HVPNL's representative before the foundation pits are back-filled. CURING The concrete after setting for 24 hours shall be cured by keeping the concrete wet continuously for a period of 10 days (minimum) after laying. The foundation be back filled with selected good earth free from harmful salts, organic material, sprinkled with necessary amount of water and well consolidated in layers not exceeding 200 mm of consolidated thickness after a minimum period of 72 hours and thereafter both backfilled earth and exposed top shall be kept wet for the remainder of the prescribed curing time. The uncovered concrete portion above the backfilled earth or vertical columns etc. shall be kept wet by providing empty cement jute bags dipped in water fully wrapped around the concrete for curing and ensuring that the bags are kept wet by the frequent pouring of water on them. In case Portland Pozzolona cement has been used, curing period shall be increased by Executive Engineer/ Civil Works Division. 14.0 DISMANTLING The contractor wherever required, shall carry out dismantling PCC/RCC/brickwork etc. & dispose it of at a suitable undisputed place outside substation. The successful bidder shall be responsible in case some dispute arises on account of disposal of dismantled material at a disputed site. 15.0 15.1 DESIGN All the foundations except walls of switch house building etc. shall be of Reinforced Cement Concrete. The design and construction of RCC structures shall be carried out as per IS: 456-2000 using minimum grade of concrete as M-20 (M-25 for water retaining structures). Higher grade of
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12.4
13.0
concrete than specified above may be used by the contractor without any additional cost to the HVPNL with proper mix design. 15.2 Limit state method of design shall be adopted unless specified otherwise in the specification/IS Codes. For design and construction of steel-concrete composite beams IS: 11384 shall be followed. For detailing of reinforcement, IS: 2502 and SP: 34 shall be followed. Two layers of reinforcement (on inner and outer shall be provided for wall & slab sections) having thickness of 150 mm and above. Clear cover to reinforcement towards the earth face shall be minimum 50 mm and for other components, same shall be as per IS: 456. The procedure used for design of the foundations shall be the most critical loading combination of 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. The contractor, for approval of drawings shall submit detailed design calculations along with drawings. Designer shall consider sub-soil water pressure that may be encountered, following relevant standard strictly. 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 without extra cost to the HVPNL. RCC column shall be provided with rigid connection at the base. All sub-structures shall be checked for sliding and overturning stability during both construction and operating conditions for various combinations of loads. Factor 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. In case of trench passing above the footing base then for over turning only dead weight of trench shall be considered.
15.3
15.4
15.5
15.6
15.7
15.8 15.9
15.10 Earth pressure for all underground structures shall be calculated using coefficient 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.
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15.11 In addition to earth pressure and ground water pressure etc. a surcharge load of 2T/sq. m shall 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 or otherwise. 15.12 Following conditions shall be considered for the design of water tank in pumps house, channels, sumps and trenches and other underground structures. a) Full water pressure from inside and no earth pressure and ground water pressure & surcharge pressure from outside, (applicable only to structures which are liable to be filled up with water or any other liquid). b) Full earth pressure, surcharge pressure from outside and no water pressure from inside. c) For any water retaining structure or any member submerged in water the minimum grade and concrete shall be M-25. d) 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 super imposed loadings. 15.13 Base slab of the any underground enclosure like water storage tank shall also be designed for empty condition during construction and maintenance stages with maximum ground water table (GWT) at 2.0 m. below ground level. Minimum factor of safety of 1.5 against buoyancy shall be ensured ignoring the super-imposed loading. Intermediate dividing piers of such enclosures shall be designed considering water in one pump sump only & the other pumps sump being empty for maintenance. 15.14 The foundations shall be proportioned so that the estimated total and differential movements of the foundations are greater than the movements that the structure or equipment is designed to accommodate. 15.15 The foundations of transformer/reactor and circuit breaker shall be of block type foundation. Minimum reinforcement shall be governed by IS: 2974 and IS:456-2000. 15.16 The tower and equipment foundations shall be checked for a factor of safety of 2.2 for normal condition and 1.65 for short circuit condition against sliding, overturning and pullout. The same factors shall be used as partial safety factor over loads in limit state design also.
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16.0
OTHER FOUNDATIONS
16.1 All foundations shall be designed in accordance with the provisions of the relevant parts of latest revisions of Indian Standards IS: 456 and other relevant Indian Standards. 16.2 Type of foundation system i.e. isolated footing or raft etc. shall be decided based on the load intensity and soil strata. 17.0 17.1 BUILDINGS GENERAL SCOPE The Scope shall include construction of switch house building including providing anti-termite treatment, plinth protection DPC of building, sanitary, water supply, sintex/diplast polyvinyl tanks, electrification including supply and providing of 2T split high wall mounted ACs, ceiling fans, 4ft. long 28W T-5, CFL tubes with fittings, modular switches, boxes, electric wire, flooring, finishing items including acrylic emulsion and whether proof (exterior acrylic paint), anodized aluminum doors/windows/ventilators frames provided with 5.0mm thick glass, fire doors, indoor cable trenches with covers in control room/battery room/ACDB/DCDB rooms etc. etc. complete in all respect as per HVPNL drawing(s). Scope shall also cover any other item(s) required for the completion of building which have not been mentioned in the specification or in the drawings but essentially are required for completion of the building. HVPNL reserves the right to alter the finishing schedule and specifications. Such changes will have no additional financial implication whatsoever on HVPNL. Rate for control room building shall be paid as per actual on per sqft. basis. 17.1.1 STORM WATER DRAINAGE FOR ALL BUILDINGS The building drains shall be provided for the collection of storm water from the roofs. This water shall be collected in junction boxes and these boxes shall drain to the main drainage system of the station. Cast iron rain water down comers conforming to IS: 1230 with water tight lead joints shall be provided to drain off the rain water from the roof. These shall be suitably concealed with masonry work of cement concrete or cladding material. The number and size of down comers shall be governed by IS: 1742 and IS: 2527.
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All drains inside the buildings shall have minimum 40mm thick grafting covers and in areas where heavy equipment loads would be coming, precast RCC covers shall be provided in place of steel grating. For all buildings, suitable arrangement for draining out water collected from equipment blow down, leakage, floor washings fire fighting etc. shall be provided for each floor. 17.2 MATERIALS The brief requirement regarding various materials to be used for construction of building are detailed below or specified in respective drawings. However, materials not specifically mentioned in the specifications/drawings, the same shall also conform to the relevant IS codes and got approved from the HVPNL before being used. The contractor shall remove from site any material not conforming of IS Standards or rejected by the representative of HVPNL/Executive Engineer/ Civil Works Division. 17.3 BRICKS AND TILES The bricks used shall be first Class bricks of nominal size (230x110x70) mm so that every four courses shall measure 30.48 cm in height. A tolerance upto 80mm in length 40mm in width and 40mm in thickness/height shall be permitted per 20 bricks. The bricks shall be made from good brick earth free from efflorescence/kankar, thoroughly burnt and uniform deep red colour, regular in size and shape with parallel faces and sharp corners, uniform in colour, free from flaws etc, and shall have all the qualities of a good brick. Bricks and tiles shall have ringing sound when struck with each other. Bricks shall have a minimum crushing strength of 105 kg/per sq. cm and shall not absorb water more than 20% of its own dry weight after 24 hours immersion in cold water. For tile terracing and tile facing, size of tile shall be (230x110x30) mm having permissible tolerance of IS Standards for length, width & height 40mm. 17.4 SAND (FOR MASONRY MORTAR & PLASTER) Sand for masonry work and plaster shall preferably consist of natural sand, However crushed stone sand or crushed gravel sand or a combination of any of them be used. Sand shall be hard, durable, clear and free from harmful impurities like iron pigments, mica salts, coal or other organic impurities. Grading of sand for use in masonry mortar shall be conforming to IS: 2116 and for use in plaster shall conform to IS: 1542 tabulated as below:
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IS Sieve Designation 10.0 mm 4.75 mm 2.36 mm 1.18 mm 600 micron 300 micron 150 micron
For mortar For Plaster Percent passing by mass 100 100 95 to 100 90 to 100 95 to 100 70 to 100 90 to 100 40 to 100 80 to 100 5 to 70 20 to 65 0 to 15 0 to 50
The maximum quantities of clay, fine silt, fine dust and organic impurities shall not exceed limits described in IS: 2386 (Part II). Clay, fine dust and silt in natural sand or crushed gravel sand or crushed stone sand not more then 5% by mass. 17.5 BRICK WORK All brickwork shall strictly be according the specifications and notes specified in the drawings. All bricks shall be soaked in stacks by spraying clean water at regular intervals to keep them wet to the satisfaction of Executive Engineer/ Civil Works Division. Each brick shall be set (with frog upwards) with bed and vertical joints completely filled with mortar. Thickness of mortar joint shall be 6.25 mm and shall not be more than 9.4 mm. For exposed brickwork, bed joint will be 7.81 mm thick and vertical joint 6.28 mm. All brickwork shall be true in plumb, straight edge, for exposed brickwork or face work bricks shall be selected for purpose. The face joints shall be duly racked to minimum depth of 13 mm when mortar is green for providing key to plaster or pointing. The mortar used for brick work/ plasterwork shall be machine mixed only. All fixtures, doors/windows/CI pipes, outlet for water, hold fasts etc. which are required to be built/laid in brickwork shall be embedded simultaneously. Each day work done shall not be more than 1m in height and no portion of the work shall be left more than 1m lower than the other. The height of brick courses shall be kept uniform. All the half brick thick walls shall be provided with 2 numbers - 6 mm bars at every fourth layer. In case of difference in the natural ground level and formation level, no extra payment on account of extra brick work whether in building or boundary wall shall be paid extra. The contractor may, therefore, visit the site before quoting rates for the brick work.
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17.6
DAMP PROOF COURSE On outer walls horizontal DPC shall be provided at level with plinth protection and on inner face vertical DPC 20 mm thick, shall be provided. On all inner walls horizontal DPC shall be provided at floor/plinth level. Horizontal DPC shall consist of cement concrete (1:1.5:3) 50 mm thick. Edge of DPC shall be straight, even and vertical. It shall be cured for at least 7 days, after which it shall be allowed to dry. Vertical DPC shall consist of two layers of plaster (1:3) with total thickness of 20 mm. Hot bitumen shall be applied over dried up surface in thin layer.
17.7
PAINTING, ACRYLIC EMULSION DISTEMPER/WHETHER PROOF ACRYLIC PAINT The switch house-cum-administrative building including walls & ceiling shall be provided with Acrylic emulsion paint of reputed make over prepared base. The outer face of building shall have peach colour cement based whether proof exterior (acrylic paint) coating. Columns, beams parapet and plastered area shall have mid cream colour whether proof coating. All the steel work, wire mesh, doors & windows etc., shall have first quality paints of approved make/shades. The boundary wall shall be provided with water proof acrylic paint. All fire fighting MS pipes shall have post office red colour
17.8
MATERIALS The lime for white washing shall be unslaked lime of good quality, which shall be slaked at spot, mixed with water at least for 24 hours, than stained through coarse cloth, Indigo & some binding material like gum be added in proper quantity before use. For colour washing pigment of approved colour in proper quantity shall be used. The Priming Paint shall conform to IS: 109 (Alkali resistant priming paint). The Acrylic emulsion distemper and whether exterior acrylic paint shall be of superior quality manufactured by standard firms like ASIAN, NEROLEC, BERGER, DULUX, SHALIMAR etc. The material should be brought to site in sealed condition and stored properly. All paints and allied materials shall be of superior quality manufactured by standard firms like ASIAN, NEROLEC, BERGER, DULUX, SHALIMAR etc. and meet the requirements of following Indian Standards for wooden and metallic surfaces and shall be of approved brands and manufacturer and of approved shade. a) Primer for woodwork shall be conforming to IS: 3536, for Iron, steal etc. shall be conforming to IS: 2074. The primer shall be ready
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mixed primer. b) Synthetic enamel paint shall be conforming to IS: 117, IS: 133 and IS: 137 of first quality.
17.9 APPLICATION All the white wash/colour wash shall be done on well-prepared surfaces to the satisfaction of Executive Engineer/ Civil Works Division. Minimum of 3 coats shall be applied. The work shall be carried out as per IS: 6278. a) DISTEMPERING: Two coats of acrylic emulsion distemper shall be applied over a priming coat as detailed below: PREPARATION OF SURFACE: For new work the surface shall be thoroughly cleaned of dust, old white or colour wash by washing and scrubbing. The surface shall then be allowed to dry for at least 48 hours. It shall then be sand papered to give a smooth and even surface. Any unevenness shall be made good by applying putty, made of plaster of pairs mixed with water on the entire surface including filling up the undulations and then sand papering the same after it is dry. PRIMING COAT: The priming coat shall be with distemper primer or cement primer. A coat of alkali resistant priming paint conforming to IS:109 shall be applied and allowed to dry for atleast 48 hours before distempering is commenced. ACRYLIC EMULSION/DISTEMPERING COAT: For new work, after the primer coat has dried for at least 48 hours, the surface shall be lightly sand papered to make it smooth for receiving the distemper, taking care not to rub out the priming coat. All loose particles shall be dusted off after rubbing. One coat of distemper properly diluted with thinner (water or other liquid as stipulated by the manufacturer) shall be applied with brushes in horizontal strokes followed immediately by vertical ones, which together constitutes one coat. The subsequent coats shall be applied in the same way. Two or more coats of distemper as are found necessary shall be applied over the primer coat to obtain an even shade. A time interval of at least 24 hours shall be allowed between successive coats to permit proper drying of to preceding coat. b) The wooden surface shall be cleaned of all unevenness, which shall be removed by rubbing with a sand paper. The surface treated for coatings, shall be dried before primer coat is applied.
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ii
iii
iv
c)
PAINTING i. All rust & scale be removed by scrapping or by brushing with steel wire brush. ii. The primer coat shall be allowed to dry before painting is started. iii. The putty around glass panes shall also be painted. iv The additional coats of paint etc. shall be provided if required for the required finish as per Executive Engineer/ Civil Works Division.
17.10 FLOORING The flooring of switch house building except battery room and toilet shall be of precast terrazzo/vitrified tiles (as detailed in the working drawing). Anti-skid tile 300x300x7.7mm flooring in toilets and pantry and Acidresistance tiles shall be provided above 40mm thick PCC (1:2:4) flooring in battery room. Before flooring work is taken up, works such as laying of services which otherwise would affect the laying of floors, plastering of all inside & outside walls, ceilings, fixing of doors and window frames in place and all heavy work in room may be completed. The base layer for all floors shall be of 100-mm thick sand and 100 mm thick cement concrete 1:5:10 laid on sand. The sand for base filling shall be clean and dry, free from clay clods and other harmful impurities such as iron pigments alkalis, coal and lignite, materials finer than 75 microns. Sand shall be of particle size ranging from 1.18 mm to 150 micron. The fineness modulus shall vary from 0.8 to 1.0. Generally sand fit for plastering is fit for sand filling under floor. The pre cast terrazzo tiles of 300x300x25mm minimum thickness (the finished thickness of the top upper layer shall be 10mm) in 50% white & 50% ordinary grey cement with marble chip conforming to IS: 1237-1980 and pre-polished granite stone (slab) flooring as approved by HVPNL shall be laid on 20 mm thick bed of cement coarse sand mortar 1:3. The mortar shall be evenly spread over the base for two rows of tiles and about three to five meters in length. The top of mortar shall be kept rough so that cement slurry can be absorbed. Neat cement slurry of honey like consistency shall be spread over the mortar bed @ 5 kg per sq. meter. The joints shall be kept as thin as possible (not exceeding 1.5 mm) and filled with neat cement slurry, treads of steps and landing, if any. The floor shall be kept wet or flooded with water and protected against damage due to traffic or any other cause, for at least seven days after finishing the tiles. After the tiles are cured and have dried up, these shall be ground evenly with machine fitted with special rapid cutting grit blocks (carborundum stone) of coarse grade (No. 60) till the marble chips are evenly exposed and the floor is smooth. After the first grinding, the surface shall be
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thoroughly washed to remove all grinding mud and covered with a grout of cement and colouring matter in same mix and proportion as the topping in order to fill any pin holes that appear. The surface shall be allowed to cure for 5 to 7 days and then rubbed with machine fitted with fine grit blocks (No.120). The surface is cleaned and repaired as before and allowed to cure again for 3 to 5 days. Finally the third grinding shall be done with machine fitted with fine grade grit blocks (No. 320) to get even and smooth surface without pinholes. The finished surface should show the marble chips evenly exposed. Where use of machine for polishing is not feasible or possible, rubbing and polishing shall be done by hand, in the same manner as specified for machine polishing except that carborundum stone of coarse grade (No. 60) shall be used for the 1st rubbing, stone of medium grade (No. 80) for second rubbing and stone of fine grade (No. 120) for final rubbing and polishing. After the final polish either by machine or by hand, oxalic acid shall be dusted over the surface @ 33 gm per square meter sprinkled with water and rubbed hard with a nemdah block (Pad of Woolen rags). The following day, the floor shall be wiped with a moist rag and dried with a soft cloth and finished clean. Anti skid floor tiles of reputed makes such as Somany, Kajaria, Nitco etc. having minimum 300x300 mm nominal size and 7.7 mm thick preferably in Beige colour shall be provided in the toilets. The tiles shall conform to relevant EN/IS codes. The tiles shall conform to relevant EN/IS codes. The tiles & the colour scheme shall be got approved from the HVPNL. Entire area around the Switch house building shall be provided with PCC paving upto 1 meter from the outer edge of the building. 17.11 SKIRTING Matching vitrified/pre-cast terrazzo tiles 300x150x25mm made in 50% white & 50% grey cement conforming to IS: 1237-1980 shall be used in areas provided with vitrified/pre-cast terrazzo tile flooring (as indicated in the working drawing). The minimum finished thickness of pre-cast terrazzo tiles shall be 12.5 mm. Tile skirting and dado shall be fixed only after laying the tiles in the floor. The portion of the wall to be covered with skirting and dado shall be left unplastered. The wall surface shall be evenly and uniformly covered with about 10 mm thick backing of cement coarse sand mortar 1:3. However, in the case of skirting, the tiles may be directly fixed without application of back as a separate course. Before the backing mortar has hardened, the back of each tile to be fixed shall be covered with a thin layer of neat cement paste and the tile gently tapped against the wall with a wooden mallet. The fixing shall be done from the bottom of the wall upwards. All the tile faces shall be set in conformity with
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one another and shall be truly vertical. The sides of the tiles shall be coated with grey or white cement slurry with or without pigment to match the shade of tiles and butt jointed. The joints shall be as thin as possible. Tiles shall be ground and polished as for flooring by hand. In case of vitrified tiles the skirting shall also be of same make, colour and style. In toilets, the skirting/dado shall be of tiles of 6.7mm thick 200x200 mm size of reputed makes such as Somany, Kajaria, Nitco etc. and should go upto 6'-9" high from floor level. The tiles shall conform to relevant EN/IS codes. The tiles & the colour scheme shall be got approved from the HVPNL. Skirting/daddo colour and style should match with the flooring. 17.12 DOORS/WINDOWS The contractor shall provide & fix Aluminum chowkhats/doors /windows/ ventilators (single & double leaf) consisting frame work including vertical styles, top rails, lock (middle) rails and bottom rails with metal fastener & screws fitted with nuts & bolts or using rawl plugs & screws as per HVPNL drawings. The Aluminum section to be used shall be of 10 gauge (3mm) anodized (15 micron) of reputed makes such as HINDALCO/JINDAL conforming to IS: 1968-1983. The doors & windows shall be fitted with 5.0 mm thick glass of reputed make like TATA FLOAT/SAINT GOBBAIN, high-class rubber gasket & aluminum beading complete so to make the glass airtight. The toilet doors shall, however, be fitted with pre-laminated board (NOVAPAN/KIT/DECCO) panels of appropriate size with aluminum beading to make it airtight. The door/floor springs, locks (six lever of Godrej or equivalent), handles, tower bolts, stoppers with rubber cushion, screws etc. shall be of 1st quality ISI make as approved by Executive Engineer/Civil Works Division. 17.13 TOILET & PANTRY FIXTURES All the water closets, wash basins, squatting panes etc. shall be of vitreous China clay in white colour, (first quality) conforms to IS: 2556. The water closet in officers toilet shall be European type with single syphonic low-level cistern. In general toilets high-level cistern shall be provided with Indian type water closet. Providing and fixing in position best Indian make 20mm dia., 600mm long towel rails fixed in raw slugs embedded in walls with CP brass screws. All fixtures/fittings shall be chromium plated of best quality and shall be approved by the Executive Engineer/Civil Works Division. Providing & fixing best Indian make white vitreous chinaware sink of size 600x450x250mm with complete fittings including 40mm CP brass waste and PVC pipe chromium plated brass tap. Granite slab 20-25mm
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thickness as approved by Executive Engineer/ Civil Works Division is to be provided in the kitchen as shown in drawing. All water supply pipes shall be GI Pipes (medium quality) conforming IS:1239 along with specials ISI marking. All drainage pipes shall be HCI pipes along with special and ISI marked, embedded in walls, having concrete 1:2:4 around the horizontal pipes up to first inspection chamber/gully trap shall also be HCI pipes. From Inspection chamber onwards to soakage pit or to existing sewerage system as the case may be SW Pipes shall be used. Construction of soakage pit near switch house building or laying of SW pipes up to sewerage system within sub-station is in scope of this bid. 17.14 RAIN WATER PIPES All rain water pipes shall be 4" dia. HCI pipes along with fixtures. Rain water pipes shall be embedded in wall during construction as shown in drawings. At top of roof proper grating shall be provided. 17.15 ELECTRICAL ITEMS IN CONTROL ROOM AND OTHER BUILDINGS The general requirement of electrical fittings shall be as per drawing attached with tender. The bidder shall prepare the actual design and detail of circuits to be provided and layout of pipes. The wiring shall be recessed conduit wiring. Heavy duty PVC conduits of 20/25/30mm size and wires 2.5/4/6 sq. mm copper for circuit wiring & 1.5 sq. mm copper for earth including wiring for sub-mains, modular switch boards, junction boxes, switches/sockets 5 Amp, 5/16 Amp and 16 Amp, 240V indoor and outdoor receptacle including 2T split/window ACs, electronic step regulator mounted on the switch boards, provision for telephone wires including telephone junction boxes/tap blocks, sockets. Depth of inspection/junction boxes shall be 80 mm in ceiling and 28 mm on wall surface which may vary as per requirement of modular switches/regulator. All the split/window ACs, ceiling fans, 28W (T-5) CFL tubes etc. shall be of reputed company like LG/Samsung/Hitachi/Videocon, Crompton/Philips/ Osram etc. All switches, fittings, sockets, fans shall be of latest modular design and of reputed make like Crompton, Havels, Philips etc. All the material shall conform to latest IS specification as ISI marked. All the electrical fitting including ACs, fans shall be as per electrical drawing to be provided by the HVPNL or developed by the successful bidder. The items not provided herein but are required to be provided as per drawing
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requirement or site requirement shall be provided by the successful bidder without and extra cost to the HVPNL. 17.16 ROOFING On top of RCC slab of building, terracing shall be done with tile brick paving. The top surface of RCC slab when thoroughly dry shall be painted uniformly with bitumen of penetration 80/25, hot cut back bitumen, the quantity of bitumen shall be 1.7 kg per sq. m of roof surface. Immediately after painting dry, clean sharp coarse sand shall be evenly sprayed and leveled over the surface after bitumen is still hot. Over the layer of bitumen the good soil with optimum moisture content shall be laid on roof to requisite thickness and slope, well compacted. After laying the mud surface shall be given a coat of mud plaster 25 mm thick and allowed to dry. Over the mud plaster flat tile bricks shall be laid using the minimum amount of plain mud mortar as bedding. The tiles shall be laid close to each other; the thickness of joints shall not be less than 6 mm and more then 12 mm in width. After tiles are well set and bedding mortar has dried joints of tiles shall be grouted with cement mortar of mix 1:3 (1 cement: 3 fine sand) such that all the joints of tiles are completely filled with mortar and the joints should be finished neatly by providing flush pointing in 1:3 cement mortar (1 cement: 3 sand). The surface shall be cured for at least 7 days. The tiles surface as completed shall be even and true to slopes of 1 in 48. 17.17 SWITCH YARD FENCING AND GATE Fencing & Gates shall be provided for Switchyard area as per General Electrical Layout Plan and any other specified area along the lines shown. The design shall be as per drawings attached with the tender. Chain link fence fabric shall of size 75mm; coated wire shall be of 3.15mm dia having zinc coating after weaving. The chain link fabric shall be fixed to the intermediate parts and at top & bottom of fence by welding/fixing 50x6mm M.S. flat all through its length. All structural steel manufactured by TISCO, SAIL, IISCO and RASHTRIYA ISPAT (primary manufacturers) shall conform to IS: 20621786 shall only be used. The bidders shall, however, be allowed to use Amba steel, Rathi steel, Kamdhenu steel, Barnala steel, P.R.S steel, Shidbali steel (manufactured by secondary manufacturers) only after obtaining nonavailability certificate from the primary manufacturers. Before using secondary steel, the selected bidder would require to conduct all physical & chemical tests (lot wise & dia. wise) to establish its conformity to IS Standards conforming to IS 2062.
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The barbed wire shall consist of two splices per reel. The barbed wire shall be formed by twisting two line wires, one containing barbs. The barbed wire shall be of 12 SWG galvanized steel with its weight 155-186 gm/m length of wire. Distance between two barbs shall be 75mm. The barbs shall carry four points and shall be formed by twisting two point wires, each two turn tightly round one line wire making altogether 4 complete turn. The barbs shall be finished in such a way that four points are set and locked at right angles to each other. The barbs shall have a length of not less than 13mm and not more than 18mm. The points shall be sharp and well pointed. Fasteners Single strand aluminum or galvanized steel, wire conforming to requirements for fence fabric 4mm diameter. Tension wires - Single strand, high tensile, galvanized steel wire 4mm diameter. Fittings and Hardware Cast aluminum alloy or galvanized steel malleable or ductile steel. Cast iron D-Clamp to be drop forged with bolt, Check nut, Thimble and other material required for stretching the Barbed wire complete in all respect. Generally the drawing attached with the tender shall be applicable. However, if due to difference of levels between formation level and Switchyard and outside, normal foundations have to be changed in some portion and retaining wall have to be provided below due to site requirements. Successful bidder for approval before execution will submit the suitable design. Nothing extra shall be payable on this account. All the structural steel shall be galvanized (conforming to IS 2629-1985 and IS 4759-1968 and withstand tests as per IS 2633-1986). The galvanizing shall be done after fabrication work is complete. However for touch-ups of damaged spots, cold galvanizing be done with paints/sprays such as ZINKOTE -20 Zinc rich paint or Zinc metal spray after cleaning the damaged spots of rust, oil, grease, dirt, moisture, water etc 18.0 BOUNDARY WALL Boundary wall on the entire land as proposed in the GELO/CLO is to be constructed as per HVPNL drawings enclosed herewith. In case the depth of boundary wall is more than that provided in the attached drawing, the successful bidder shall provide RCC retaining wall design upto DPC level and the upper brickwork sections for front wall, side (C-fence) wall and U/C-walls shall be constructed as per HVPNL drawings. The design so evolved shall be got approved from HVPNL. All the structural steel/barbed wire shall be galvanized (conforming to IS 2629-1985 and IS 4759-1968 and withstand tests as per IS 2633-1986).
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The galvanizing shall be done after fabrication work is complete. However, for touch-ups of damaged spots, cold galvanizing be done with paints/sprays such as ZINKOTE -20 Zinc rich paint or Zinc metal spray after cleaning the damaged spots of rust, oil, grease, dirt, moisture, water etc. The measurement/payment of boundary wall shall be carried out in two parts as detailed below: a). The brick work in foundation upto DPC level shall be measured in cubic meter. Nothing extra shall be paid for 100mm thick PCC 1:4:8 below brick foundation and 25mm thick horizontal DPC, cement plaster with finishing items on outer or inner side of wall, as the case may be (inner side, if earth level outside sub-station boundary is at higher level). The brick work above DPC (excluding DPC) for construction of front wall, side (c-fence) wall and U/C-walls shall be measured in running meter complete in all respects as per HVPNL drawings. Nothing extra shall be paid for pointing, cement plaster, PCC posts, angles, grills, flats, barbed wire, galvanization, finishing items etc. The main entry gate(s) shall be measured in running meter (above DPC level) complete in all respects as per HVPNL drawings and payment shall be made as per rates quoted for the type of boundary wall where the gates are proposed.
b).
c).
19.0
FIELD QUALITY CONTROL PLAN The contractor shall submit the field quality control plan for effective control on quality of civil works for approval from HVPNL before the start of work. All cost of testing as per approved field Quality control plan or as directed by HVPNL shall be borne by the Contractor.
20.0
After completion of civil works, a completion plan giving all details of foundations, trenches, culverts, fencing budding etc. as built shall be submitted with original tracing.
21.0 Any material or activity not covered under the specifications or drawings shall be, as governed by relevant IS specification/National Building Code of India. 22.0 GENERAL The work shall be carried out by specialists in the trade. Workers shall be provided with gum boots and hand gloves. Minimum overlaps of 100mm shall be given at the ends and sides of the strips of the felts/tissue and properly bonded with bitumen. Joints in the successive layers of the fibre
- 39 -
glass based felt/tissue shall be staggered. There shall be no air pockets. Corners shall be treated flush without any air pockets or voids. a. The materials and the sub-contractors executing the work shall be duly approved by the Executive Engineer/Civil Works Division. b. Adequate covering shall be provided during work to avoid splashing or staining of adjacent works and surfaces. Any surface or work splashed or stained shall be thoroughly cleaned to the full satisfaction of the Executive Engineer/ Civil Works Division. 23.0 SPECIAL NOTE Fully galvanized angles, flat, nut & bolts etc. shall be used in all the items covered under this scheme. Galvanizing of the steel section shall confirm to IS 2629-1985 and IS 4759-1968. All galvanizing members shall withstand test as per IS 2633-1986. The galvanizing shall be done after all fabrication work is completed, except that the nuts may be tapped or rerun after galvanizing. Threads of the bolts and nuts shall have a neat fit and shall be such that they can be turned with finger throughout the length of the threads of bolts and they shall be capable of developing full strength of the bolts.
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G-11/Pkg-B LIST OF FOUNDATION DRAWINGS A. SR. NO. 1. 2. 3. 4. 5. 6. B. S. N. 1. 2. 3. 4. 5. 6. 1. 2. 3. 4. 1. TOWER FOUNDATIONS DESCRIPTION OF TOWERS BT-1 BT-3 BT-4 BT-6 DT-2 DT-3 EQUIPMENT FOUNDATIONS DESCRIPTION OF EQUIPMENTS 132kV Side LA Isolator/L&E Switch CVT/CT Post Insulator NCT 20/25, 16/20 MVA T/F 33kV Side LA Isolator/L&E Switch CT, PT NCT 11kV Side NCT
ANNEXURE
DRAWING NO. HVPN-004R1 HVPN-004 R1 HVPN-004 R1 HVPN-004 R1 HVPN-006 R1 HVPN-006 R1
DRAWING NO.
0017 R1 0016 R1 0012 R1 0019 R1 0014 R1 HCD/TS-1140 0022 R1 0020 R1 0021 R1 0021 R1 0027 R1
-1-
G-11/Pkg-B
ANNEXURE
C.
OTHER DRAWINGS
S.N. DESCRIPTION OF EQUIPMENTS Boundary wall 1. Main Entrance Gate 2. Sump pit cum pump 3. chamber Switch Yard fencing 4. Switch Yard gate 5. Indoor cable trench 6. Outdoor cable trench cum 7. Trench X-ing road (Trench culvert) Rain harvesting 8. (rechargeable well) for control room building -do- for Yard 9. 10. X-section of concrete road 11. X-section of bitumen road of PCC 12. X-section pavement/Parking 13. Soakage Pit
Architectural (Job No.) 1358/1 &2 1357/1 564/1 -
Civil (Drawing No.) HCD/TS-1176 HCD/TS-1175 HCD/TZ-389 HCD/TS-1024 HCD/TS-1025 HCD/TS-1020 (COM) HCD/TS-1019 (COM)
HCD/TS-1224 (COM)
HCD/TS-1226 (COM) HCD/SK-181 HVPN-001 (R) HCD/SK-172 HCD/TS-182 (T)
Note:
The architectural and structural drawings of Switch House Building are being evolved.
-2-
CONTROL AND RELAY PANELS

Sr. No.
I. 1.
Description
PANELS. Dimension of the C&R panels. i) Depth ii) Overall height iii) Width
PARTICULARS Required Offered
610 mm 2312 mm
2.
Width of corridor (applicable in case 762 mm of `Duplex' type panels). Dimension of supporting channel. 102 mm Thickness of the sheet steel proposed Min. 10 SWG for base frame, door for fabrication of panels. frame, front & rear portions of cubicle and not less than 14 SWG for doors, sides, top & bottom portion SWITCH BOARD WIRING. Insulation of wiring. 650V PVC Material of wiring conductor. Copper Size of wiring conductor for: i) C.T. Circuits. 2.5 mm2 ii) C.V.T./P.T. Circuits. 2.5 mm2 iii) D.C. supply circuits. 1.5 mm2 iv) A.C. Supply Circuit. 1.5 mm2 v) Other circuits. 1.5 mm2 Size of earthing bar for safety 25mm X 6mm Copper earthing. Type of terminals used in wiring the stud panel. INDICATING AND INTEGRATING INSTRUMENTS(AMMETER, VOLTMETER, MW METER, MVAR METER AND KWH METER TO BE FILLED IN SEPARATELY FOR EACH ITEM). Make Type Size. VA burden a) Current coil.
3. 4.
II. 1. 2. 3.
4. 5.
III.
1. 2. 3. 4.
144 Sq. mm

5. b) Potential coil. Power consumption. a) Current coil. b) Potential coil. I.S. Standard grade of accuracy. Class 1 Range of dial. 9. Limits of error in effective range. 9. Calibration for : a) CT Ratio. b) P.T. Ratio. Finish. Black Short time overload capacity. Descriptive leaflet reference Nos. submitted. Type & make of selector switch for: a) Ammeter. b) Voltmeter. CONTROL SWITCHES FOR CIRCUIT BREAKER & ISOLATORS. Make. Type. Type of handle provided. Number of position . Whether no. of Normally closed & Normally open contacts sufficient for seheme requirements? (Yes / No). Whether spring return to neutral or stay-put type. Type of lock provided. Making capacity/breaking capacity at 220 Volt DC for both inductive &
6. 7. 8.
10. 11. 12.
13.
IV. 1. 2. 3. 4. 5.
Pistol Grip 3
6. 7. 8.
Spring Return Neutral Non lockable
to
9. V.
1. 2. 3. 4. 5. 6. 7.
non-inductive current. Descriptive leaflet number submitted. SEMAPHORE INDICATORS (FOR CIRCUIT BREAKER, ISOLATOR & EARTH SWITCH). Make. Type. Diameter of the disk. Operating voltage. 220V DC Burden. Whether latch-in type or supply Supply failure type failure type. Descriptive leaflet number submitted.

VI. 1. 2. 3. 4. 5. 6. VII. 1. 2. 3. 4. INDICATING LAMPS. Make. Type. Operating voltage. Size of lens. Wattage of the lamp. Descriptive leaflet number submitted. OVER CURRENT & EARTH FAULT RELAY. Make. Type of relay. Current coil rating. 1A/5A Potential coil rating (applicable 110V/63.5V only in case of directional relays). Tap range. 50-200% o/c 20-80% e/f 500-2000% o/c 200-800% e/f
220V DC/230V AC
5.
6. 7.
8. 9. 10. VIII 1. 2. 3.
Range of high set elements (wherever applicable). VA burden. a) Highest tap. b) Lowest tap. Time V/S current characteristics. Trip contact rating. Descriptive leaflet No. submitted.
IDMT
4. 5. 6.
7. 8. IX. 1. 2. 3.
AUXILIARY RELAYS. Make. Type. Capacity of contacts: i) Continuously. ii) for 3 seconds. Operating coil VA burden. Voltage operated or current operated. No. of Normally closed & Normally Yes open contacts sufficient for seheme requirements (Yes / No). Contacts hand or self reset type. Descriptive leaflet number submitted. FACIA ANNUNCIATOR . Make . Type. Size.

4. 5. No. of windows of the standard facia. No. of additional windows that can be added to the standard facia, as at Sr.No. 3 above. Provision of Àccept', `Reset', and Provided Separately `Lamp test', push buttons in the facia. Mode of inscription on the facia window. Operating voltage. Description of leaflet submitted. TRANSFORMER DIFFERENTIAL RELAY. Make. Type. Minimum differential current at which relay operations. Range & steps of bias setting. Operating time at twice the relay setting. VA burden of the relay. Descriptive leaflet No. submitted. No. of Normally closed & normally open contacts sufficient for scheme requirement TRIP CIRCUIT SUPERVISION RELAY. Make. Type Rating Minimum voltage for satisfactory operation (% of rated voltage). Monitoring of breaker trip coil in both close & open position provided. Safety resistors provided to limit the current if the relay coil is short-circuited. No. of Normally closed & Normally open contacts sufficient for seheme requirements (Yes / No). RESTRICTED EARTH FAULT RELAY . Make. Type. Tap range. Timer setting range. V A Burden. Time/Current characteristics
6.
7.
8. 9. X. 1. 2. 3. 4. 5. 6. 7. 8.
220V DC
15% Max. 20-50% 30m sec. max. at 5 times rated current
Yes
XI. 1. 2. 3. 4. 5.
220V DC
Yes
6.
Yes
7.
Yes
XII. 1. 2. 3. 4. 5. 6.
10-40%

7. 8. XIII 1. 2. 3. 4. 5. 6. Short time rating of relay. Descriptive leaflet No. submitted. T/F OVER FLUXING RELAY. Make Type. Rated Voltage (V,AC) Rated DC Voltage. Operating principle. No. of Normally closed & Normally open contacts sufficient for seheme requirements (Yes / No). Contacts self/hand reset. Burden. Setting range. i) V/F ii) Time for alarm. iii) Time for tripping. Whether inverse time operating characteristics provided. Whether different time multiplier settings provided. Max. operating time of the relay at i) 1.4 times the rated value of V/F. ii) 1.25 times the rated value of V/F. Reset time. LOCAL BREAKER BACK UP RELAYS . Make. Type. Setting range (% of rating) a) Phase faults. b) Ground faults. Operating time (m sec.) Reset time (m sec). Burden. Timer range. Whether no. of Normally closed & Normally open contacts sufficient for scheme requirements? (Yes / No). OVER LOAD ALARM RELAY. Make. Type. Rated Voltage. Setting Ranges. Operating time. Setting range continuously variable.
110 V 220 V V/F Yes
7. 8. 9.
100-130% 0.1-6 Sec. Yes
10. 11.
12.
13. XIV. 1. 2. 3.
4. 5. 6. 7. 8.
20-80% 20-80% 15m Sec. Max. 15m Sec. Max. 0.05-0.5 sec. Yes
XV. 1. 2. 3. 4. 5. 6.
50-120%, 50-200% For T/F, For Line Yes

XVI. SELECTOR SWITCHES (AUTORECLOSING IN/OUT, CARRIER PROTECTION IN/OUT SWITCH, TRIP TRANSFER SWITCH). 1. Make. Type. Type of handle. No. of positions.
2. 3. 4. 5.
6. 7. XVII. 1. 2. 3. 4.
As per requirement No. of Normally closed & Normally Yes open contacts sufficient for seheme requirements (Yes / No). Making & breaking capacity of contacts. Descriptive leaflet number submitted. DISTANCE RELAYS. Make. Type of relay. Type of distance measuring elements. Details of starting units and their
scheme
5.
6.
7,
8.
9 10. 11.
Switching sequence, if applicable. Range of settings (in secondary ohms). for Zone-I, Zone-2 & Zone-3. Operating times: i) First zone timing. Max. 40m sec. upto breaker at 50% of reach for zone-I SIR 0.01-4 ii) Second zone time setting adjustable between---secs to --- 0-3 Sec. secs. iii) Third zone time setting adjustable between -------- secs 0-5 Sec. to ------- secs. Contacts rating: i) First Zone. ii) Second Zone. iii) Third Zone. VA burden : i) Current circuit of the scheme. ii) Potential circuit of the scheme. Is the VA burden at Sr.No.8 above is continuous ? (yes/No) Operating time versus ZS/ZL curves of the distance scheme. Descriptive leaflet no. submitted.

XVIII. 1. 2. 3. 4. 5. 6. 7. XIX. 1. 2. 3. 4. 5. 6. 7. 8. 9. CHECK SYNCHRONIZING RELAY: Make. Type. Rating ( V, ac ) Aux. Voltage ( V, dc ) Permissible voltage difference (%) Permissible phase angle difference (degree) Response time of relay (without timer)( m Sec ) AUTO RECLOSING : Make. Type. Multi shot or single shot. Rating (V, dc) Suitable for 1 & 3 phase. Dead time setting range (Sec.) Reclaim time setting range (sec.) Four position selector switch provided. Alarm contacts provided for Àuto-reclosed', `Reclosure unsuccessful'. SYNCHRONISING SWITCH : Make. Type. Contact rating. No. of position. No. of contacts. Removable handle type ? BUS-BAR PROTECTION Make. Type. Applicable standard. Rated Voltage/Frequency. Operating time (maximum). Resetting time (maximum). Does the offer meet the requirements of technical specification? Yes/No
63.5 V 220 V 10% max. 350 max. <200m sec.
Single shot 220 V Yes 0.1-2 sec. 5-300 sec. Yes
XX. 1. 2. 3. 4. 5. 6. XXI. 1. 2. 3. 4. 5. 6. 7.
3 As per requirement Yes
scheme
110VAC, 50Hz, 220V DC 15m sec. at 5 times setting Yes/No
CURRENT TRANSFORMERS
Sr. No.
1. 2. 3. 4. 5. 6.
Description Required
Manufacturer's Name Type/Installation. Conforming to standard. Rated voltage. Rated frequency. Detail of cores. *Core No. I II III IV Purpose of cores. Rated Secondary Current. Class of accuracy. Accuracy limit factor. Formula governing minimum knee point voltage at CT Secondary resistance corrected to 75 C. Instrument security factor. Secondary limiting voltage. Maximum Secondary resistance corrected to 75 C. Rated burden. Exciting current for Distance protection core at Vk, for Bus Bar protection core & REF Core at Vk/2. and for differential protection Core at Vk/4 * No. of cores as per applicability for a particular type of current Rated primary current. Rated short time withstand current (kA rms) for 1 second duration. Rated dynamic withstand current (kA peak). Rated continuous thermal current (pu). One minute power frequency withstand voltage (kV rms) a) Dry b) Wet
132KV Offered
Outdoor IS:2705 132kV 50 Hz As per annexures attached with Tech. Specification
6.1 6.2 6.3 6.4 6.5
6.6 6.7 6.8 6.9 6.10
7. 8.
As per annexures attached with Tech. Specification 31.5
9. 10. 11.
78.75 1.25
275 38 for NCT 275 38 for NCT
12. 13. 1.2/50 micro-second impulse withstand voltage (kV peak) One minute power frequency withstand voltage of secondary winding (kV rms) Minimum creepage distance (mm) Maximum creepage factor. Winding a) No. of primary turns b) Primary amp. turns (Dynamic condition) c) Current density d) Area of Cross-section & material i) Primary turns ii) Secondary turns I.S. to which the oil conforms. Weight of oil (kg). Quantity of oil (Ltrs) Total weight (kg). Maximum shipping weight (kg) Overall dimension. Mounting details. Maximum permissible temperature rise of winding when referred to maximum ambient temperature of 50 C in terms of clause 7.2 (Table 2 of IS:2705 Part-1-1992 ) or Equivalent IEC 650 95 for NCT 3
14. 15. 16.
3625 440 for NCT 4
17. 18. 19. 20. 21. 22. 23. 24.
IS 335
CAPACITIVE VOLTAGE TRANSFORMER

Sr. No. 1. 2. 3. 4. a) b) c) 5. 6. a) b) c) 7. a) b) c) 8. a) b) c) 9. Description Name of manufacturer Type and model Rated voltage (kV) Capacitance : Primary capacitance C1 (pf) Secondary capacitance C2 (pf) Equivalent capacitance C (pf) Number of secondary windings Rated secondary windings : Winding-I (volts) Winding -II (volts) Winding-III (Volts) Rated secondary burden: Winding - I (VA) Winding - II (VA) Winding - III (VA) Accuracy class of each secondary : Winding -I (VA) Winding - II (VA) Winding - III (VA) Rated voltage factor with rated burden. 132 132KV Required Offered
8800+10%-5% 3 110/3 110/3 110/3 50 25 10 1/3P 3P 0.2S 1.2 continuous & 1.5 for 30 seconds 275
10.
One minute power frequency withstand: Test (Dry) voltage (kV rms) One minute power frequency withstand test (wet) voltage (kV rms) 1.2/50 micro second impulse wave withstand test voltage (kV p) One minute power frequency withstand voltage on secondaries (kV rms)
11.
275
12.
650
13.
CAPACITIVE VOLTAGE TRANSFORMER

14 14. 15. Total creepage distance (mm) Creepage factor (mm) Is CVT suitable for carrier frequency in the range of 40 to 500 KHz? (Yes/No) Natural frequency of coupling capacitors Rated Primary burden of potential devices (VA) Temperature rise at 1.2 times rated voltage with rated burden (C) Guaranteed value of temp. coefficient. (percent per Ce Guaranteed value of radio interference voltage in micro-volts at different voltages. Guaranteed sealing test. The pressure at which sealing test is to be carried out. Guaranteed value of the H.F capacitances and equivalent series resistance at different. Value of stray capacitance and stray conductance in the carrier frequency range of 40 to 500 KHz. Weight of oil and the standard to which it conforms In capacitor unit (Kg/IS) In measuring unit. (Kg/IS) Total weight (Kg) Over -all dimensions (mm) Mounting flange dimensional details Whether CVT are suitable for Carrier communication, carrier protection, carrier telemetering and carrier teleprinting services, metering, relaying protection, synchronising and interlocking purposes. Do the CVTs contain built in (Yes/No) compensating reactors and damping device in P.T. portion? 3625 min. 4 max. Yes
16. 17. 18.
>500k Hz
19. 20.
21. 22. 23.
8800+50%-20%
24. i) ii) 25. 26. 27. 28.
IS 335
Yes
29.
Yes
Sr. No.
1. 2. 3. 4. 5. 6.
Description Required
Manufacturer's Name Type/Installation. Conforming to standard. Rated voltage. Rated frequency. Detail of cores. *Core No. I II III IV Purpose of cores. Rated Secondary Current. Class of accuracy. Accuracy limit factor. Formula governing minimum knee point voltage at CT Secondary resistance corrected to 75 C. Instrument security factor. Secondary limiting voltage. Maximum Secondary resistance corrected to 75 C. Rated burden. Exciting current for Distance protection core at Vk, for Bus Bar protection core & REF Core at Vk/2. and for differential protection Core at Vk/4 * No. of cores as per applicability for a particular type of current Rated primary current. Rated short time withstand current (kA rms) for 1 second duration. Rated dynamic withstand current (kA peak). Rated continuous thermal current (pu). One minute power frequency withstand voltage (kV rms) a) Dry b) Wet
33KV Offered
Outdoor IS:2705 33kV 50 Hz As per annexures attached with Tech. Specification
6.1 6.2 6.3 6.4 6.5
6.6 6.7 6.8 6.9 6.10
7. 8.
As per annexures attached with Tech. Specification 26.3
9. 10. 11.
65.75 1.25
70 38 for NCT 70 38 for NCT
12. 13. 1.2/50 micro-second impulse withstand voltage (kV peak) One minute power frequency withstand voltage of secondary winding (kV rms) Minimum creepage distance (mm) Maximum creepage factor. Winding a) No. of primary turns b) Primary amp. turns (Dynamic condition) c) Current density d) Area of Cross-section & material i) Primary turns ii) Secondary turns I.S. to which the oil conforms. Weight of oil (kg). Quantity of oil (Ltrs) Total weight (kg). Maximum shipping weight (kg) Overall dimension. Mounting details. Maximum permissible temperature rise of winding when referred to maximum ambient temperature of 50 C in terms of clause 7.2 (Table 2 of IS:2705 Part-1-1992 ) or Equivalent IEC 170 95 for NCT 3
14. 15. 16.
900 440 for NCT 4
17. 18. 19. 20. 21. 22. 23. 24.
IS 335
POTENTIAL TRANSFORMER
Sr. No. 1. 2. 3. 4. 5. 6. a) b) 7. a) b) 8. a) i) ii) b) i) ii) 9. a) b) 10. 11. Description Required Manufacturer's type and designation. Type Rated Frequency Rated primary voltage Number of secondary windings Rated secondary windings : Winding-I Winding -II Class of Accuracy. Winding - I Winding -II Limits of errors. Winding -I Percentage voltage ratio error Phase displacement. (Minutes) Winding - II Percentage voltage ratio error Phase displacement (minutes) Rated burden. Winding - I Winding-II Rated voltage factor and time Temperature rise at 1.2 times rated voltage when applied continuously with rated burden (C) Insulation class of Primary windings Secondary windings One minute power frequency: (Dry) withstand Test voltage (kV) 70 50 Hz 33 kV 3 110/3V 1103V 33KV Offered
0.2 1/3 P
10 VA 50 VA 1.2 Continuous & 1.5 for 30 Sec.
12. a) b) 13.
14.
One minute power frequency (wet) withstand test voltage (kV) 1.2/50 micro second impulse withstand test voltage (kV peak) One minute power frequency withstand voltage on secondaries (KV rms) a) Creepage distance. Creepage factor Standard to which the equipment conforms Standard to which the oil conforms Total weight of the P.T. Overall dimensions Mounting details Weight of the oil
70
15.
170
16.
17. a) 18. 19. 20. 21. 22. 23.
900 mm Min. 4 Max. IS3156 IS335
24. Total shipping weight.
GTP of 220V 200AH VRLA Battery

SR. NO. 1 2 3 4 5 6 7 8 9 10 a.) b.) 11 12 DESCRIPTION PARTICULARS Required Offered 220 V, 200AH 220 V, 200AH
Manufacturer's name and country of manufacturer Whether requirements of Battery manufacturer's furnished Guaranteed AH. Capacity at ten hours discharge rate to 1.75 volts per cell at 27C AH Capacity at one hour discharge rate to1.75 volts per cell at 27C Cell designation in accordance with Indian Standards Applicable Indian Standards Average life in years (min) Recommended range of float charging voltage/Boost Charging voltage Boost charging current Open circuit voltage of cell when completely discharged at 27Deg C At ten hours discharge rate At one hour discharge rate Type of construction of positive pates Type of construction of negative plates
200 AH >90% Yes IS: 15549 20 Years
1.75V/cell Flat pasted heavy duty,durable flat plate using lead alloy pasted semi radial squarish grid. Sealed
13 a. b. 14 15 16 17 18 19
Containers Type Material Sediment space (mm) Cell dimensions (mm) Recommended cell centres distance (mm) Amount and specificgravity of electrolyte per cell require for first filling at 27C Specific gravity of electrolyte when fully charged at 27C Maximum electrolyte temperature that cell can withstand continuously without injurious effects. Battery Racks Type of material
20 a.
Metalic Stand with two coats of acid resistant paint Yes
b. c.
Outline dimensions (mm) Whether anti-acid coating provided
GTP of 220V 200AH VRLA Battery

SR. NO. d. 21 22 a. b. 23 24 25 26 DESCRIPTION PARTICULARS Required Offered 220 V, 200AH 220 V, 200AH Polypropylene
Net weight (kg) Insulators material (for racks and cells) Weight per cell Net dry weight (Kg) With electrolyte (Kg) Total shipping weight of acid for one battery unit(Kg) Total shipping weight of one battery unit (without electrolyte) Short circuit current at Battery terminals
Time for which the battery can withstand short circuit at terminals 27 Internal resistance of each cell I. Full charged condition II. Fully discharged condition 28 Recommended air charges per hour Note: If there is any change in the above GTPs, same shall conform to Technical Specifications/relevant ISS. If there is any change in GTPs, so warranted by specific make of equipment, same shall be taken care at the time of approval of drawings.
GTP OF 120 KV SURGE ARRESTERS Sr. NO. DESCRIPTION PARTICULARS Required 120kV 1 a) b) c) d) 2 a) b) c) GENERAL Manufacturers Name Country of origin Manufacturers type designation Applicable standards ELECTRICAL CHARACTERISTICS Arrester class and type Offered 120kV
Station Class Heavy Duty IEC 99-4 IS : 3070 Gapless type, Station Class
Rated arrester voltage (kV) 120kV rms. Maximum continuous operating voltage 104kV rms. (COV) at design ambient temperature
d)
Nominal discharge current (8/20 micro 10KA sec.wave)(kA) 5 kJ/KV e) i) Minimum discharge capability (kJ/kV) referred to rated voltage at minimum of discharge characteristics ii) f) Line Discharge class, as per IEC Maximum equivalent front of wave protection level (discharge voltage with 0.5x1.5 micro sec, 10 kA impulse current) Maximum switching surge residual voltage, at 1 kA (kVp) 280 3
g)
Sr. NO.
DESCRIPTION
PARTICULARS Required 120kV Offered 120kV
h) i. ii. iii. i)
Maximum residual voltage for 8/20 micro sec current wave at 50 % nominal discharge current (kVp) at 100 % nominal discharge current (kVp) at 200 % nominal discharge current (kVp) One minute power frequency (dry) withstand voltage of arrester (kV rms)(Min.) Impulse withstand test voltage of arrester housing with 1.2/50 micro sec wave, (KVp) impulse currentwithstand a) Transformers and Reactors (kVp) b) Other equipment and lines (kVp) High current short duration (4/10 micro sec. wave) (kAp) Maximum internal ionisation at 50 Hz voltage equal to 1.05 COV 1.0 COV Reference voltage and corresponding reference current of arrester Pressure relief class Energy absorption capability in kJ per operation of the arrester, during a switching surge discharge
340
j)
k)
i. l) i. ii. m) n) o)
550 650 100
>120kV A
Sr. NO.
DESCRIPTION
PARTICULARS Required 120kV Offered 120kV
p)
Internal pressure required to operate pressure relief device as a percentage of burst pressure of porcelain Minimum prospective symmetrical fault 26.3 current (kA rms) Rated voltage of ZnO disc (kV) No. of ZnO discs in a unit No. of units/arrester Height/Thickness of ZnO discs (mm) Diameter of ZnO disc (mm) EXTERNAL INSULATION Applicable standard Impulse voltage withstand test voltage of housing with 1.2/50 micro sec wave (kVp) One minute power frequency withstand voltage of arrester housing dry & wet (kV rms) Total creepage distance of of arrester housing (mm) Overall dimensions Height(mm) Diameter(mm) Net weight(Kg.) Cantilever strength (Kg. M) 3625
q) r) i) ii) iii) iv) 3 a) b)
c)
d) 4 a. b. 5 6
Note: If there is any change in the above GTPs, same shall conform to Technical Specifications/relevant ISS. If there is any change in GTPs, so warranted by specific make of equipment, same shall be taken care at the time of approval of drawings.
GTP OF 16/20 MVA 132/11 KV T/F S. NO. 1 2 3 4 5 6 7 8 9 10 a DESCRIPTION Required Manufacturers Name Rating (MVA) Voltage Ratio (KV) Winding Connection Vector Group Number of Phase Frequency (Hz) Type of cooling Rating available at different cooling % Impedance data Guaranteed positive sequence impedance between HV-LV at 75 deg.C with 100% rating at i. Principal Tap ii. Maximum Tap Iii. Minimum Tap Zero sequence impedance at principal tap Guaranteed losses at 100% rated voltage (excluding cooler loss) at 75 deg.C between HV and LV Iron loss (KW) (max) Copper loss (KW) (max) Guaranteed cooler losses at 100% load (max) (KW) Cooling equipment details Number of coolers and rating as per % of transformer cooling equipment Mounting Fan motor data Number per cooler and rating as % of cooler requirement (also indicate no.of spare fans) Type Rating (KW) Locked rotor current (Amps) Temp. range over which cooler control is adjustable (deg.c to deg.C) Oil pump motor data Number per cooler and rating as % of cooler requirement (also indicate no.of spare pump) Type Rating (KW) Locked rotor current (Amps) Temp. range over which cooler control is 50 0C to 1200C adjustable (deg.c to deg.C) PARTICULARS Offered
16/20 132/11 Star/Star YY0 3 50+5% ONAN/ONAF 80%/100%
10.00%
b 11
a b 12 a 13 a b c i
15.5 78.2 1.5
ii iii iv v d i
50 0C to 1200C
ii iii iv v
GTP OF 16/20 MVA 132/11 KV T/F S. NO. e f i ii iii iv v 14 a b DESCRIPTION Required Type of oil pump and motor (whether oil submerged type) Radiator details Overall dimensions lxbxh (mm) Total weight with oil (Kg) Total weight without oil (Kg) Thickness of Radiator tube (mm) Type of mounting Thermal Data Temperature rise in top oil over an ambient of 50 deg.C Temp rise in winding by resistance measurement method over an ambient of 50 deg.C Thermal time constant (Hours) Withstand time for three phases short circuit at terminals (secs) Over excitation withstand time (sec) 1.25 1.4 1.5 Bushings High voltage Manufacturer Type Total creepage distance (mm) Protected creepage distance (mm) Mounting Rated current (Amps) Low voltage Manufacturer Type Mounting Total creepage distance (mm) PARTICULARS Offered
35 0C 45 0C
c 15 16 i ii iii 17 a i) ii) iii) iv) v) vi) b i) ii) iii) iv)
2 sec.
condenser 3625 1812 tank cover 800
Oil communicating tank cover 300
GTP OF 16/20 MVA 132/11 KV T/F S. NO. v vi) C DESCRIPTION Protected creepage distance (mm) Rated current (Amps) Neutral Bushing Required 150 1200 HV LV PARTICULARS Offered
i) ii) iii) iv)
Manufacturer Type Mounting Total creepage distance (mm) oil communicating tank cover 900 300
v)
Protected creepage distance (mm)
450
150
vi)
Rated current (Amps)
630
1200
18
Is Vacuum filling required, if so state absolute pressure (mm of Hg) Total quantity of oil (ltrs) Tap changing equipment Voltage class and current Number of steps Range Step voltage Type 132 kV & 300A 16 (+)5% to (-)15% 1.25% High speed transition type
19 20 a) b) c) d) e)
f) g)
Rated voltage of drive motor (volts) No.of revolutions to complete one step
GTP OF 16/20 MVA 132/11 KV T/F S. NO. h) DESCRIPTION Required Time to complete one step on manual / auto operation (sec) Power required (kw) Insulation level HV windings Lightning impulse withstand voltage Power frequency withstand voltage (kv rms) LV Winding Lightning impulse withstand voltage Power frequency withstand voltage (kv rms) HV Bushing Lightning impulse withstand voltage Power frequency withstand voltage rms) LV Bushing Lightning impulse withstand voltage Power frequency withstand voltage (kv rms) Neutral Bushing Lightning impulse withstand voltage Power frequency withstand voltage (kv rms) 170 70 75 28 75 28 650 (kv 275 75 28 550 230 PARTICULARS Offered
i) 21 a) i) ii)
b) i) ii)
c) i) ii)
d) i) ii)
e) i) ii)
GTP OF 16/20 MVA 132/11 KV T/F S. NO. DESCRIPTION Required 22 a) b) Approximate dimensions Tank (lxbxh) mm Overall dimensions with (mm) coolers lxbxh Shipping dimensions (mm) (lxbxh) Height for untanking (mm) Dimensions of largest (mm) package (lxbxh) Weights of transformer components Core (Kg) Windings (Kg) Insulation (Kg) Tank and fittings (Kg) Oil (Kg) Untanking weight (heaviest piece) (Kg) Total weight Kg Weight of heaviest package KG Total shipping weight (Kg) Parts detached for transport Permissible overload (% of rating & time As per IS:6600 & IEC:354 in minutes) Clearances Minimum clearance between phases In oil (mm) PARTICULARS Offered
c) d) e)
23 a) b c) d) e) f) g) h) i) j) 24
25 a) i)
GTP OF 16/20 MVA 132/11 KV T/F S. NO. DESCRIPTION Required ii) b) In air (mm) Minimum clearance of HV winding to tank in oil (mm) Minimum clearance of HV winding of earth in oil (mm) Clearance between core (mm) and coil Clearance between coil (mm) Clearance between neutral to ground in air (mm) Conservator Total volume (ltrs) Volume between highest and lowest levels (ltrs) Capacitance values HV to earth (pf) LV to earth (pf) Type of oil preservation Material of air cell Continuous temp. withstand capability of the air cell No.of pressure relief device provided 2 or 1 No. PRD & 1 No. Explosion Vent PARTICULARS Offered
1220/280 (CBIP)
c)
d) e) f)
26 a) b)
27 a) b) 28a) b) c)
29 a)
b)
Operation pressure of pressure relief device Oil Quality of oil
30 a)
GTP OF 16/20 MVA 132/11 KV T/F S. NO. i) ii) iii) iv) v) b) c) 31 a) b) c) d) e) f) g) DESCRIPTION Required Moisture content (ppm) Max tan delta value (at 90 deg.C) Resistivity (ohm cm) Breakdown strength (kv) Interfacial tension at 27 deg.C (min) Quantity including 10% extra (Ltrs) Standards applicable Core Type of construction Net core area (mm.sq) Core material and grade used Type of joint between core and yoke Thickness of stamping (mm) Percentage silicon content (%) Maximum flux density in core at rated frequency at 90% voltage (wb/sq.m) 100% voltage (wb/sq.m) 110% voltage (wb/sq.m) Winding Type of winding Built of section/disc coil. Spiral winding not accepted 1.6 0.27mm (max) M4 HiB or Superior Core Type PARTICULARS Offered
i) ii) iii) 32 a)
b) i) ii)
Current density at rated load HV (A/Sq.cm) LV (A/Sq.cm) 250 200
GTP OF 16/20 MVA 132/11 KV T/F S. NO. DESCRIPTION Required PARTICULARS Offered
GTP OF 16/20 MVA 132/11 KV T/F S. NO. iii) c) DESCRIPTION Regulating winding (A/Sq.cm) Conductor area i) HV (sq.mm) ii) LV (sq.mm) Iii) Regulating winding d) Maximum current density under short circuit i) HV (sq.mm) ii) LV (sq.mm) e) f) Magnetising inrush current (Amps) No load current (Amps) at rated frequency and at 90% voltage (wb/sq.m) 100% voltage (wb/sq.m) 110% voltage (wb/sq.m) Magnetising current at rated frequency and at rated voltage Tank Type Material Approx Thickness of Sides (mm) Bottom (mm) Cover (mm) Radiator Make Bell/Conventional Low carbon steel Required 250 PARTICULARS Offered
i)
i) ii) iii) g)
33 a) b) c) i) ii) iii) 34 a)
GTP OF 16/20 MVA 132/11 KV T/F S. NO. DESCRIPTION Required PARTICULARS Offered
GTP OF 16/20 MVA 132/11 KV T/F S. NO. b) c) 35 a) b) 36 a) b) 37 a) i) ii) iii) b) i) ii) DESCRIPTION Required Material Thickness Vacuum withstand capability of Main tank (torr) Radiators accessories (torr) Pressure withstanding capability of Main Tank Radiator and accessories Temperature indicators OTI Manufacturer Range Accuracy WTI Manufacturer Range 500 C to 1200C 500 C to 1200C PARTICULARS Offered
GTP OF 16/20 MVA 132/11 KV T/F S. NO. DESCRIPTION Required iii) c) i) ii) iii) iv) 38 a) b) c) Accuracy RWTI Manufacturer Range Accuracy Auxiliary supply used Terminal connectors Make Whether type tested Governing standard 220 V DC 500 C to 1200C PARTICULARS Offered
S. DESCRIPTION NO.
GTP OF 9 KV SURGE ARRESTERS PARTICULARS Required 9kV Offered 9kV
1 a) b) c) d) 2 a) b) c)
GENERAL Manufacturers Name Country of origin Manufacturers type designation Applicable standards ELECTRICAL CHARACTERISTICS Arrester class and type Rated arrester voltage (kV) Gapless type, Station Class 09kV rms. Station Class Heavy Duty IEC 99-4 IS : 3070
Maximum continuous operating voltage 7kV rms. (COV) at design ambient temperature Nominal discharge current (8/20 micro sec.wave)(kA) 10KA
d)
e) i) Minimum discharge capability (kJ/kV) referred to rated voltage at minimum of discharge characteristics ii) f) Line Discharge class, as per IEC Maximum equivalent front of wave protection level (discharge voltage with 0.5x1.5 micro sec, 10 kA impulse current) Maximum switching surge residual voltage, at 1 kA (kVp) Maximum residual voltage for 8/20 micro sec current wave at 50 % nominal discharge current (kVp)
5 kJ/KV
g)
21
h)
i.
S. DESCRIPTION NO.
ii.
at 100 % nominal discharge current (kVp) at 200 % nominal discharge current (kVp) One minute power frequency (dry) withstand voltage of arrester (kV rms)(Min.) Impulse withstand test voltage of arrester housing with 1.2/50 micro sec wave, (KVp) impulse currentwithstand a) Transformers and Reactors (kVp) b) Other equipment and lines (kVp) High current short duration (4/10 micro sec. wave) (kAp) Maximum internal ionisation at 50 Hz voltage equal to 1.05 COV 1.0 COV Reference voltage and corresponding reference current of arrester Pressure relief class Energy absorption capability in kJ per operation of the arrester, during a switching surge discharge Internal pressure required to operate pressure relief device as a percentage of burst pressure of porcelain
25
iii.
i)
j)
k)
75 75 100
i.
l)
i. ii. m)
>9kV
n) o)
p)
q)
Minimum prospective symmetrical fault 18.4 current (kA rms)
S. DESCRIPTION NO.
r) i) ii) iii) iv) 3 a) b)
Rated voltage of ZnO disc (kV) No. of ZnO discs in a unit No. of units/arrester Height/Thickness of ZnO discs (mm) Diameter of ZnO disc (mm) EXTERNAL INSULATION Applicable standard Impulse voltage withstand test voltage of housing with 1.2/50 micro sec wave (kVp) One minute power frequency withstand voltage of arrester housing dry & wet (kV rms) Total creepage distance of of arrester housing (mm) Overall dimensions 300
c)
d)
a. Height(mm) b. Diameter(mm) 5 Net weight(Kg.) 6 Cantilever strength (Kg. M) Note: If there is any change in the above GTPs, same shall conform to Technical Specifications/relevant ISS. If there is any change in GTPs, so warranted by specific make of equipment, same shall be taken care at the time of approval of drawings.
GTP OF 33 KV SURGE ARRESTERS

S. NO. 1 a) b) c) GENERAL Manufacturers Name Country of origin Manufacturers type designation Station Class Heavy Duty IEC 99-4 IS : 3070 DESCRIPTION PARTICULARS Required Offered 33kV 33kV
d) 2 a)
Applicable standards ELECTRICAL CHARACTERISTICS Arrester class and type
Gapless type, Station Class 33kV rms. 25kV rms.
b) c)
Rated arrester voltage (kV) Maximum continuous operating voltage (COV) at design ambient temperature Nominal discharge current (8/20 micro sec.wave)(kA)
d)
10KA
e) i) Minimum discharge capability (kJ/kV) referred to rated voltage at minimum of discharge characteristics ii) f) Line Discharge class, as per IEC Maximum equivalent front of wave protection level (discharge voltage with 0.5x1.5 micro sec, 10 kA impulse current) g) Maximum switching surge residual voltage, at 1 kA (kVp) h) Maximum residual voltage for 8/20 micro sec wave at 50 % nominal discharge current (kVp) at 100 % nominal discharge current (kVp) at 200 % nominal discharge current (kVp) One minute power frequency (dry) withstand voltage of arrester (kV rms)(Min.) Impulse withstand test voltage of arrester housing with 1.2/50 micro sec wave, (KVp)
5 kJ/KV
70
i. ii. iii. i)
85
j)
S. NO. k)
DESCRIPTION
PARTICULARS Required Offered 33kV 33kV 170 170 100
impulse currentwithstand a) Transformers and Reactors (kVp) b) Other equipment and lines (kVp) High current short duration (4/10 micro sec. wave) (kAp) Maximum internal ionisation at 50 Hz voltage equal to 1.05 COV 1.0 COV Reference voltage and corresponding reference Pressure relief class Energy absorption capability in kJ per operation of the arrester, during a switching surge discharge Internal pressure required to operate pressure relief device as a percentage of burst pressure of Minimum prospective symmetrical fault current (kA rms) Rated voltage of ZnO disc (kV) No. of ZnO discs in a unit No. of units/arrester Height/Thickness of ZnO discs (mm) Diameter of ZnO disc (mm) EXTERNAL INSULATION Applicable standard Impulse voltage withstand test voltage of housing with 1.2/50 micro sec wave (kVp) One minute power frequency withstand voltage of arrester housing dry & wet (kV rms) Total creepage distance of of arrester housing (mm) Overall dimensions Height(mm) Diameter(mm) Net weight(Kg.) Cantilever strength (Kg. M)
i.
l)
i. ii. m) n) o)
>33kV A
p)
q)
26.3
r) i) ii) iii) iv) 3 a) b)
c)
d) 4 a. b. 5 6
900
S. NO.
DESCRIPTION
PARTICULARS Required Offered 33kV 33kV
Note: If there is any change in the above GTPs, same shall conform to Technical Specifications/relevant ISS. If there is any change in GTPs, so warranted by specific make of equipment, same shall be taken care at the time of approval of
GTP of 415 V ACDB Sr. Description No. Particulars Required
Offered
1.
Standard: The specific standard to which the switches are designed Rating of switches a) Number of phases b) Service voltage c) Normal current d) Frequency e) Type of contacts f) Material of contacts of switches and their plating g) Clearance between phases h) Between live parts and earth Particulars of bus bar a) Material i) Phases Neutral Normal current rating Area i) Phases ii) Neutral d) Shape Bus bar chamber a) Whether vermin proof. b) Thickness of sheet c) M. S. angle size Rupturing capacity of bus bar switchgear/cartridges Temperature rise, under continuous load in oC Thickness of the sheet for a) Main board b) Metering chamber b) c) ii)
2.
3 415V 50 HZ Quick make and break type Cu with silver plating
3.
High conductivity Cu or aluminum
Rectangular Yes
4.
5. 6. 7
2 MVA, 20KA at 415V
GTP of 415 V ACDB Sr. Description No. Particulars Required
Offered
8 9
Current density assumed for current conducting components Rated short circuit making capacity of switches at 415 V in KA
10 Current transformer for metering i) ii) iii) 15VA VA burden 1 Accuracy class Instrument security factor
11 Make of i) Switch boards ii) Switches iii) Selector switch iv) HRC fuses v) CTs vi) KWH meter vii) Voltmeter viii) Ammeter 12 Details of type test supplied 13 Details of drawings supplied 14 List of references to which similar switch fuse units have been in service Note: If there is any change in the above GTPs, same shall conform to Technical Specifications/relevant ISS. If there is any change in GTPs, so warranted by specific make of equipment, same shall be taken care at the time of approval of drawings.
GTP of 11 KV Capacitor Sr.N Description o. Required A 1 2 3 i. ii iii Shunt Capacitor Name of manufacturer and country Applicable Standard Capacitor unit Rated Voltage Max. permissible continuous over voltage as a percentage of rated voltage Short Time over voltage for 30 minutes for 1 minute for 3 cycles a) Nominal capacitance at 250 C, 50 0 C b) Manufacturing tolerance on capacitance value a) Rated output at rated voltage and 50 HZ b) Maximum output Particulars Offered
IS:13925 (Part-I) 1998 7.3KV
iv
11.94 at 500C
200 KVAR 130% of the rated output Non PCB Type impregnate External Expulsion fuse
vi vii viii ix
Type of impregnant used Type of fuse used Temp. category as per ISS Discharge resistor value
50V of less with in 5 Minute as per our technical specification
x xi
xii
xiii xiv
Discharge time for 50 volts BUSHINGS a) Noofbushingsperunitand type b) Rated voltage c) Rated insulation level d) Total creepage distance a) Type of dielectric used b) Voltage stress for dielectric c) Thickness of dielectric a) 10 seconds test voltage b) Lightning impulse test voltage a) Capacitor unit material b) c) Finish/paint details Type of welding
75 kV (Peak) Sheet steel of 2 mm CRC
GTP of 11 KV Capacitor Sr.N Description o. xv FUSES Type No. per unit Max. energy which fuse carrier can withstand without Deterioration as a percentage of capacitor unit nominal current Max. recovery voltage at which fuse can operate Overall Dimension a) Height b) Mounting c) Thickness xvii Losses under stabilized condition xviii Weight per unit 4 CAPACITOR BANKS 1. Rated Voltage i. 2. Max. permissible continuous over voltage as a ii percentage of rated voltage 3. Nominal capacitance at 25 0C, 500C iii 4. Manufacturing tolerance on value iv 5. Variation of capacitance due to ambient temp. v. and load 6. Variation of capacitance due to loss of vi units/elements a) At alarm stage b) At trip stage 7. No. of units in parallel per phase per series vii section 8. 9. ix 10. 11. xi 12. xii 13. No. of series sections per phase Connection Symbol Rated output Rated current per phase Withstand voltage of capacitor banks while switching on/off Power frequency withstand voltage Single star xvi Particulars Required External Expulsion fuse Offered
12.65 kV
59.67
28 kV RMS
GTP of 11 KV Capacitor Sr.N Description o. Required 14. 15. xv Creepage distance Unbalance voltage in open delta of RVT (Volts a) Under normal condition b) 1 capacitor unit is out in a section c) 2 capacitor units are out in a section Total guaranteed losses at rated voltage and frequency under stabilised condition Max. residual voltage at de-energisation Time taken in attaining the residual voltage Annual failure rate Total weight of Capacitor unit and Capacitor Bank including elevating structure Overall dimensions of capacitor bank RESIDUAL VOLTAGE TRANSFORMER Name of manufacturer and country Type Rated voltage VA Burden Connection Accuracy class a) Protection Winding b) Metering winding Voltage factor Power frequency withstand voltage Lightning impulse withstand voltage Energy Discharge capability 3P 11 100VA Star/open delta Particulars Offered
16. 17. 18. 19. 20.
21. B 1. 2. 3. 4. 5. 6.
7. 8. 9. 10.
28 75
GTP of 11 KV Capacitor Sr.N Description o. Required 11. 12. 13. Total weight of RVT Overall Dimensions Whether inter stack and base insulators and terminal connectors for bank included in scope of supply Whether bus-bar material for capacitor banks included in scope of supply Whether galvanized support structure and stack rack for capacitor banks included in scope of supply ISOLATORS Make Type Reference standard Rated voltage No. of poles Rated normal current Rated peak withstand current Rated short time current for 1 second i) 1.2/50 micro sec. Impulse withstand voltage positive and negative polarity a) Across the isolating distance b) To earth and between poles ii) One minute power frequency withstand voltage a) Across the isolating distance b) To earth and between poles Type of isolater Creepage distance Weight of complete isolator Type of operating mechanic 18.4 KA 12 KV 3 Particulars Offered
14. 15.
1. 2. 3. 4. 5. 6. 7. 8. 9.
10. 11. 12. 13.
GTP of 11 KV Capacitor Sr.N Description o. Required 14. 15. 16. No. of auxiliary contacts provided Total weight Overall Dimension Particulars Offered
GTP of 33 KV Capacitor Bank Sr.No. A 1 2 3 i. ii Description Shunt Capacitor Name of manufacturer and country Applicable Standard Capacitor unit Rated Voltage Particulars Required Offered
IS:13925 (Part-I) 1998 7.3KV
iii
iv
110% Max. permissible continuous over voltage as a percentage of rated voltage Short Time over voltage for 30 minutes for 1 minute for 3 cycles a) Nominal capacitance at 11.94 at 500C 250 C, 50 0 C b) Manufacturing tolerance on capacitance value a) Rated output at rated voltage and 50 HZ b) Maximum output Type of impregnant used Type of fuse used Temp. category as per ISS Discharge resistor value Discharge time for 50 volts BUSHINGS a) Noofbushingsperunitand type b) Rated voltage c) Rated insulation level d) Total creepage distance a) Type of dielectric used b) Voltage stress for dielectric c) Thickness of dielectric a) 10 seconds test voltage b) Lightning impulse test voltage a) Capacitor unit material b) Finish/paint details c) Type of welding 75 kV (Peak) Sheet steel of 2 mm CRCA 200 KVAR 130% of the rated output Non PCB Type impregnate
vi vii viii ix x xi
12 KV 28 KV (rms)/75 KV Peak 300mm
xii
xiii
xiv
GTP of 33 KV Capacitor Bank Sr.No. xv Description Particulars Required Offered
xvi
xvii xviii 4 1. 2.
i. ii
3. 4. 5. 6.
iii iv v. vi
FUSES Type No. per unit Max. energy which fuse carrier can withstand without Deterioration as a percentage of capacitor unit nominal current Max. recovery voltage at which fuse can operate Overall Dimension a) Height b) Mounting c) Thickness Losses under stabilized condition Weight per unit CAPACITOR BANKS Rated Voltage 38 kV 110% Max. permissible continuous over voltage as a percentage of rated voltage Nominal capacitance at 250C, 15.87 micro F 500C Manufacturing tolerance on value Variation of capacitance due to ambient temp. and load Variation of capacitance due to loss of units/elements a) At alarm stage b) At trip stage No. of units in parallel per phase per series section No. of series sections per phase Connection Symbol Double star Rated output 7.2 MVAR Rated current per phase 109.39 A Withstand voltage of capacitor banks while switching on/off 70 kV RMS
7. 8. 9. 10. 11. 12.
vii
ix xi xii
13.
xiv Power frequency withstand voltage
GTP of 33 KV Capacitor Bank Sr.No. 14. 15. xv xv Description Creepage distance Unbalance voltage in open delta of RVT (Volts a) Under normal condition b) 1 capacitor unit is out in a section c) 2 capacitor units are out in a section Total guaranteed losses at rated voltage and frequency under stabilised condition Max. residual voltage at deenergisation Time taken in attaining the residual voltage Annual failure rate Total weight of Capacitor unit and Capacitor Bank including elevating structure Overall dimensions of capacitor bank 25mm/kv Particulars Required Offered
16.
17. 18. 19. 20.
21.
S. NO. 1
GTP OF 220 V 200H VRLA BATTERY CHARGER DESCRIPTION PARTICULARS Required Offered 220V BATTERY CHARGER Manufacturers Name & country of manufacture Whether requirements of Charger manufacturer's furnished Charger dimensions Height (mm) Depth (mm) Width (mm) Sheet thickness (mm) Charger weight (Kg) Charger rated output Current Float charging mode Boost charging mode Load limiter current setting range (Trickle mode) Automatic voltage regulator (Float Mode): Type Percentage stabilisation of the output DC Voltage Voltage setting range Response time of automatic voltage Regulator Manual voltage regulator (Float mode): Type Voltage setting range Boost charging current setting range Boost charging limit setting range 0 to full load DC Load variation 50 to 100% 2mm Yes
3 I. II. III. IV. 4 5 a. b. 6
7 I. II.
III. IV.
8 I. II. 9 10
S. NO.
GTP OF 220 V 200H VRLA BATTERY CHARGER DESCRIPTION PARTICULARS Required Offered 220V BATTERY CHARGER Rectifier assembly: Type of semiconductor material Rated direct current percell Rated direct voltage Rated input voltage Type of connections of rectifier elements Fully/half controlled bridge type IS:4540
11 I. II. III. IV. V.
VI. 12 I.
Standard applicable Rectifier transformer: Type
Dry- Aircooled of class F Insulation type As required
II. III.
Rated KVA & % impedance Input line winding connection in vector representation Cell winding connection in vector representation One minute power frequency withstand voltage (KV) Standard applicable Instruments: Type
IV.
V.
VI. 13 I.
IS 2026/IS 4540
Flush Type dust proof and moisture resistant
II. III. IV. V.
DC Voltmeter range DC Ammeter range Dial size Accuracy class as per IS 15
S. NO. 14 I. II. III. IV. V. VI. Contactor: Type Rated voltage Rated current
GTP OF 220 V 200H VRLA BATTERY CHARGER DESCRIPTION PARTICULARS Required Offered 220V BATTERY CHARGER
No.of power contacts No., type and rating of aux. contacts Operating coil voltage
VII. Drop out voltage 15 I. II. Thermal Overload relay: Tripping current range Whether single phasing protection provided
III. 16 I. II. III. IV. V. 17 I. II. III.
Standard applicable Air Break Switches Type Rated voltage Rated current Type and material of contacts Standard applicable Fuses: Type Rupturing capaity Standard applicable HRC-Link Type Air Break Type 500 V AC/250 V DC
GUARANTEED TECHNICAL PARTICULARS FOR 11 kV, Single Core 630 mm sq XLPE CABLE , 11kV, 3core 50mm XLPE CABLE & 11kV, 3core 185mm XLPE CABLE . Sr. Descritption No. 11 kV, Single Core 630 mm sq XLPE CABLE Required 11kV, 3core 11kV, 3core 185mm XLPE 50mm XLPE CABLE CABLE Particulars Offered 11kV, 11kV, 3core 3core 50mm 185mm XLPE XLPE CABLE CABLE
11kV, 3core 300mm XLPE CABLE
11 kV, Single Core 630 mm sq XLPE CABLE
1 2 3 4
Name of manufacturer Type of cable Voltage rating Applicable standard
11kV Earth system IS: 7098 (pt-II) IS: 7098 (pt-II) 1985, IS: 1985, IS: 8130/84 with up 8130/84 with up to date to date amendment amendment Aluminium EC Grade Aluminium Aluminium of Conductor as per IS: 8130/84 H2/H4 Grade Aluminium as per IS: 8130/84
11kV
11kV Earth system IS: 7098 (pt-II) 1985, IS: 8130/84 with up to date amendment EC Grade Aluminium of H2/H4 Grade Aluminium as per IS: 8130/84 3Cx185 mm2
11kV Earth system IS: 7098 (pt-II) 1985, IS: 8130/84 with up to date amendment EC Grade Aluminium of H2/H4 Grade Aluminium as per IS: 8130/85 3Cx300 mm3
5 a.
Conductor Material
b.
Single Corex630 3Cx50 mm2 No & Nom Cross sectional mm2 area Minimum no. of wires in each Core Dia. Of each wire in Core 6
c.
30
d.
In IS: 8130/84 latest only Min. No of wire are specified and hence not applicable. Stranded Compacted circular
e.
Shape
6 a.
Conductor screen Material
Semi conducting material 0.3
b. 7
Thickness (mm) Min Insulation
a.
Material
Cross linked Cross linked Cross linked polyethylene IS- polyethylene IS- polyethylene IS7098 (2) 1985 7098 (2) 1985 7098 (2) 1986 3.6 ( shall not 3.6 with be less than 3.6-tolerance as per ISS ( shall 0.1 mm not be less than +0.1*3.6) 3.6- 0.1 mm +0.1*3.6) 3.6 with tolerance as per ISS ( shall not be less than 3.60.1 mm +0.1*3.6)
b.
Nom. Thickness (mm)Nom
8 a. i.
Insulation Non metallic part Material Semi conducting compound 0.3 Semi conducting compound 0.3 Semi conducting compound 0.3
ii. b. I Ii 9
Thickness (mm) min Metallic part Material Thickness (mm) min Core Identification
Copper tape 0.045
Copper tape 0.045
Copper tape 0.045
By coloured By coloured By coloured By coloured strips as per CI: strips as per CI: strips as per CI: strips as per CI: 13.of 7098/85 13.of 7098/85 13.of 7098/86 13.of 7098/85
10
Inner Sheath
a.
Material
PVC compound PVC compound PVC compound type ST: 2 as type ST: 2 as per IS: 5831:84 per IS: 5831:85
b. 11 a. b.
Minimum thickness mm Armour Material Nom. Thickness of strip Outer Sheath Material i) Thickness (mm) Min Approx. overall dia. of cable mm Standard packing length Approx. weight of cable kg./ KM. Min Bending Radius Maximum D.C. resistance of conductor ohm/Km Approx. reactance at 50 Hz ohm/KM Non-magnetic material
0.5
0.7
GI strip as per IS: 3975/84
4.0mm +/-10% 4.0mm +/-10% 4.0mm +/-10% x 0.8mm +/-10% x 0.8mm +/x 0.8mm +/10% 10% Extruded PVC PVC compound PVC compound PVC compound 1.88 48+/-2mm 500+/-5% Metre -15 times the overall dia of the cable 2.36 66+/-2mm 500+/-5% Metre -15 times the overall dia of the cable 0.164
12 a.
13 14
15 16
17
18
19
Approx. A.C. resistance of conductor at Maximum operating temp. ohm/Km Approx. capacitance per phase mf/Km Continuous current carrying capacity under standard conditions In air at 400 C In ground sat 300 C In duct at 300 C Maximum permissible conductor temperature At rated current At short circuit condition Short circuit rating of conductor
20
21
a. b. c. 22
a. b. 23
S. NO. 1 2 3 (a) (b) 4 5 6 (a) (b) 7 8 9
DESCRIPTION
GTP OF 200 KVA 11/0.4 KV LT T/F PARTICULARS Required Offered
Manufacturer's Name & Address Service Rated Voltage : HV Winding LV Winding Rated frequency Number of phase Connections : HV Winding LV Winding Connection symbol Type of cooling Delta Star neutral broughtout Dyn-11 ONAN 11 kV 0.433 kV 50Hz 3 Outdoor
Rating available at different cooling (if 200 kVA any) in % Tap changing equipment Manufacturer Type No. of steps Guaranteed positive sequence impedance at 75C with 100% rating at Principal tap Maximum tap Off circuit tap changer (+)3% to (-)3%
10 (a) (b) (c) 11
(a) (b)
4.5%
S. NO.
DESCRIPTION
(c) 12
Minimum tap Temperature rise over an ambient of 50C Top oil (if applicable) C
0 40 C
(a) (b)
Windings (by resistance measurement 500C method) C
13
Guaranteed losses at rated voltage on principal tap at rated freequency
(a) (b) 14
No load loss or iron loss Copper loss at full load at 75C Withstand time for three phase short circuit at terminals (secs.) No load current at rated Voltage and rated frequency Insulation level Separate source power frequency voltage withstand HV Winding LV Winding Induced over voltage withstanding HV Winding LV Winding Full wave lightning impulse withstanding
0.4 KW 3.135 KW
15
2% of full load current (max)
16 (a)
(i) (ii) (b) (i) (ii) (c)
28kV 3kV
S. NO.
DESCRIPTION
(i) (ii) 17 (a) (b) 18 (a) (b) (c) 19 (a) (i) (ii) (iii)
HV Winding LV Winding Regulation at full load at 75C At unity power factor At 0.8 power factor Terminal arrangement High voltage Low voltage LV Neutral Bushings High Voltage Manufacturer Type Minimum Creepage distance
75 kV -
Porcelain 300mm
(b) (i) (ii) (iii)
Low Voltage Manufacturer Type Minimum Creepage distance Porcelain 25mm
S. NO.
DESCRIPTION
(c) (i) (ii) (iii) 20
LV Neutral Manufacturer Type Minimum creepage distance Total quantity of oil (litres) required for first filling (wherever applicable) Porcelain 25mm
21
Is vacuum filling required if so, stated absolute pressure
22
Efficiency at 75C at unit power factor.
(a) (b) (c) 23 (a) (b) 24 25 (a)
At full load At 3/4 full load At 1/2 full load Approximate dimensions Tank enclosure LxBxH Overall LxBxH Untanking height Approximate Weight Core and winding
S. NO. (b) (c) (d) 26 (a)
DESCRIPTION
Tank fittings Oil (if applicable) Total Weight Despatch details Approximate mass of heaviest package Approximate dimensions of largest package Length Breadth Height Reference Standards IS:2026
(b)
(i) (ii) (iii) 27
S. NO. 1 2 3 (a) (b) 4 5 6 (a) (b) 7 8 9 10 (a) (b) (c) 11
DESCRIPTION
GTP OF 200 KV 33KV LT TRANSFORMERS PARTICULARS Required Offered
Manufacturer's Name & Address Service Rated Voltage : HV Winding LV Winding Rated frequency Number of phase Connections : HV Winding LV Winding Connection symbol Type of cooling Rating available at different cooling (if any) in % Tap changing equipment Manufacturer Type No. of steps Guaranteed positive sequence impedance at 75C with 100% rating at Principal tap Maximum tap Minimum tap Temperature rise over an ambient of 50C Top oil (if applicable) C Windings (by resistance measurement method) C Guaranteed losses at rated voltage on principal tap at rated freequency No load loss or iron loss Copper loss at full load at 75C Withstand time for three phase short circuit at terminals (secs.) No load current at rated Voltage and rated frequency
Outdoor 33 kV 0.433 kV 50+5% Hz 3 Delta Star neutral broughtout Dyn-11 ONAN 200 kVA
Off circuit tap changer -5% to +10% in steps of 2.5%
(a) (b) (c) 12 (a) (b) 13 (a) (b) 14 15
4.5%
400C 500C
0.5 3
2% of full load current (max)
S. NO. 16 (a) (i) (ii) (b) (i) (ii) (c) (i) (ii) 17 (a) (b) 18 (a) (b) (c) 19 (a) (i) (ii) (iii) (b) (i) (ii)
DESCRIPTION
Insulation level Separate source power frequency voltage withstand HV Winding 70 kV LV Winding 3kV Induced over voltage withstanding HV Winding LV Winding Full wave lightning impulse withstanding HV Winding LV Winding Regulation at full load at 75C At unity power factor At 0.8 power factor Terminal arrangement High voltage Low voltage LV Neutral Bushings High Voltage Manufacturer Type Minimum Creepage distance Low Voltage Manufacturer Type Porcelain Porcelain 900mm 170 kV -
S. NO.
DESCRIPTION
(iii) (c) (i) (ii) (iii) 20
Minimum Creepage distance LV Neutral Manufacturer Type Minimum creepage distance Total quantity of oil (litres) required for first filling (wherever applicable)
25mm
Porcelain 25mm
21
Is vacuum filling required if so, stated absolute pressure Efficiency at 75C at unit power factor.
22
(a) (b) (c) 23 (a) (b) 24 25 (a) (b)
At full load At 3/4 full load At 1/2 full load Approximate dimensions Tank enclosure LxBxH Overall LxBxH Untanking height Approximate Weight Core and winding Tank fittings
S. NO. (c) (d) 26 (a)
DESCRIPTION
Oil (if applicable) Total Weight Despatch details Approximate mass of heaviest package
(b)
Approximate dimensions of largest package Length Breadth Height
(i) (ii) (iii)
27 Reference Standards IS:2026 Note: If there is any change in the above GTPs, same shall conform to Technical Specifications/relevant ISS. If there is any change in GTPs, so warranted by specific make of equipment, same shall be taken care at the time of approval of drawings.
GTP OF 33 KV VCB 630A
Sr. No. 1
Description
Particulars Required Offered
SWITCHGEAR
1.1 Manufacturers name and country of manufacturer 1.2 Type 1.3 Nominal system voltage 1.4 Highest system voltage 1.5 Frequency 1.6 Normal current ratings a. At rated ambient temp. as per relevant standard b. At site conditions. 1.7 Symmetrical breaking capacity 1.8 Asymmetrical breaking capacity 1.9 a) Symmetrical breaking current. b) Short time current rating for 1 sec. 1.10 Making capacity 1.11 1.2/50 Micro second impulse wave withstand test voltage (KVp) 1.12 One minute power frequency withstand test voltage (KV rms) 1.13 No. of poles 1.14 No. of breaks in circuit per pole 1.15 Length of break per phase 1.16 Opening time (ms) 1.17 Making time (ms) 1.18 Arc duration 1.19 a) Type and material of main contacts b) Material and thickness of plating of contacts 1.20 Type of arcing contacts and / or arc control device
Vacuum 33 Kv 36 kV 50+2.5Hz 630A
26.3KA
26.3KA 26.3KA
170 kV (peak)
70 kV (rms)
3 1
GTP OF 33 KV VCB 630A
Sr. No.
Description
1.21 a) Whether the circuit breaker is trip free ? b) Whether it is with lock out preventing closing ? 1.22 Nominal voltage of closing mechanism 1.23 Power required to close circuit breaker at nominal voltage 1.24 Minimum clearance in air a. Between phases b. Between the live parts and earth 1.25 Minimum clearance in vacuum a. Between phases b. Between the live parts and earth 1.26 Total weight of complete breaker 1.27 Dimensions and mounting details 1.28 Applicable Standard (i.e. standard to which on forms)
tripfree
220V DC
As per IEC:56, IS:13118
1.29 Details of reference drawings attached Note: If there is any change in the above GTPs, same shall conform to Technical Specifications/relevant ISS. If there is any change in GTPs, so warranted by specific make of equipment, same shall be taken care at the time of approval of drawings.
GTP OF 20/25 MVA 132/33 KV POWER T/F S. DESCRIPTION NO. 1 2 3 4 5 6 7 8 9 Manufacturers Name Rating (MVA) Voltage Ratio (KV) Winding Connection Vector Group Number of Phase Frequency (Hz) Type of cooling Rating available at different cooling % 20/25 132/33 Star/Star YY0 3 50+5% ONAN/ONAF 78.125%/100% PARTICULARS Required Offered
10 a
Impedance data Guaranteed positive sequence impedance between HVLV at 75 deg.C with 100% rating at i. Principal Tap 10.00% ii. Maximum Tap Iii. Minimum Tap Zero sequence impedance at principal tap Guaranteed losses at 100% rated voltage (excluding cooler loss) at 75 deg.C between HV and LV
b 11
a b 12 a 13 a
Iron loss (KW) (max) Copper loss (KW) (max) Guaranteed cooler losses at 100% load (max) (KW) Cooling equipment details Number of coolers and rating as per % of transformer cooling equipment Mounting Fan motor data
23 100
2.2
b c
S. DESCRIPTION NO.
Number per cooler and rating as % of cooler requirement (also indicate no.of spare fans) Type Rating (KW) Locked rotor current (Amps) Temp. range over which cooler control is adjustable (deg.c to deg.C) Oil pump motor data Number per cooler and rating as % of cooler requirement (also indicate no.of spare pump) Type Rating (KW) Locked rotor current (Amps) Temp. range over which cooler control is adjustable (deg.c to deg.C) Type of oil pump and motor (whether oil submerged type) Radiator details Overall dimensions lxbxh (mm) Total weight with oil (Kg) Total weight without oil (Kg) Thickness of Radiator tube (mm) Type of mounting Thermal Data Temperature rise in top oil over an ambient of 50 deg.C 50 0C 50 0C to 1200C 50 0C to 1200C
ii iii iv v
d i
ii iii iv v
f i ii iii iv v 14 a
Temp rise in winding by resistance measurement method over an ambient of 50 deg.C Thermal time constant (Hours)
55 0C
S. DESCRIPTION NO.
15
Withstand time for three phases short circuit at terminals (secs) Over excitation withstand time (sec) 1.25 1.4 1.5 Bushings High voltage Manufacturer Type Total creepage distance (mm) Protected creepage distance (mm) Mounting Rated current (Amps) Low voltage Manufacturer Type
2 sec.
16 i ii iii 17 a i) ii) iii) iv) v) vi) b i) ii)
condenser 3625 1813 tank cover 800
Oil communicating
iii) iv) v vi) C
Mounting Total creepage distance (mm) Protected creepage distance (mm) Rated current (Amps) Neutral Bushing
tank cover 900 450 1000 HV LV
S. DESCRIPTION NO.
i) ii)
Manufacturer Type oil communicating
iii) iv)
Mounting Total creepage distance (mm)
tank cover 900 900 450 450 630 HV-N 1000 LV-N
v)
Protected creepage distance (mm)
vi)
Rated current (Amps)
18
Is Vacuum filling required, if so state absolute pressure (mm of Hg) Total quantity of oil (ltrs) Tap changing equipment Voltage class and current Number of steps Range 66kV & 300A 16 (+)5% to ()15% 1.25% High speed transition type
19 20 a) b) c)
d) e)
Step voltage Type
f) g) h)
Rated voltage of drive motor (volts) No.of revolutions to complete one step Time to complete one step on manual / auto operation (sec) Power required (kw) Insulation level HV windings Lightning impulse withstand voltage Power frequency withstand voltage (kv rms) 550 230
i) 21 a) i) ii)
S. DESCRIPTION NO.
b)
LV Winding
S. DESCRIPTION NO. i) ii) c) i) ii) d) i) ii) e) i) Lightning impulse withstand voltage Power frequency withstand voltage (kv rms) HV Bushing Lightning impulse withstand voltage Power frequency withstand voltage (kv rms) LV Bushing Lightning impulse withstand voltage Power frequency withstand voltage (kv rms) Neutral Bushing Lightning impulse withstand voltage 170 170 70 70 170 70 650 275
PARTICULARS Required 170 70 Offered
ii)
Power frequency withstand voltage (kv rms)
22 a) b) c) d) e) 23 a) b c) d) e) f) g) h)
Approximate dimensions Tank (lxbxh) mm Overall dimensions with (mm) coolers lxbxh Shipping dimensions (mm) (lxbxh) Height for untanking (mm) Dimensions of largest (mm) package (lxbxh) Weights of transformer components Core (Kg) Windings (Kg) Insulation (Kg) Tank and fittings (Kg) Oil (Kg) Untanking weight (heaviest piece) (Kg) Total weight Kg Weight of heaviest package KG
S. DESCRIPTION NO.
i) j) 24
Total shipping weight (Kg) Parts detached for transport Permissible overload (% of rating & time in minutes) As per IS:6600 & IEC:354
25 a) i) ii) b)
Clearances Minimum clearance between phases In oil (mm) In air (mm) Minimum clearance of HV winding to tank in oil (mm)
c)
Minimum clearance of HV winding of earth in oil (mm)
d) e) f) 26 a) b) 27 a) b)
Clearance between core (mm) and coil Clearance between coil (mm) Clearance between neutral to ground in air (mm) Conservator Total volume (ltrs) Volume between highest and lowest levels (ltrs) Capacitance values HV to earth (pf) LV to earth (pf)
28a) Type of oil preservation b) c) Material of air cell Continuous temp. withstand capability of the air cell 2 or 1 No. PRD & 1 No. Explosion Vent and 1 No. Pressure Relief
29 a) No.of pressure relief device provided
S. DESCRIPTION NO.
b) 30 a) i) ii) iii) iv) v) b) c) 31 a) b) c)
Operation pressure of pressure relief device Oil Quality of oil Moisture content (ppm) Max tan delta value (at 90 deg.C) Resistivity (ohm cm) Breakdown strength (kv) Interfacial tension at 27 deg.C (min) Quantity including 10% extra (Ltrs) Standards applicable Core Type of construction Net core area (mm.sq) Core material and grade used CRGO-SI Steel, M4 HiB Grade or Superior Core Type
d) e) f) g) i) ii)
Type of joint between core and yoke Thickness of stamping (mm) Percentage silicon content (%) Maximum flux density in core at rated frequency at 90% voltage (wb/sq.m) 100% voltage (wb/sq.m) 1.6 Tesla Max. 0.27mm (max)
S. DESCRIPTION NO. iii) 32 a) 110% voltage (wb/sq.m) Winding Type of winding
Built of section/disc coil. Spiral winding not accepted
b) i) ii) iii) c)
Current density at rated load HV (A/Sq.cm) LV (A/Sq.cm) Regulating winding (A/Sq.cm) Conductor area i) HV (sq.mm) ii) LV (sq.mm) Iii) Regulating winding 250 Max. 250 Max. 250 Max.
d) i)
Maximum current density under short circuit i) HV (sq.mm) ii) LV (sq.mm)
e) f) i) ii) iii) g)
Magnetising inrush current (Amps) No load current (Amps) at rated frequency and at 90% voltage (wb/sq.m) 100% voltage (wb/sq.m) 110% voltage (wb/sq.m) Magnetising current at rated frequency and at rated voltage Tank Type Bell/Convention al Low carbon steel
33 a)
b)
Material
S. DESCRIPTION NO. c) Approx Thickness of
S. DESCRIPTION NO.
i) ii) iii) 34 a) b) c) 35 a) b) 36 a) b) 37 a) i) ii)
Sides (mm) Bottom (mm) Cover (mm) Radiator Make Material Thickness Vacuum withstand capability of Main tank (torr) Radiators accessories (torr) Pressure withstanding capability of Main Tank Radiator and accessories Temperature indicators OTI Manufacturer Range
0 0 50 C to 120 C
iii) b) i) ii)
Accuracy WTI Manufacturer Range 50 C to 120 C

0 0
iii) c) i)
Accuracy RWTI Manufacturer
S. DESCRIPTION NO. ii) Range
PARTICULARS Offered Required 0 0 50 C to 120 C
iii) iv) 38 a) b) c)
Accuracy Auxiliary supply used Terminal connectors Make Whether type tested Governing standard 220 V DC
DISC INSULATOR/LONG ROD INSULATOR

S. NO. 1 2 3 4 DESCRIPTION Name of Manufacturer Address of Manufacturer Weight of single disc(kg) Size and Designation of pin ball shank(mm) PARTICULARS
Required
Offered
5 6 7
Diameter of disc (mm) Tolerence on Diameter (mm) Ball to ball spacing between disc (mm) Tolerance on spacing (mm) Minimum nominal creepage distance of single disc (mm) Tolerance on creepage distance (mm) Electromechanical Strength of disc (kN) Material of Shell (Porcelain/Toughened glass) Power frequency flashover voltage of single disc Dry (kV rms) Wet (kV rms) Power frequency withstand voltage of single disc Dry (kV rms) Wet (kV rms) Power frequency puncture voltage of single disc (kV rms) 28 28 28 28 28 45-90-120 Porcelain (Anti Fog type) 25mm/KV
8 9
10 11 12
13
(a) (b) 14
(a) (b) 15
DISC INSULATOR/LONG ROD INSULATOR

S. NO. 16 (a) (b) 17 (a) (b) 18 DESCRIPTION Impulse flashover voltage of single disc (dry) Positive (kV peak) Negative kV peak Impulse withstand voltage of single disc (dry) Positive (kV peak) Negative (kV peak) Steepness of impulse voltage which the disc insulators can withstand in steep wave front test (kV/micro sec) 19 Visible discharge test of single disc (dry) (kV rms) Maximum RIV at 1 MHz and 10 kV AC (rms) voltage of single disc (micro V) Purity of zinc used for galvanising (%) No. of dips in standard preece test Socket Ball Pin Axial and Radial run out (According to IEC) As per pointer A (mm) As per pointer B (mm) Drawings enclosed 6 6 9 75 75 75 75 PARTICULARS
Required
Offered
20
50
21 22 (a) (b) 23 (a) (b) 24
99.95
GTP OF BUSHING/ SUPPORT INSULATORS

S. NO. 1 2 3 4 I) ii) iii) 5 6 7 DESCRIPTION PARTICULARS Required Offered 33 KV 145 KV 145 KV 33 KV
Manufacturer's name Type Applicable Standard Solid core IS 5350, IS:2544, IEC 168
Height Diameter (top) Diameter (bottom) Creepage Distance Rated voltage(KV) Power Frequency withstand Voltage for 1 min (KVrms) dry and wet 1.2/50 microsec.impulse withstand Voltage 25 mm/KV 145 275 25 mm/KV 36 70
Radio interference Voltage at 1.1 times the rated phase to earth voltage
10 11 12 13
Weight (Kg) Max. allowable span(mm) Cantilever strength(Kg.) OGA Drg enclosed 400 400
GTP OF ACSR CONDUCTOR

S. NO. DESCRIPTION Required ACSR ZEBRA CONDUCTOR 1 2 2.1 (a) (b) 2.2 (a) (b) (c ) (d) (e) 2.3 (a) 3 3.1 (a) (b) (c ) 3.2 3.3 Name and address of manufacturer PARTICULARS OF RAW MATERIALS Aluminium Minimum purity of aluminium Maximum copper content Steel Wires/Rods Carbon Manganese Phosphorous Sulphur Silicon Zinc Minimum purity of zinc ALUMINIUM STRANDS AFTER Diameter Nominal Maximum Minimum Minimum Breaking load of strand Maximum Resistance of 1 m length of strand at 20 deg.C mm mm mm kN ohm % 99.95 % % % % % 0.50 to 0.85 0.50 to 1.10 Not more than 0.03 Not more than 0.04 0.10 to 0.35 % % 99.5 0.04 PARTICULARS Offered

S. NO. 4 4.1 (a) (b) (c ) 4.2 4.3 (a) DESCRIPTION Required STEEL STRANDS AFTER STRANDING Diameter Nominal Maximum Minimum Minimum Breaking load of strand Galvanising Minimum weight of zinc coating per Sq. mtr of uncoated wire surface Minimum number of one minute dips that the galvanised strand can withstand in the standard preece test Min. Number of twists in a guage length equal to 100 times dia of wire which the strand can ithstand in the torsion test ASCR CONDUCTOR UTS of conductor Lay ratio of conductor Outer steel layer 12 wire aluminium layer 18 wire aluminium layer 24 wire aluminium layer DC resistance of conductor at 20 deg. C Minimum corona Extinction Voltage (line to ground) under Dry Condition ohm/km kV(rms) 154 (for 220kV) kN Min. 13 10 10 10 gm mm mm mm kN PARTICULARS Offered
(b)
Nos.
(c )
Nos.
5 5.1 5.2 (a) (b) (c) (d) 5.3 5.4

S. NO. DESCRIPTION Required 5.5 RIV at 1 MHz at 154 kV (rms) under dry conditions Standard length of conductor Maximum length of conductor Tolerance on standard length of conductor Direction of lay for outside layer Linear mass of the Conductor Standard Minimum Maximum Drum is as per specification No. of cold pressure butt welding equipments available at works Nos. kg/km kg/km kg/km 1621 1621-5% 1621+5% Yes microvolts PARTICULARS Offered
Less than 1000
5.6 5.7 5.8
m m %
5.9 5.10 (a) (b) (c ) 6.0 7.0
right
GTP OF EARTH WIRE

S. NO. DESCRIPTION 7/3.66 mm EARTHWIRE 1 2 2.1 (a) (b) (c ) (d) (e) 2.2 (a) 3 3.1 (a) (b) (c ) 3.2 3.3 (a) Name and Address of Manufacturer PARTICULARS OF RAW MATERIALS Steel Wires/Rods Carbon Manganese Phosphorous Sulphur Silicon Zinc Minimum purity of zinc STEEL STRANDS AFTER STRANDING Diameter Nominal Maximum Minimum Minimum Breaking load of strand Galvanising Minimum weight of zinc coating per Sq. mtr of uncoated wire surface Minimum number of one minute dips that the galvanised strand can withstand in the standard preece test gm mm mm mm kN % 0.9995 % % % % % Max. 0.55% 0.40% to 0.90% Max.0.04% Max.0.04% 0.15% to 0.35% PARTICULARS Required Offered
(b)
Nos.
1minute=3 dips 1/2minute=1 dip
GTP OF EARTH WIRE

S. DESCRIPTION NO. (c ) Min. Number of twists in a guage length equal to 100 times dia of wire which the strand can withstand in the torsion test 4 4.1 4.2 STRANDED EARTHWIRE UTS of earthwire Lay length of outer steel layer kN mm 68.4 Std. 181mm Max. 198mm Min. 165mm 2.5 Ohms/Km(Max.) Nos. PARTICULARS Required Offered 18
4.3 4.4 4.5 4.6 4.7 (a) (b) (c ) 5
DC resistance of earyhwire at 20 deg.C Standard length of earthwire Tolerance on Standard length Direction of lay of outer layer Linear mass of earthwire Nominal Maximum Minimum Drum is as per specification
ohm/km m m
right hand
kg/km kg/km kg/km
583 595 578 Yes
GTP OF INSULATOR STRINGS

S. NO. 1 b) 2 a) b) 3 4 a) b) 5 6 7 a) b) 8 a) b) 9 a) b) 10 DESCRIPTION Manufacturer Hardware Type of String Single/Double Suspension/Tension Applicable Standards Type of Insulators Ball & Socket/ other Normal / antifog Insulating Material No. of Units per String Size of each unit Diameter of disc (mm) Spacing between Units (mm) Weight Each Disc (Kg) Complete string (Kg) Creepage Distance Each Disc (mm) Complete String (mm) Power Frequency Withstand Voltage 25mm/KV Ball & Socket Fog Type Porcelain Single/Double Suspension/Tension IS:2486 PARTICULARS Required Offered
a) i)
Each Disc Dry (KV) 28KV rms
GTP OF INSULATOR STRINGS

S. NO. DESCRIPTION PARTICULARS Required Offered 28KV rms
ii) b) i) ii) 11 a)
Wet (KV) Complete string Dry (KV) Wet (KV) Impulse Withstand Voltage Each disc I) ii) Positive (kVp) Negative (kVp)
75 75
b)
Complete Strings I) ii) Positive (kVp) Negative (kVp)
12
Power Frequency Puncture Withstand Voltage of each Disc (KV rms) Electro Mechanical Strength of each Disc (Kg)
13
GTP OF INSULATOR HARDWARE

S. NO. 1 2 3 a) b) c) d) e) 4 a) b) c) d) e) f) g) h) i) j) DESCRIPTION Manufacturer Applicable Standards Materials Ferrous Parts Nuts & C14Bolts Cotter Pins Split Pins Strain and suspension clamps Ultimate Strengths Complete assembly (kg) Suspension clamps (kg) Strain clamp (kg) D-Shackle (kg) Ball eye (Kg) Ball clevis (kg) Clevis eye (Kg) Socket eye (kg) Socket clevis (Kg) Yoke Plate (Kg) Forged steel MS Hot Dip Galvanised Stainless steel/Brass Stainless steel/Brass Aluminium Alloy-LM-6 IS-2486 & IS-2633 PARTICULARS Required Offered
GTP OF CLAMPS AND CONNECTORS

S. DESCRIPTION NO. 1 Manufacturers Name and address 2 3 4 5 a) b) 6 Applicable standards Application Type For connection to Conductor size and arrangement Equipment terminal and arrangement Material (state percentage composition of constituents and impurities present) Clamp body Al. alloy CR(A6) 4600, IS-617, 1975 PARTICULARS Required Offered
IS-5561-1970 Outdoor Bolted type
a)
b) c) d) 7 8
Bolts and Nuts Spring washers Liners, if any Rated Current (A) Maximum temperature rise over reference ambient temperature specified in project information rated current (C) Rated terminal load (kg) Minimum thickness of any part(mm) Weight of Clamp complete with hardware (Kg)
M.S. Hot dip Galv. IS-1367, 1979 Spring steel - Electro Galv. Cu./Al./2mm thick
9 10 11
110 10mm
S. DESCRIPTION NO. 1 1.1 1.2 1.3 1.4 1.5 1.6 a) b) 1.7 1.8 1.9 a) b) 1.1 1.1 Switchgear: Manufacturer's name and Country of Manufacturer Type Nominal system voltage Highest system voltage Frequency Normal current ratings: At rated ambient temperature as per relevant standard At site conditions Symmetrical breaking capacity Asymmetrical breaking capacity Symmetrical breaking current
Vacuum 11 kV 12 kV 50 +1.5Hz I/C 1250A O/G 400A 350MVA/18.4KA
18.4KA 18.4KA (min) 75 28 3 1
Short time current rating for 1 sec. Making capacity 1.2/50 micro second impulse wave withstand test voltage (KVp) 1.1 One minute power frequency withstand test voltage (kV rms) 1.1 No. of poles 1.1 No. of breaks in circuit per pole 1.2 Length of break per phase 1.2 Opening time (ms) 1.2 Making time (ms) 1.2 Arc duration 1.19 Type and material of main Contacts a) b) Material and thickness of plating of contacts 1.2 1.2 Type of arcing contacts and/or Control device Whether the circuit breaker is trip free Whether it is with lock out preventing closing? Nominal voltage of closing mechanism Power required to close Circuit Breaker at nominal voltage Minimum clearance in air : Between phases Between the live parts and earth Minimum clearance in vacuum Between phases Between live parts and earth Total weight of complete breaker Dimensions and mounting details
trip free
1.2 1.2 1.2 a) b) 1.3 a) b) 1.3 1.3
220V DC
1.3
Applicable Standard
width should not be more than 710mm IEC:56, IS:13118
S. DESCRIPTION NO. 1.3 2 2.1 a b c d e Details of referance drawing attached INSTRUMENT TRANSFORMERS : CURRENT TRANSFORMER Rated primary current Rated secondary current Rated transformation ratio VA output at rated current and accuracy Class of accuracy
15VA 1/5P10/PS
S. DESCRIPTION NO. f Rated over-current factor with time in seconds with time in seconds Type of CTs (whether wound or bar type) One minute power frequency withstand test voltage 1.2/50 micro second impulse withstand voltage Applicable Standard VOLTAGE TRANSFORMER Rated primary voltage (V) Rated secondary voltage (V) Rated burden Class of accuracy Rated voltage factor and time One minute power frequency withstand test voltage 1.2/50 micro second impulse withstand test voltage Applicable standard RELAYS Type and make Setting range Other details Applicable Standaard BUS BAR Material Normal current rating Nominal area per phase Shape Type of insulation VACUUM INTERRUPTOR BOTTLE Name of manufacturer Whether imported or indigenous Manufacturer's type, normal Amps & rupturing capacity for vacuum bottles used on incoming panel Manufacturer's type, normal Amps & rupturing capacity for vacuum bottles used on outgoing panel Manufacturer's type, normal Amps & rupturing capacity for vacuum bottles used on Capacitor Control panel Degree of vacuum inside the vacuum interruptors Short time rating of vacuum bottles Number of full short circuit operation, as per test duty 1 to 5 of IEC-56 Which the Vacuum bottles offered can safely withstand
g h i j 2.2 a b c d e f g h 2.3 a b c d 2.4 a b c d e 2.5 a b c
wound/ring type 28kV (rms) 75 kVp IS:2705 11000/root 3 110/root 3 100VA 1 28 kV (rms) 75 kV (peak) IS:3156 numerical
IS:3231 Electrolytic Copper 1250A 1200mm2(min) heat shrunk PVC sleeves
2000A, 12 kV, 25 KA 2000A, 12 kV, 25 KA 2000A, 12 kV, 25 KA
f g h
25KA Min 100
S. DESCRIPTION NO. i Whether the vacuum bottles used on incoming and outgoing panels are same of different Whether the operating mechanism is imported indegenous
PARTICULARS Required same Offered
Sr. NO.
DESCRIPTION
GTP OF 132/33 KV ISOLATORS Particulars Required 33 KV Offered 132 KV 33 KV
132 KV 1 a) b) c) d) e) f) g) GENERAL Name of the Manufacturer
Manufacturer's type designation Double Break - DB Standard applicable for isolators and earthing switches Max. design voltage as which the insulator can operate Rated voltage Rated current Max. current that can be safely interupter by the isolator Inductive Capacitive (under site conditions at 50 deg.C ambient Rated frequency Pole to pole spacing GUARANTEED RATINGS: Rated short time current of isolator for 1 sec. (KA) and dynamic current 31.5 KA 78.75 KA (peak) 50 Hz 3000 mm
Double Break - DB
IS: 9921 (Part I to V) IS: 9921 (Part I to V) 132 KV 145 KV 1600 Amps 33 KV 36 KV 630/2000 Amps
i) ii)
h) I) 2 a)
50 Hz 1220 mm
26.3 KA 65.75 KA (peak)
Sr. NO.
DESCRIPTION
Particulars Required 33 KV Offered 132 KV 33 KV
132 KV b) Temperature rise over 50 deg. C ambient temperature corresponding to a maximum continuous current Dielectric withstand capacity of completely assembled isolator and earth switch One minute dry power frequency withstand test voltage (KV rms) Against ground (KV rms) Across isolating distance (KV rms) 1.2/50 micro second impulse withstand test voltage Against ground (KV peak) Across isolating distance Total creepage distance to ground Operating Mechanism for Main Blades & Earth switch Type of operating drive mechanism Manufacturer's type Interlocks Whether mechanical/ constructional interlock between isolator and earth switch provided Yes 650 KV (peak) 750 KV (peak) 3625 mm
a)
i) ii)
275 KV rms 315 KV rms
70 KV rms 100 KV rms
b)
i) ii) c)
170KV (peak) 195 KV (peak) 900 mm
a)
b) 5 a)
Yes
Sr. NO.
DESCRIPTION
132 KV b) Details of electrical interlock enclosed for I) Isolator ii) Earth Switch Arrangement provided to prevent operation unless interlock conditions are satisfied Constructional features Minimum clearance in air Between phases Between live parts to earth Between line parts when switch is open -on the same pole -between adjacent poles b) Yes
c)
Yes
6 a) i) ii) iii)
Whether position of earth switch Yes., Earth switches Yes., Earth switches are interchangeable are interchangeable can be interchanged at site to either side of pole
c)
Minimum clearance between live part and earth switch blade throughout the entire operational arc of earth switch Terminal pad details Diameter & length Material of pad Insulator data HDE copper flat HDE copper flat
d) i) ii) e)
Sr. NO.
DESCRIPTION
132 KV i) ii) iii) iv) v) vi) vii) viii) f) i) ii) iii) iv) v) Height Type No. of insulators/stack Mechanical & Electrical parameters of insulator Top and bottom fitting PCD Weight of insulators Minimum creepage distance B.I.L Main contacts Type of contacts Contact area Material of contacts Contact pressure Maximum current density under normal current carrying capacity Thickness of silver plating Number of auxiliary contacts on isolator switch/pole for Employer's use h) Number of auxiliary contacts on earth switch/pole for Employer's use Auxiliary contacts 3 NO + 3 NC HDE Copper
Solidcore One
Solidcore One
25 mm/KV 650 KV (peak)
25 mm/KV 170 KV (peak)
HDE Copper Medium pressure
Medium pressure
vi) g)
10 NO + 10 NC + 2 MBB
10 NO + 10 NC + 2 MBB
3 NO + 3 NC
I)
Sr. NO.
DESCRIPTION
Particulars Required 33 KV Three Two Horizontal Motor Offered 132 KV 33 KV
132 KV j) k) l) m) i) No. of insulator per pole No. of break per pole Type of closing/opening Mechanism Bearing material and size of housing No. of bearings, location and size Tandem pipe: Size class and No. of pipes Auxiliary contacts Rated voltage Rated continuous current 220 V DC 10 Amps Three Two Horizontal Motor
ii)
n) i) ii) i) ii) iii)
220 V DC 10 Amps 2 Amps
Rated DC breaking current with 2 Amps 20 ms time constant
S. NO. 1 a) b) c) d) e) f) i. ii. g) h) I) j) 2 a) i. ii. iii. b) i. ii. c1)
GTP OF 145 KV SF6 CIRCUIT BREAKER DESCRIPTION Particulars Required General Name of the Manufacturer Type of Circuit Breaker Manufacturers type designation Standard Applicable Rated Voltage (KV rms) Rated Current Under normal condition (A) Under site Conditions (A) Rated frequency (Hz) Number of poles Whether 3 pole or single pole unit Whether All The 3 poles ganged electrically or mechanically. Guaranteed Technical Particulars Rated short circuit breaking current Symmetrical component at highest system voltage (kA) DC Component (%) Asymmetrical breaking current at highest system voltage (kA) Rated Making Capacity At higher rated voltage (kAp) At lower rated voltage (kAp) Maximum Total break time under any duty condition for any current upto rated breaking current with limiting conditions of voltage and pressure (ms) Offered
3 pole outdoor SF-6 IEC:56, IS:13118 145 1600 1600 50 3 3 pole gange operated
31.5 As per IEC:56
78.75 78.75 less than 3 cycles or 60msec.
c2) d) e) f) g) h) i) j) k) l) m) n)
Rated break time as per IEC Closing time (ms) max.150msec. Minimum opening time under any condition with limiting voltage and pressure (ms) Maximum opening time under any condition with limiting voltage and pressure (ms) Maximum close open time under any condition with limiting voltage and pressure ( ) pole to clear factor First as per IEC/IS Short time current rating (kA) for 1sec 31.5 Rated operating duty O-0.3 sec-CO-3 min-CO Maximum over voltage (p.u) on switching capacitor banks of rating upto 20 MVAR Maximum pole discrepancy (ms) Maximum arc duration and corresponding current under lockout pressure Maximum temperature rise for main contacts over design ambient temperature
S. NO. o) p) q) r) 3 a) i. ii. b) i. ii. c) d) i. ii. 4 a) i ii b) c) i. ii. 4.1 a) b) i. ii. c) i. ii. iii. d) e) f)
DESCRIPTION
Particulars Required 220V DC & 85%-110% 220V DC & 85%-110% Offered
Rated voltage & pick up range for trip coil (V) Rated voltage & pick up range for closing coil (V) Rated pressure and limits of pressure of operating mechanism Rated pressure and limits of pressure of extinguishing medium Dielectric Withstand of Complete Breaker
One minute dry & wet power frequency withstand voltage Between live terminal and ground (KV rms) 275 Between terminals with breaker contacts open (KV rms) 1.2/50 micro second impulse withstand test voltage Between live terminals and ground (KVp) Between terminals with breaker contacts open (KVp) Maximum radio interference voltage (micro V) at 1.1 Ur/ root 3 Total creepage distance To ground (mm) Between terminals (mm) Operating Mechanism Type of operating mechanism for Closing Opening Manufacturers type designation Normal power consumption (W) at rated voltage of 220-V DC Trip coil Closing coil Pneumatic operating mechanism Rated operating pressure (kg/sq.cm) Range of pressure for (kg/sq.cm) Closing Opening Air Consumption at rated pressure for Closing (m3) Opening (m3) Close-Open (m3) Number and Capacity (m3) of breaker local air storage receivers No. of close operations for which sufficient air is available in local receiver Capacity of compressor (m3/hr) and working pressure (kg/cm2) 275
650 650
3625mm (min) 3625mm (min)
Spring
Not applicable
S. NO. g) h) i) ii) i) i) ii) j) i) ii) k) l) m) n) i) ii) 4.2 a) b) c)
DESCRIPTION
Maximum time for which compressor can operate continuously (min) Time to fill Air receiver after one CO operation (min) For making up of losses occurring in 4 hours (min) Pressure at which compressor Starts (kg/cm2) Stops (kg/cm2) Safety valve Low pressure stage blow off at (kg/cm2) High pressure stage blow off at (kg/cm2) Safety valve opens at (kg/cm2) No. of stored Co operation in breaker air receiver Alarm switch closes on air receiver at (kg/cm2) Lockout pressure (kg/cm2) Closing Opening Spring charged mechanism Number of close open operations possible after failure of AC supply to motor Time required for motor to charge the closing spring (min) Whether indication of spring charged condition provided in central control cabinet Type of Breaker SF6 Circuit Breakers Quantity of SF6 per pole (CuM) at rated pressure Guaranteed maximum leakage rate per 1% year Rated pressure of SF6 in operating chamber (kg/cm2) Limits of pressure at which breaker operates correctly (kg/cm2) Standard to which SF6 gas complies As per IEC:376 Capacity & filling ratio of containers in which SF6 gas would be shipped (CuM) and the corresponding pressure (kg/Sq cm)
5 5.1 a) b) c) d) e) f)
S. NO. g) h) i) ii) iii) 5.2 a) b) c) d) e) f) i. ii. iii. 6 a) b) c) d) e) f) i. ii. g) h) I) j) i. ii.
DESCRIPTION
Particulars Offered
Required Whether breakers are dispatched filled with SF-6 or required to be filled at site. Density/Pressure gauge setting Lockout Alarm Minimum time interval between make/break operation General Weight of complete 3 phase breaker for foundation design (kg) Weight of heaviest part of Breaker (Kg) part of breaker (kg) Impact loading for foundation design Seismic level for which breaker is designed 0.3g (horizontal) Minimum safety clearance from earther objects Minimum clearance in air between live parts (mm) live parts to earth (mm) Live parts to ground level (mm) Constructional Details Whether arcing contacts provided Type and material of main contacts and arcing contacts Contact pressure on main contacts (kg/Sq cm) Contact separation in arcing position (mm) Contact separation in open position (mm) Rate of contact travel Opening (m/sec) Closing (m/sec) Whether the making & breaking contacts are hermetically sealed Number of auxiliary contacts per pole provided for Owner's use Rated voltage of auxiliary contacts (V) Current rating of auxiliary contacts Continuous (A) DC breaking with 20 ms time constant (A)
1700 1300 4000 Yes
Yes 10 NO+10NC 220V DC 10 2
S. NO. a)
DESCRIPTION
GTP OF DC DISTRIBUTION BOARD PARTICULARS Required Offered
Size of cable required for connection of the battery charger to the DC Distribution Board. Size of sheet steel(SWG)of the DC distribution Board Cabinet Make and type of instruments may be indicated as per details below Make of DCDB Make Type Rotary Moving Coil for DC Range / Capacity 200A 0-200 A 0-400 V
b)
c)
Sr. Description of Instruments No. 1 Incoming Rotary Switch 2 Voltmeter
3 4
Ammeter Ammeter/Voltmeter for detecting earth leakage Change over contactor Outgoing feeder switches of rating H.R.C. fuses with fittings
As Above Moving Coil 20-0-20 mA
5 6
Electro-mechanical Rotary
20 A 100 A, 50 A,10 A
Aluminium b) Size of Main Bus Bar c) Size of Negative Bus Bar 25 X 6 mm 25 X 6 mm

132 KV SS

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132 KV SS

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HARYANA VIDYUT PRASARAN NIGAM LIMITED (INDIA) ICB No.

VOLUME II (PART- II)

132 kV S/Stn. Badli

Double Bus arrangement

132 kV S/Stn. Gharnawati

Double Bus arrangement

132 kV S/Stn. Bhattu Khurd (Sotter)

Name of S/Stn. 132kV S/Stn. Beri

Scheme Double Bus arrangement bar

132kV S/Stn. Aherwan

Double Bus arrangement

vi) vii) viii) ix) x) xi) xii)

100 26 900 195 1000 45 0.3 g

NAME OF SUB STATION

ANNEXURE-A-I BILL OF QUANTITIES

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. a)

14. 15. 16. 17. 18. 19.

No. No. No. No. No. Set

22. 23. 24. 25. 26. 27. 28. 29.

30. 31. 32(a) 32(b) 33. 34. 35.

37. 38. 39. 40. 41.a)

132kV S/Stn. Bhattu Khurd (Sotter) 2

132kV S/Stn. Bhattu Khurd (Sotter) Lot

No. No. No. No. No. No. Lot

Earthmat area 18383m2 (approx).

Earthmat area 7690m2 (approx).

Earthmat area 9149m2 (approx.)

Earthmat area 15000m2 (approx.)

132 kV S/Stn. Machhrauli

132 kV S/Stn. Badli

132 kV S/Stn. Gharnawati

132kV Total S/Stn. Bhattu Khurd (Sotter) 6

132 kV 132 kV 132 kV S/Stn. S/Stn. Gharnawati S/Stn. Machhrauli Badli

10. 11. 12. 13. 14.

No. No. Set.

132kV Total S/Stn. BhattuKhurd (Sotter) 2 6 6 2 18 6 1 1

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

132 kV S/Stn. Beri 6

132kV S/Stn. Aherwan 6

Lot Lot L/S

Lot Lot L/S

Lot Lot L/S

Lot Lot L/S

Mtr. Lot Lot

275 Lot Lot

250 Lot Lot

525 Lot Lot

Cum Cum Cum Cum Cum Cum

15,000 20,000 14,000 30,000 -

Cum Cum Cum Cum Cum Cum

UNIT TOTAL PRICE PRICE 5 6

No. No. No. No. No. No.

No. No. No. No. No. No.

No. No. No. No. No. No.

No. No. No. No. No. No.

UNIT TOTAL PRICE PRICE 5 6

UNIT TOTAL PRICE PRICE 5 6

No. No. No. No. No.

Set Set Set

UNIT TOTAL PRICE PRICE 5 6

Set Set Set Set Set Set

UNIT TOTAL PRICE PRICE 5 6

Lot Lot Lot Lot Lot Lot