Technical Specification Lohardaga

NTPC ELECTRIC SUPPLY COMPANY LTD.
(A Wholly Owned Subsidiary of NTPC LTD.)
RURAL ELECTRIFICATION WORKS UNDER RGGVY SCHEME FOR

JHARKHAND STATE ELECRTRICITY BOARD
IN
LOHARDAGA DISTRICT OF JHARKHAND
TECHNICAL SPECIFICATION
VOLUME-II
BID DOCUMENT NO. : NESCL/REC/CS-LH-808
INDEX
VOLUME- II
SECTION CHAPTER-I E1 E2 E3 CHAPTER-II PARTA: 33/11 KV SUBSTATION E0- REV.-03 E1- REV.-03 E2- REV.-03 E3- REV.-03 E4- REV.-03 E5- REV.-03 E6-REV.-03 E7-REV.-03 E8-REV.-03 E9-REV.-03 E10-REV.-03 E11-REV.-03 E12-REV.-03 E13-REV.-03 E14-REV.-03 E15-REV.-03 E16-REV.-03 E17-REV.-03 E18-REV.-03 GENERAL CONSTRUCTIONAL PRACTICES 33/11KV ISOLATORS INSTRUMENT TRANSFORMER SURGE ARRESTERS CONTROL AND PROTECTION PANELS 11KV VACUUM CIRCUIT BREAKER CONTROL AND POWER CABLES AUXILIARY ITEMS SITE TESTING AND COMMISSIONING POWER TRANSFORMER BATTERY & BATTERY CHARGER POST INSULATORS CT/PT OPERATED STATIC ENERGY METER CIVIL & STRUCTURAL WORKS GEO -TECHNICAL INVESTIGATION 11KV XLPE CABLES ACDB & DCDB 33KV VACUUM CIRCUIT BREAKER STATION TRANSFORMERS PROJECT SYNOPSIS SCOPE OF WORKS GENERAL TECHNICAL CONDITIONS DESCRIPTION
RGGVY WORKS STANDARD TECHNICAL SPECIFICATION (REV.- 03)
INDEX
Page 1 of 1
PARTB: 33KV, 11KV AND LT SYSTEM SECTION E0-REV.-03 E1-REV.-03 E2-REV.-03 E3-REV.-03 E4-REV.-03 E5-REV.-03 E6-REV.-03 E7-REV.-03 E8-REV.-03 DESCRIPTION GENERAL CONSTRUCTIONAL PRACTICES PCC POLE AAAC, AAC & ACSR CONDUCTORS HT & LT INSULATOR FITTINGS 11KV XLPE CABLE LT AERIAL BUNCHED CABLES 11KV AIR BREAK SWITCHES PIERCING CONNECTOR MISCELLANEOUS ITEMS A) B) C) D) E) F) G) H) I) J) K) BOLTS & NUTS HOT DIP GALVANISED STEEL SOLID WIRE HOT DIP GALVANISED MS STRANDED WIRE CLAMPS & CONNECTOR EARHING CONDUCTOR CABLE GLANDS & LUGS GALVANISED MS CHANNEL ANGLE & FLAT COMPOSITE SPACER FOR LT LINE GS STAY SETS DANGER PLATE EARTHING COIL
INDEX
Page 2 of 2
SECTION DESCRIPTION L) HELICALLY FORMED FITTINGS FOR 11 KV AND LT LINES CROSS-ARMS FOR 33KV AND 11KV OVERHEAD POWER LINES HOT DIP GALVANISED STEEL BARBED WIRE
M)
N) E9-REV.-03 E10-REV.-03
33KV & 11KV COMPOSITE INSULATOR 11KV AERIAL BUNCHED CABLES
PARTC: DISTRIBUTION TRANSFORMER CENTER E0-REV.-03 E1-REV.-03 GENERAL CONSTRUCTIONAL PRACTICES SINGLE AND THREE PHASE DISTRIBUTION TRANSFORMER CT OPERATED STATIC ENERGY METER FOR 3 PHASE DT CT OPERATED STATIC ENERGY METER FOR 1 PHASE DT MCCB LTDB COMMON METER READING INSTRUMENT (CMRI) 11KV HORN GAP FUSE 11KV DROP OUT FUSE LT CABLES
E2-REV.-03 E3-REV.-03 E4-REV.-03 E5-REV.-03 E6-REV.-03 E7-REV.-03 E8-REV.-03 E9-REV.-03
PARTD: BPL HOUSE WIRING E0-REV.-03 E1-REV.-03 E2-REV.-03 GENERAL CONSTRUCTIONAL PRACTICES SINGLE PHASE ENERGY METER LT CABLES
INDEX
Page 3 of 3
CHAPTER-III PART-A STANDARD DRAWINGS THE FOLLOWING STANDARD DRAWINGS ARE FINALISED FOR THE PROJECT AND THESE DRAWINGS ARE BE FOLLOWED FOR ERECTION OF THE LINES .NO SEPARATE APPROVAL IS ENVISAGED FOR STANDARD DRAWINGS. S.NO. DESCRIPTION GENERAL DRAWINGS NEW S/S SLD 1 2 3 4 5 6 7 8 9 8M/200 KG PCC POLE DETAILS 9M/300 KG PCC POLE DETAILS DISPLAY BOARD AT DT STATION(300MMX300MM) DANGER BOARD 415 V RCC BASE PAD FOR POLE DETAILS GA & COMPONENT DETAILS OF PIPE EARTHING GA & COMPONENT DETAILS OF 11KV GUY AND LT GUY FOUNDATION DETAILS OF 8M/9M PSC POLE FILLING WITH EXCAVATED SOIL, BRICK BATTING AND COMPACTION CONCRETE FOUNDATION DETAILS FOR PSC POLES STRUT POLE ARRANGEMENT GA & COMPONENT DETAILS OF SPIKE EARTHING 11KV LINE ARRANGEMENT DRAWINGS GA & COMPONENT DETAILS OF11 KV LINE FORMATION ON SINGLE PCC POLE (IN LINE ARRANGEMENT) GA & COMPONENT DETAILS OF 11KV LINE FORMATION WITH DOUBLE PCC POLE (IN LINE ARRANGEMENT) GA & COMPONENT DETAILS OF 11 KV LINE FORMATION WITH GUYS FOR ANGULAR LOCATION(0-10 ON SINGLE POLE) DRAWING NO. NESCL:ENGG:RGGVY:LH: 33/11 KVS:001 NESCL-RE-GEN-001A NESCL-RE-GEN-001B NESCL-RE-GEN-002 NESCL-RE-LT-016 NESCL-RE-GEN-004 NESCL-RE-GEN-006 NESCL-RE-GEN-007
NESCL-RE-GEN-008 NESCL-RE-GEN-009 NESCL-RE-GEN-010 NESCL-RE-GEN-012
10 11 12
13
NESCL-RE-11KV-001
14
NESCL-RE-11KV-002
15
NESCL-RE-11KV-003
INDEX Page 4 of 4
S.NO. 16 DESCRIPTION GA & COMPONENT DETAILS OF 11 KV LINE FORMATION WITH GUYS FOR ANGULAR LOCATION(10-60 ON DOUBLE POLE) GA & COMPONENT DETAILS OF 11 KV LINE FORMATION WITH GUYS FOR ANGULAR LOCATION (60 DEG TO 90DEG) GA & COMPONENT DETAILS OF 11 KV LINE TAPPING FROM EXISTING LINE ON SINGLE POLE GA & COMPONENT DETAILS OF11 KV LINE TAPPING ARRANGEMENT WITH DOUBLE POLE GA & COMPONENT DETAILS OF 11 KV LINE FORMATION WITH DOUBLE PCC POLE (AT DEAD END LOCATION) GA & COMPONENT DETAILS OF 11 KV POLE EXTENSION FOR SINGLE PCC POLE GA & COMPONENT DETAILS OF11 KV LINE PROTECTIVE GUARDING ACROSS THE ROADS/CANALS/LINE CROSSING DANGER BOARD 11KV DRAWING NO. NESCL-RE-11KV-004
17
NESCL-RE-11KV-005
18
NESCL-RE-11KV-008
19
NESCL-RE-11KV-008A
20
NESCL-RE-11KV-006
21
NESCL-RE-11KV-010
22
NESCL-RE-11KV-011
23 24
NESCL-RE-11KV-022
GA & COMPONENT DETAILS OF 11KV NESCL-RE-DT-004 /0.433KV 3PH-16/25KVA DTR ARRANGEMENT ON DOUBLE 9M PCC POLE. (DEAD END LOCATION) LT LINE ARRANGEMENT RAWINGS GA & COMPONENT DETAILS OF LT LINE HORIZONTAL FORMATION ON SINGLE PCC POLE, 3-PH, 4 WIRE (IN LINE ARRANGEMENT) GA & COMPONENT DETAILS OF LT LINE HORIZONTAL FORMATION ON SINGLE PCC POLE,3PH-4 WIRE (ANGULAR LOCATION)
25
NESCL-RE-LT-001
26
NESCL-RE-LT-002
INDEX
Page 5 of 5
27 GA & COMPONENT DETAILS OF LT LINE HORIZONTAL FORMATION ON SINGLE PCC POLE , 3-PH, 4 WIRE ( DEAD END ARRANGEMENT) GA & COMPONENT DETAILS OF LT LINE HORIZONTAL FORMATION ON SINGLE PCC POLE, 1-PH, 2 WIRE(IN LINE ARRANGEMENT) GA & COMPONENT DETAILS OF LT LINE HORIZONTAL FORMATION ON SINGLE PCC POLE , 1-PH, 2 WIRE ( ANGULAR LOCATION) GA & COMPONENT DETAILS OF LT LINE HORIZONTAL FORMATION ON SINGLE PCC POLE , 1-PH, 2 WIRE ( DEAD END ARRANGEMENT) GA & COMPONENT DETAILS OF LT LINE VERTICAL FORMATION ON SINGLE PCC POLE, 3-PH, 4 WIRE ON (IN LINE ARRANGEMENT) GA & COMPONENT DETAILS OF LT LINE VERTICAL FORMATION ON SINGLE PCC POLE,3PH-4 WIRE ( ANGULAR LOCATION) GA & COMPONENT DETAILS OF LT LINE VERTICAL FORMATION ON SINGLE PCC POLE , 3-PH, 4 WIRE ( DEAD END ARRANGEMENT) GA & COMPONENT DETAILS OF LT LINE VERTICAL FORMATION ON SINGLE PCC POLE, 1-PH, 2 WIRE (IN LINE ARRANGEMENT) GA & COMPONENT DETAILS OF LT LINE FORMATION ON SINGLE PCC POLE( IN LINE ARRANGEMENT) WITH LT ABC GA & COMPONENT DETAILS OF LT LINE FORMATION ON SINGLE PCC POLE( AT DEAD END) WITH LT ABC NESCL-RE-LT-003
28
NESCL-RE-LT-004
29
NESCL-RE-LT-005
30
NESCL-RE-LT-006
31
NESCL-RE-LT-007
32
NESCL-RE-LT-008
33
NESCL-RE-LT-009
34
NESCL-RE-LT-010
35
NESCL-RE-LT-013
36
NESCL-RE-LT-014
INDEX
Page 6 of 6
PART-B TENDER DRAWINGS THESE ARE PRELIMINARY DRAWINGS FOR BIDDING PURPOSE ONLY AND ARE SUBJECT TO CHANGES THAT MAY BE NECESSARY DURING DETAILED ENGINEERING AFTER AWARD KEEPING THE BASIC PARAMETERS AS SPECIFIED. 33/11 KV SUB-STATION SL. NO. 1 FOUNDATION DETAILS FOR POWER TRANSFORMER NESCL: ENGG: RGGVY: 33/11SS:05 DESCRIPTION DRAWING NO
FOUNDATION DETAILS FOR 33 KV NESCL: ENGG: RGGVY: 33/11SS:06 VACUUM CIRCUIT BREAKER DETAILS OF CABLE TRENCH SECTIONS (PART-1) NESCL: ENGG: RGGVY: 3/11SS:07(A)
3.
11 KV AND LT LINE 1 11 KV LINES PROTECTIVE REC CONSTRUCTION STANDARD: GUARDING ACROSS THE A-1 ROADS/CANALS/LINE CROSSINGS 11 KV LINES CONDUCTOR REC CONSTRUCTION STANDARD: FORMATION AND CLEARANCES A-2 OF 11 KV 3 PHASE LINE 11 KV AND L.T. HYBRID TRANSMISSION SYSTEM WITH PROTECTIVE GUARDING 11 KV V CROSS-ARM NESCL: ENGG: RGGVY: 11KV LINE: 03
REC CONSTRUCTION STANDARD : A-6 REC CONSTRUCTION STANDARD : A-7 NESCL: ENGG: RGGVY: 11KV LINE:04
5 6
11 KV POLE TOP BRACKET GA OF LT HORIZONTAL FORMATION
INDEX
Page 7 of 7
7 ARRANGEMENT OF CONDUCTORS ANGLE LOCATIONS 11 KV LINES TAPPING ARRANGEMENT FIRST STRUCTURE OF LENGTHY SPUR LINE 1 1KV LINES ARRANGEMENT AT TENSION LOCATIONS GA OF 11KV LINE FORMATION ON DP 8M PCC POLE (IN LINE) 11 KV LINES CONDUCTOR FORMATION & ARRANGEMENT OF GUYS FOR 0 TO 10 ANGLE LOCATIONS 12 11 KV LINES CONDUCTOR REC CONSTRUCTION STANDARD : A-24 FORMATION & ARRANGEMENT OF GUYS FOR 10 TO 60 ANGLE LOCATIONS (SINGLE POLE SUPPORT) 11 KV LINES CONDUCTOR REC CONSTRUCTION STANDARD : A-25 FORMATION & ARRANGEMENT OF GUYS FOR 10 TO 60 ANGLE LOCATIONS (DOUBLE POLE SUPPORT) 11 KV LINES CONDUCTOR REC CONSTRUCTION STANDARD : A-26 FORMATION & ARRANGEMENT OF GUYS FOR 60 TO 90 ANGLE LOCATIONS (FOUR POLE SUPPORT) 11 KV LINES CONDUCTOR REC CONSTRUCTION STANDARD : A-27 FORMATION & ARRANGEMENT OF GUYS FOR DEAD-END LOCATIONS (DOUBLE POLE SUPPORT
TECHNICAL SPECIFICATION Page 8 of 8
REC CONSTRUCTION STANDARD: A-10
REC CONSTRUCTION STANDARD: A-12
REC CONSTRUCTION STANDARD : A-21
10
NESCL: ENGG: RGGVY: 11KV LINE:05 REC CONSTRUCTION STANDARD : A-23
11
13
14
15
INDEX
16 415/240V LINE PROTECTIVE GUARDING ACROSS THE ROAD FOR HORIZONTAL FORMATION(FOR ROAD CROSSINGS) NESCL: ENGG: RGGVY: LT LINE:06
17
GA OF LT HORIZONTAL NESCL: ENGG: RGGVY: LT LINE:07 FORMATION ON 8M PCC POLE(3 PH 4 WIRE) LT LINE VERTICAL FORMATION NESCL: ENGG: RGGVY: LT LINE:08 3PH, 4WIRE USING AAC GNAT CONDUCTOR AT DEAD END LOCATIONS LT LINE VERTICAL FORMATION NESCL: ENGG: RGGVY: LT LINE:09 3PH, 4WIRE ON 8M 200KG PSCC POLE LT LINE VERTICAL FORMATION NESCL: ENGG: RGGVY: LT LINE:10 1PH, 2WIRE USING AAC GNAT CONDUCTOR AT DEAD END LOCATIONS LT LINE PVC SPACERS REC CONSTRUCTION STANDARD : B 16
18
19
20
21
22
450/240 V LINES CONDUCTOR REC CONSTRUCTION STANDARD : B-24 FORMATION ARRANGEMENT OF GUYS FOR DEAD ENDLOCATIONS 11 KV INSULATORS & FITTINGS REC CONSTRUCTION STANDARD : C-1 INSULATOR PIN 11 KV INSULATORS & FITTINGS REC CONSTRUCTION STANDARD : C-2 CLEVIS AND TONGUE TYPE STRAIN INSULATOR SET HOLDING OF CONDUCTOR ON 11 REC CONSTRUCTION STANDARD : CKV PIN INSULATOR STRAIGHT 3 RUN (USING HELICALLY FORMED FITTING) HOLDING OF CONDUCTOR ON 11 REC CONSTRUCTION STANDARD : CKV PIN INSULATORANGLE 4
TECHNICAL SPECIFICATION INDEX Page 9 of 9
23
24
25
26
LOCATION (USING HELICALLY FORMED FITTING) 27 11 KV CONDUCTOR DEADEND REC CONSTRUCTION STANDARD : C-5 ARRANGEMENT (USING HELICALLY FORMED FITTINGS) 415/240 V INSULATORS FITTINGS PIN INSULATORS 415/240 V INSULATORS FITTINGS PIN INSULATORS & REC CONSTRUCTION STANDARD : D-1
28
29
&
REC CONSTRUCTION STANDARD : D-2
30
415/240 V SHACKLE INSULATORS
REC CONSTRUCTION STANDARD : D 3
31
415/240 V INSULATORS & REC CONSTRUCTION STANDARD : D-4 HARDWARE FITTING FOR TYPE 2 SHACKLE INSULATORS 415/240 V INSULATORS & REC CONSTRUCTION STANDARD : D-5 HARDWARE FITTING FOR TYPE 1 SHACKLE INSULATORS LT CONDUCTOR STRAIGHT RUN AND DEAD END ARRANGEMENTS(USING HELICALLY FORMED FITTINGS) HELICALLY FORMED FITTINGS TCONNECTORS DEAD-END CLAMP HOOKS FOR ABC AND EYE REC CONSTRUCTION STANDARD : D-6
32
33
34
REC CONSTRUCTION STANDARD : E-32
35
REC CONSTRUCTION STANDARD : E34,35 REC CONSTRUCTION STANDARD : E-36
36
NON TENSION LT CONNECTORS FOR TAPPING OF LINES AND SERVICE CONNECTIONS FOR ABC SYSTEM LT CONNECTORS (NON TENSION) GUY-END ASSEMBLY USING HELICALLY FORMED FITTING
37 39
REC CONSTRUCTION STANDARD : E-38 REC CONSTRUCTION STANDARD : G-2
INDEX
Page 10 of 10
40 GUY ARRANGEMENTS FLY GUY, BOW GUY AND STRUT COIL EARTHING PIPE / ROD EARTHING R.C.C. BASE / ANCHOR PLATE BACK CLAMP FOR CROSS ARM REC CONSTRUCTION STANDARD : G-4
41 42 43 44 44
REC CONSTRUCTION STANDARD : J-1 REC CONSTRUCTION STANDARD : J -2 REC CONSTRUCTION STANDARD : K- 1 REC CONSTRUCTION STANDARD : K- 2
DETAILS OF REINFORCEMENT 8.0 REC DRG. NO-4 M/200 KG. PRESTRESSED CONCRETE POLE CONSTRUCTION DRG. OF NESCL: ENGG: RGGVY: PC:17 INSULATING PIERCING CONNECTOR FOR LT ABC (MAIN) / SERVICE LINE ANTI CLIMBING DEVICE HT ABC CONNECTING DETAILS DT STATION NESCL: ENGG: RGGVY: ACD:18 NESCL: ENGG: RGGVY: HTABC:19
45
46 47
SL. NO. 1.
DESCRIPTION
DRAWING NO.
11 KV/433-250 V DISTRIBUTION SUB-STATION WITH A.B SWITCH & HORN GAP FUSES 11 KV/433-250 V DISTRIBUTION SUB-STATION (FOR ON LINE LOCATIONS ALONG LINE) 11 KV/433-250 V DISTRIBUTION SUB-STATION (FOR ON LINE LOCATIONS ACROSS LINE) 11 KV/433-250 V DISTRIBUTION SUBSTATION LOCATION OF EARTH PITS AND CONNECTION
REC CONSTRUCTION STANDARD : F-2
2.
3.
4.
INDEX
Page 11 of 11
5. 6. 11 KV H.G. FUSE 11 KV H.G. FUSE MOUNTING DETAILS EARTHING ARRANGEMENT FOR DISTRIBUTION TRANSFORMER REC CONSTRUCTION STANDARD : F - 6 REC CONSTRUCTION STANDARD : F - 7
7.
8.
L.T. DISTRIBUTION BOX (FOR 25 NESCL: ENGG: RGGVY: LTDB:21 AND 63 KVA DT) DETAILS OF SAMPLING VALVE H.T. BUSHING APPENDIX-II L.T. BUSHING APPENDIX-II DRAIN-CUM- NESCL: ENGG: RGGVY: DT:22
9.
10.
TERMINAL NESCL: ENGG: RGGVY: DT:24
11.
TERMINAL NESCL: ENGG: RGGVY: DT:25
SERVICE CONNECTION SL. NO. 1. SERVICE CONNECTIONS SINGLE PHASE (INSULATED WIRE) 2. SERVICE CONNECTION SINGLE PHASE METER BOARD SERVICE CONNECTIONS SINGLE PHASE METER BOARD (ALTERNATIVE II) 5. SERVICE CONNECTIONS SINGLE PHASE METER BOARD WITH MCB
TECHNICAL SPECIFICATION INDEX Page 12 of 12
DESCRIPTION
DRAWING NO.
REC CONSTRUCTION STANDARD H-1
4.
CONTROL (WITH SEPARATE NEUTRAL AND EARTH) 6. SERVICE CONNECTIONS SINGLE PHASE METER BOARD WITH PLUG IN TYPE M.C.B (WITH SEPARATE NEUTRAL AND EARTH) REC CONSTRUCTION STANDARD H-12
CHAPTER-IV SAMPLE QUALITY PLAN FQP: SECTION DESCRIPTION FQP-1 CONDUCTOR, EARTH WIRE ERECTION (HT&LT) DISTRIBUTION TRANSFORMERS (OUTDOOR TYPE) ERECTION WORK OF CABLES CIVIL CONDUCTOR STRINGING DTR STRUCTURES & COMPONENTS ERECTION OF 11 KV POLE ACCESSORIES ERECTION WORK-AB SWITCH ERECTION WORK-LIGHTINING ARRESTER PSCC POLES(11KV& LT),POLE EARTHING AND GUY ERECTION ERECTION WORK-SAFE
FQP-2
FQP-3 FQP-4 FQP-5 FQP-6 FQP-7
FQP-8 FQP-9
FQP-10
FQP-11
INDEX
DISMANTLING FQP-12 FQP-13 ERECTION OF BPL CONNECTION ERECTION WORK- STEEL STRUCTURE VACUUM CIRCUIT BREAKER ERECTION WORK-PAINTING
FQP-14 FQP-15
SECTION DESCRIPTION FQP-16 FQP-17 FQP-18 FQP-19 FQP-21 FQP-21 ERECTION OF POLE ACCESSORIES D.C SYSTEM ERECTION OF CT AND PT CONTROL AND RELAY PANEL LIGHTING AB SWITCH
MQP MQP-1 THREE PHASE CT OPERATED STATIC ENERGY METER SINGLE PHASE WHOLE CURRENT ENERGY METER ALL ALUMUNIUM CONDUCTOR(AAC) 11KV AB SWITCH ACSR CONDUCTOR CROSS ARMS FOR 11KV LINES 11KV DISC INSULATORS
MQP-2
MQP-3
MQP-4 MQP-5 MQP-6 MQP-7
INDEX
MQP-8 GUY STRAIN INSULATORS(TYPEAAND C) LT PVC UN-ARMOURED CABLE 11KV HG FUSE M S FABRICATED ITEMS
MQP-9 MQP-10 MQP-11
SECTION DESCRIPTION MQP-12 MQP-13 MQP-14 MQP-15 MQP-16 MQP-17 MQP-18 MQP-19 MQP-20 MQP-21 MQP-22 MQP-23 PIN INSULATORS PCC POLES SHACKLE INSULATORS SOLID GI WIRE GI STRANDED WIRE LTDB LT XLPE CABLE GALVANISATION DO FUSE CONTROL AND RELAY PANEL 33 KV ISOLATOR AAAC(ALL ALUMINIUM ALLOY CONDUCTOR) PT(POTENTIAL TRANSFORMER CT(CURRENT TRANSFORMER)
MQP-24 MQP-25
INDEX
Page 15 of 15
CLAUSE NO.
PROJECT SYNOPSIS INTRODUCTION The national policy of Rural Electrification prescribes that i) ii) The electrification of all the villages of the country shall be completed by 31/03/2007. Universal access of power to all the households shall be made available by the year 2012.
1.00.00 1.01.00
1.02.00
To fulfill this objective, the Government of India has launched a new scheme Rajiv Gandhi Grameen Vidyutikaran Yojana (RGGVY). The scheme shall be implemented through the Rural Electrification Corporation (REC) with association of CPSUs. NESCL has taken up the RE works in Lohardaga district of Jharkhand state on behalf of Jharkhand State Electricity Board (JSEB). Under this package Construction of new 33/11kV Substations, construction of 11 kV lines, Distribution Transformer Substation (DTS), LT line, Service connection & house wiring of BPL household as per Kutir Jyoti norms of Government of India shall be taken up. The District of Lohardaga is located in the south western part of Jharkhand State between 32030 to 23040 north latitude and between 84040 to 84050 east longitude covering an area of 190.82 Km2 in the tribal belt of Chotanagpur plateau. The administrative set up of the district is divided into 5 development blocks viz : (i) Kuru (ii) Kisko (iii) Senha (iv) Bhandra and (v) Lohardaga. The district includes 5 police stations having 353 villages spread over in 67 Gram Panchayats. Lohardaga is the only town in the district.The district is divided into two broad physical divisions viz : (i) the Hilly Tract and (ii) the Plateau Region. The hilly tract is extended in the West and North-Western parts of the district which includes the parts of Kisko, Senha and Kuru development blocks. The high hill tops of this region are known as Pat. The region is covered mainly with sal forests. The Plateau region is a part of the Gumla plateau, comprised with entire part of Lohardaga and Bhandra development blocks and some parts of Senha, Kuru and Kisko developments blocks. This region has a number of small hill blocks covered with forests. The general slope of the district is from west to east. The main rivers of the district are South Koel, Sankh, Nandni, Chaupats and Fulijhar etc. These are mainly Rainfed Rivers and dried up in the summer months. The district enjoys a healthy and pleasant climate throughout the year. The annual average temperature is 230 centigrade and the district receives an annual average rainfall of 1000-1200 mm. The rainfall increases from west to east.
1.03.00
RGGVY WORKS LOHARDAGA-JSEB Bid Doc. No. : NESCL/REC/CS-LH-808
TECHNICAL SPECIFICATION VOL-II-A
CHAPTER-I SECTION-E1 Project Synopsis
Page 1 of 1
CLAUSE NO.
PROJECT SYNOPSIS APPROACH TO SITE Loharda district lies between 32030 to 23040 north latitude and between 84040 to 84050 east longitude covering an area of 190.82 Sq. Kms. in the tribal belt of Chotanagpur plateau. The district is surrounded by Ranchi district in the east, Gumla districts in the south-west, Palamau district in the north and Chhattisgarh State in west. The district is served only by State Highway, Major district roads and a section of South Eastern Railways.
2.00.00
3.00.00 3.01.00 4.00.00 4.01.00
RAILWAY SIDING The nearest rail-head is Loharda railway station of Eastern Railways. Lohardaga is last Railway Station and trins come only from Ranchi Railway Station. SITE The site is spread in Loharda revenue district of Jharkhand state. The Loharda district is sub-divided into 5 Blocks as detailed below: S. No 1. 2. 3. 4. 5. Kisko Kuru Lohardaga Senha Bhandra Name of Block No. of Villages
90 75 42 88 56
An indicative list of all the villages along with their census code with associated habitations to be included in the scope of works in Lohardaga district is given as annexure to this chapter. However, bidders shall verify this at site during survey as per clause 2.01.00 in Chapter-I, Section-E2 (Scope of Works) and approval of the same shall be obtained from the Employer/Engineer-in-Charge. 5.00.00 5.01.00 SERVICE CONDITIONS All out door Equipment/material to be supplied against this specification shall be suitable for satisfactory continuous operation under tropical conditions as specified below: 1. 2. 3. 4. Maximum ambient temperature ( C) Minimum ambient temperature ( C) Relative humidity (%) Range Maximum Annual rainfall (cm)
0 0
50 0 10 - 100 70 - 200
CHAPTER-I SECTION-E1 Project Synopsis Page 2 of 2
CLAUSE NO.
PROJECT SYNOPSIS 5. 6. Maximum wind Pressure (Kg/m2.) Moderately hot and humid tropical, climate, conductive to rust and fungus growth Seismic level (horizontal acceleration) 75 Yes
7. 5.02.00 6.00.00
0.3 g
For indoor equipments / materials the requirements are specified in the respective volumes of technical specification. The district map of Lohardaga is given below.
Page 3 of 3
CLAUSE NO.
PROJECT SYNOPSIS
Sr. No. 1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41
Block Name: KISKO (0001) Village Name Census Code Murmu 02626500 Khiriwar alias Kharcha 02631800 Hondaga 02632800 Nawadih 02632900 Kisko 02633900 Hesapiri 02634300 Bethat 02634400 Patratu 02634500 Area 02634600 Bul Bul 02625800 Kerar 02625900 Honhe 02626000 Kurse 02626100 Partu 02626200 Manha 02626300 Manchi 02626400 Mukrum 02627300 Kita 02627400 Bariatu 02627700 Panrepura 02627800 Keradih 02627900 Sarjupawa 02628000 Barwadih 02628100 Madanpur (Jampani) 02628500 Dugo (Kadojana) 02628600 Chainpur (Turitoli) 02628700 Putrar (Purbetoli) 02628800 Kauwadanr 02628900 Chandalgi (Dipatoli) 02629100 Husru 02629400 Mahugaon 02629500 Barchorgain 02629700 Jogiara 02629800 Agardih 02629900 Barwatoli 02630000 Jamhre 02630100 Bonga 02630300 Chotchorgain 02630500 Korgo 02630600 Bagru (Karantoli) 02630800 Kekrang (Behrakona) 02631200
TECHNICAL SPECIFICATION VOL-II-A CHAPTER-I SECTION-E1 Project Synopsis Page 4 of 4
CLAUSE NO.
PROJECT SYNOPSIS
42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87
Bonrobar Jobang Uldag Bahabar Khariya Nari Kocha Barnag Bitloung Chhechhranawadih Patgachha Charhu Kotsa Sagodih Kopia Sembhua Semartanr Siram Pahargir Rubed Jamdih Ambapawa Makka Onegara Pesrar (Nawatoli) Rorad Tetardanr Merle Hisri Chanpi Bhusar
Banpur Datma Pakhar Deodariya Lawadag Salaiya Tisiya Hutap Durhul Nini Kasiyadih Kharki Semardih Huahar Parhepat
02631400 02631700 02631900 02632000 02632100 02632600 02633100 02633200 02633400 02633600 02634100 02634800 02626600 02626800 02626900 02627000 02627100 02627200 02627500 02627600 02628200 02628300 02628400 02629000 02629200 02629300 02629600 02630200 02630400 02630700 02630900
02631000 02631100 02631300 02631500 02631600 02632200 02632300 02632400 02632500 02632700 02633000 02633300 02633500 02633700 02633800
CLAUSE NO.
PROJECT SYNOPSIS
88 89 90
Anandpur Lawagain Nirhu
02634000 02634200 02634700
Sr. No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39
Block Name: KURU (0002) Village Name Census Code

Kakargarh Jima Chiri Lawagain Jangi Nontilo Chandu Kundi Kuru Taku Doba Urumuru Jingi Baridih Maradih Jilinga Pandra Rajrom Kokar Mahugaon Chirna Lapur Hanhat 02642300 02636800 02636900 02637100 02637300 02637400 02637500 02637800 02637900 02638000 02638100 02638300 02640100 02640200 02640600 02640700 02640800 02641100 02641400 02641900 02642100 02642200 02642400
Khamhar Rocho Tiko Umri Jonjro Kharta Gitilgarh Huddu Makra Tan Rahe Masiyatu Dhaura Salgi Hotwar Jario
02635000 02635400 02637700 02638400 02638800 02639500 02639600 02639700 02639800 02639900 02640000 02635100 02635200 02635300 02635500 02635600
CLAUSE NO.
PROJECT SYNOPSIS
40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75
Chund Kundgara Dubang Barkichanpi Banduwa Chhotkichanpi Kamle Sukumar Opa Sundru Bisramgarh Karak Kolsimri Tati Jido Sinjo Bardih Sukurhuttu Kairo Utka Baksi Eradon Sarhawe Tati Hurhad Makandu Merle Chitakoni Chetar Henjla Chandlaso Charra Phulsari Barmaratola Itra Jajgunda Torang
02635700 02635800 02635900 02636000 02636100 02636200 02636300 02636400 02636500 02636600 02636700 02637000 02637200 02637600 02638200 02638500 02638600 02638700 02638900 02639000 02639100 02639200 02639300 02639400 02640300 02640400 02640500 02640900 02641000 02641200 02641300 02641700 02641500 02641600 02641800 02642000
Sr. No. 1 2 3 4 5
Block Name: LOHARDAGA (0003) Village Name Census Code Baksi 02642500 Banjarkisko 02642700 Jori 02642800 Waina 02643000 Kutmu 02643100
TECHNICAL SPECIFICATION VOL-II-A CHAPTER-I SECTION-E1 Project Synopsis Page 7 of 7
CLAUSE NO.
PROJECT SYNOPSIS 6 7 8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
Bamandiha Nigni Nadiya Harmu Juriya Inta Rampur Bhakso Harratoli Manho (Baratola) Kujra Kurse Hesal Hendlaso Hirhi (Barkatoli) Burgaon Kujji Bakarni Saida Tigra Bejwali Bhunjania Mundo Bhantkhijri Arkosa Khakhparta Kaimo Burhu Baramtpur Barantpur Bagha Aine Nadinagra Basri Nagra Chipo Irgaon Baghi Gunri
02643200 02643300 02643400 02643500 02643600 02643800 02644300 02644500 02644700 02644900 02645000 02645200 02645300 02645400 02642600 02645100 02646300 02642900 02643700 02643900 02644000 02644100 02644200 02644400 02644600 02644800 02645500 02645600 02645700 02645800 02645900 02646000 02646100 02646200 02646400 02646500 02646600
Sr. No.
1 2 3 4
Block Name: SENHA (0004) Village Name Census Code

Badla Arru Jogna Jhakhra
02651700 02652200 02652300 02653100

CLAUSE NO.
PROJECT SYNOPSIS
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
Buti Senha (East) Serenghatu Torar Sithio (Mandaptola)
02653200 02654900 02655200 02655300 02655400
Pundag Banri Hesag (Baghat Tola) Pahardanru Hendehas Totro Kham Baladih Jawal Turiadih Batru Dundru Hundi Jurhni Pirtaul Sanai Nindi Henhe (Nichatoli) Garatu Churwe Sendur Rankoli Gamharia Chanri Manhepat Chaprong Tuimu (Baratoli) Hurmhur Ganeshpur Chandwa Mugo Birhni (Mahugantoli) Murki Parhi Jamira Minthgara Ichri Tengria Murpa Pali (Kochitola) Patlo
02646700 02646800 02646900 02647000 02647100 02647200 02647300 02647400 02647500 02647600 02647700 02647800 02647900 02648000 02648100 02648200 02648300 02648400 02648500 02648600 02648700 02648800 02648900 02649000 02649100 02649200 02649300 02649400 02649500 02649600 02651300 02651400 02652000 02652700 02652900 02653000 02653500 02653600 02653700 02654100 02654200
CLAUSE NO.
PROJECT SYNOPSIS
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88
Gageya Garhgaon Chau Churku Chamru Alaundi Heswe Sake Chaukni Darru Uru Ara Manhe Garhkasmar Nawadih Fatehpur Turiyadih Chandkopa Arahasa (Baratoli) Gobarsila Bansari Torar Bhargaon Kalhepat Doka Kundgari (Jhantitola) Kandra Korambe (Nayatoli) Ugra (Kathaltoli) Jhaljamira (Tanka toli) Ghata Barhi Chatakpur Datri Danru Merho Ekaguri Chitri
02654300 02649700 02649800 02649900 02650000 02650100 02650200 02650300 02650400 02650500 02650600 02650700 02650800 02650900 02651000 02651100 02651200 02651500 02651600 02651800 02651900 02652100 02652400 02652500 02652600 02652800 02653300 02653400 02653800 02653900 02654000 02654400 02654500 02654600 02654700 02654800 02655000 02655100
Sr. No. 1 2
Block Name:-BHANDRA (0005) Village Name Census Code Bedal 02655800 Bhainsmundoalias
02655900
CLAUSE NO.
PROJECT SYNOPSIS Bhaiyagaon 3 4 5 6 7 8 9

10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46
Bhandra Bhaunro Bitpi Dhanamunji Tetarpoka Jharo Jhiko Toto (Bara Tola) Burka Udrangi Baimari Ambera Banda Akasi Kumhariya Hati Kaspur (Naya Toli) Naudiha Soranda Gararpo Porha (Triyon Tola) Palmi Tilsiri Wakilambua Nagri Bhitha Khawasambawa Pachagain Narauli Khanda Gajni Mahuari Chalho Ulti Garadih Nagjua Charma Kanjo Baragain Khawaskhijri Bamhandiha Kundo Kachmachi Dumri
02656900 02657000 02657700 02657900 02658400 02660300 02661000 02655500 02655700 02656000 02656100 02656200 02656300 02656400 02656500 02656600 02656700 02656800 02657100 02657200 02657300 02657400 02657600 02658200 02658600 02658700 02658800 02658900 02659000 02659100 02659200 02659300 02659400 02659500 02659600 02659700 02659800 02659900 02660000 02660100 02660200 02660400 02660500 02660700
CLAUSE NO.
PROJECT SYNOPSIS
47 48 49 50 51 52 53 54 55 56
Pandaria Masmanothakurgaon Amdari Semra Balsota Pajhri Dhobali Makunda (Rusba Toli) Kota Jamgain
02660800 02655600 02657500 02657800 02658000 02658100 02658300 02658500 02660600 02660900
Page 12 of 12
CLAUSE NO.
SCOPE OF WORKS SCOPE OF WORKS The scope of works include execution on turnkey basis with complete system design, procurement/manufacture, manufacturers quality assurance, shop testing (including type testing where specified/required), transportation, storage, erection, including all civil/structural works, site testing, commissioning of all items & materials as elaborated below including all associated activities that though not exclusively specified here in but are required for the completion of the entire works under this package. A three tier quality monitoring system as per relevent REC guidelines shall be followed for the works which has been described else where in the bid document.
1.00.00 1.01.00
1.02.00
This specification intends to cover but not restrict to the following activities, services and works. i) Complete design and engineering of all the systems, sub-systems, equipment, material and services. Providing engineering data, drawings and O&M manuals for Owners review, approval and records. Manufacturing, supply, testing, packing, transportation and insurance from the manufacturers work to the site. Receipt, storage, insurance, preservation and conservation of equipment at the site. All civil and structural works as required. Fabrication, pre-assembly (if any), erection, testing and putting into satisfactory operation of all the equipment/material including successful commissioning. In addition to the requirements indicated in this section (Technical Specifications), all the requirements as stated in other sections shall also be considered as a part of this specification as if completely bound herewith. The Bidder shall be responsible for providing all material, equipment and services specified or otherwise which are required to ensure operability, maintainability and the reliability of the complete work covered under this specification. All services & activities required to be given contractually, by the bidder, during warranty period.
ii)
iii)
iv)
v) vi)
vii)
viii)
ix)
TECHNICAL SPECIFICATION VOL-II
CHAPTER-I SECTION-E2 Scope of Works
Page 1 of 15
CLAUSE NO.
SCOPE OF WORKS For individual equipment specifications reference shall be made to the relevant sections of this specification given under Chapter-II of Technical Specification. Guaranteed Technical Parameters (GTP) of different equipments are given at the end of each section of technical specification for individual item. The GTPs are divided into two parts i.e. Part-A and Part-B. Parameters indicated in Part-A of GTP are to be complied by the equipments to be supplied and no separate approval from owner in respect of these parameters is envisaged. Wherever, Part-B is provided, the bidder shall fill up the parameters and submit for approval of owner either in the bid or at the time of award . Standard and Tender drawings for different general arrangements are provided in Vol-II, Chapter-III of technical specification.
1.03.00
The package envisages following works to be implemented on turnkey basis at different locations in Lohardagar district in the state of Jharkhand. i) ii) iii) iv) Survey, Pole Spotting for all HT & LT Lines and Finalisation of DT Location. Construction of New 33KV/11KV S/S Construction of 33kV, 11kV & LT Lines Augmentation of existing 33/11kV Sub-Station, wherever specified, by a. v) vi) Construction of new 33kV Bays
1.03.01
Construction of Distribution Transformer Centers (DTC) Service Connections to all BPL (Below Poverty Line) Consumers
2.00.00 2.01.00 2.01.01
DETAILED SCOPE Route Survey Bidder shall finalise the route alignment for all HT & LT Lines along with Pole Spotting, Stay arrangement, crossing of roads, rail track ,rivers, etc., and location of Distribution Transformer station. The details shall be plotted on scaled maps as detailed below and submitted to Employer Engineer-in-Charge for approval, before execution.
2.01.02
District map shall be modified if required to indicate correctly the following. The final As-built maps shall be with a scale of 1:15000 or better. i. 220KV/132KV SS & 220/132KV lines
TECHNICAL SPECIFICATION VOL-II CHAPTER-I SECTION-E2 Scope of Works
Page 2 of 15
CLAUSE NO.
SCOPE OF WORKS ii. Existing & Proposed 33KV SS & 33KV lines
2.01.03
Block wise maps is also to be prepared by the Contractor indicating correctly the following. The final As-built maps shall be with a scale of 1:15000 or better. i. ii. iii. Village boundaries and their respective census codes Existing and proposed 33/11kV substations & 33 kV Lines. Existing and proposed 11kV lines and Distribution transformer Stations.
The bidders are advised to use GIS handheld tools for capturing the line routes along with prominent land marks for geo-referencing. 2.01.04 Village level map shall be prepared by the Contractor indicating the following. The final As-built maps shall be with a scale of 1:5000 or better indicating the following. i. ii. iii. iv. v. vi. 2.02.00 2.02.01 Village geographical features and landmarks with clear depiction and label All the habitations in the village Existing & proposed HT & LT lines, DTs List of individual consumer fed from each pole Estimated loading. All distance and locations of electrical system from key reference points.
Construction of New 33KV/11KV S/S Construction of new 33/11kV sub-stations at following locations & as per following detail. Drawing no. NESCL:ENGG:RGGVY/LH:33/11 KV SS-01 shall be refered in these substations.
Sl No. Proposed Substation (33/11 kV ) Transformer rating 33kV bays
Transfor.
11kV bays
Transfor.
Line
Line
1. 2. 3. 4.
Kisko Kuru Senha Bhandra
1X1.6 + 1X3.15 1X3.15 + 1X1.6 1X3.15 + 1X1.6 1X1.6 + 1X1.6
2 2 2 2
1 1 1 1
2 2 2 2
4 4 4 4
Page 3 of 15
CLAUSE NO.
SCOPE OF WORKS
2.02.02
Electrical Works a) 33 kV outdoor sub-station with complete works comprising of 33/11 kV Power Transformers, 33 kV bays using 33 kV Vacuum Circuit Breakers, Isolators, Current Transformers, Voltage Transformers, Surge Arrestors, , Control & protection and metering including energy metering units. To carry out all civil works including equipment foundations, trenches, supply & erection of equipment support structures are in contractors scope. Strung bus shall be with ACSR Panther conductor. b) Supply, erection and commissioning of 11 kV out door Switchgear with 11 kV bays( 11 kV incomer bay and outgoing feeder bays) consisting of 11 kV Vacuum Circuit Breaker, isolator CT, PT, Surge Arrester, Mimic, Protection, Metering, take off arrangement with double pole structure & 400A AB Switch with required conductor to take off point and all other associated equipment. Supply, erection and commissioning of 11/0.415 kV, 63 kVA Station Transformer with associated 11kV AB Switch and HG fuse arrangement on DP structure. Supply, erection and commissioning of indication, control and protection system (Indoor), metering for both 33kV as well as 11kV bays. CT/PT operated energy meters with 0.5 class accuracy, as per description in technical specification in Volume-II shall be provided on all 33 kV incoming and outgoing feeders, 33kV Transformer bay and 11 kV outgoing feeders. Supply, erection and commissioning of LT Switchgear (AC/DC Distribution Boards) including connection to station transformer (AC) and DC Battery & Battery Charger System through power cable. Fire Fighting System consisting of portable fire extinguishers (DCP and CO2 type), Fire Buckets and Sand as per specification enclosed shall be used. 45Ah, 24 Volts sealed maintenance free Nickel Cadmium batteries & battery charger (25A ) shall be supplied, erected & commissioned as per specification. Battery and Battery Charger shall be suitable for indoor applicator. Supply and erection of 1.1 kV grade PVC, Power & Control Cable along with complete accessories is under the scope of bidder.
c)
d)
e)
f)
g)
h)
i)
Page 4 of 15
CLAUSE NO.
SCOPE OF WORKS j) Supply and erection of the galvanized steel lattice structures for all equipments and switchyard as per specification enclosed. Insulator strings and hardware, clamps & connectors, conductors for bus, jumpers, droppers and earthing materials, Bay marshalling box, cable trenches with supporting angles/channels, Trench cover, Junction box. Designing, supply and erection of the lightning protection of the complete substation. Designing, supply and erection of the yard lighting for the complete sub-station and control room lighting. Terminal connectors of all types & rating for all the equipments (including terminal connectors for 33 / 11 kV Power Transformer and 11/0.433 kV Station Transformer).
k)
l) m)
n)
2.02.03
Civil Works Complete civil works including design for all electrical works indicated at 2.01.01 including : The scope of civil works shall include design & construction of all Civil & Structural works including supply of all materials, complete for all equipment and Gantry Structures, and control room building. a) b. c) Soil Investigation to be carried out at new 33/11kV Sub-Stations, if felt necessary, at the existing substations, where bay extension is proposed. Site preparation, soil sterilization/ antiweed treatment including gravel filling, but excluding major leveling. Excavation, de-watering, carriage of excavated earth, PCC, mudmat, casting of reinforced concrete foundations, backfilling, etc. for Sub-Station structures, equipment supports, their control cubicles, bus posts supports and bay marshalling kiosks. Excavation, de-watering, carriage of excavated earth, PCC, mud mat and construction of RCC trenches for cable and pipe with necessary precast RCC removable covers with lifting facility, sump pits, back-filling, cable tray supports. Excavation, de-watering, carriage of excavated earth, PCC, mudmat, casting of Transformer Foundations, etc. Single lane concrete road with in Sub-Station (periphery and within Sub Station for maintenance), connecting to the approach road and complete drainage system within sub-station. Equipment foundations. Earthmat using 25 sq.mm. MS Rod.
TECHNICAL SPECIFICATION VOL-II CHAPTER-I SECTION-E2 Scope of Works Page 5 of 15
d)
e) f)
g) h)
CLAUSE NO.
SCOPE OF WORKS i) j) Drainage system and culverts inside the sub-station. The Civil Works for the Sub-Station Control Room Building at the SubStation shall include design & execution of works of flooring, construction of RCC ,cable trench, and brick work, etc. for cabling and panel installation with all electrical wiring & fittings, sanitary fitting, water supply and sewerage system. Civil and Structural Works associated with Cable trench from individual bays, terminal point including connection to Owners control room building. The civil work associated with panels in the control room building. Fencing as per Technical Specification . Culvert for approach, if required. Water supply system as per Technical Specification . Painting and finishing. All protection measures to prevent any damage to the adjoining structures / facilities.
k)
l) m) n) o) p)
q) 2.03.00
All other Civil Work as per Technical specification for the out door type Substation. Construction of New 33kV Lines Construction of 33 kV line using 100 sq.mm. (7/4.26) ACSR Conductor equivalent to ACSR Dog conductor with an average span of 100 mtrs on 9 mtr, 400 Kg PCC Poles complete with pin insulators, Disc Insulator, ' V ' Cross arm, Pole top bracket, back clamp for V cross arm, DP Structure with DP Channel & Clamp, DP Cross bracing & clamp as required, earthing, anti-climbing device with fasteners, danger plate, preformed insulator bindings, stay sets as required, bolts, nuts & washers and any other hardware required to complete the work as finalised during detailed engineering. The new 33kV lines are to be constructed in the sections as given below in table: Sl. No . 1. 2. 3. 4. 5. Name of Originating substation Lohardaga (P) GSS Lohardaga (P) GSS Lohardaga (P) GSS Lohardaga (P) GSS Lohardaga (P) GSS GRAND TOTAL Name of Terminating sub-station (E)/(P) Lohardaga (E) PSS Kisko (P) PSS Senha (P) PSS Bhandra (P) PSS Kuru (P) PSS Type and Size of Conductor Dog Dog Dog Dog Dog Length of Section (Km.) 2.00 19.00 19.00 13.00 11.00 64.00
Page 6 of 15
CLAUSE NO.
SCOPE OF WORKS Guarding arrangement, as detailed elsewhere in the technical specification, shall be provided at all the crossing i.e. road, telecommunication & power lines, railway line, nallah (drain/Canal) etc. and also in the section of line passing over habitated area of the village, as finalised during detailed engineering.
2.04.00 2.06.04
Construction of 11kV Line 11kV lines shall be constructed on 8 mtr, 200 kg PCC Single Pole complete with Pin/Disc insulators, 'V' cross arm, pole top bracket, back clamp for 'V' cross arm, extension arrangement with 100x50x6 mm channel up to 2 m wherever required to maintain the minimum clearance, DP/Four pole Channel & Clamp and DP/ Four pole Cross bracing & Clamp for DP/ Four pole Structure as required, Earthing, Anti climbing device with fasteners, Danger plate, Preformed insulator bindings, Stay sets as required, Bolts, nuts & washers and any other hardware required to complete the work (as finalized during detailed engineering). Guarding arrangement, as detailed elsewhere in the technical specification, shall be provided in the 11kV Line (with AAAC conductor) at all the crossing i.e. road, telecommunication & power lines, railway line, nallaha etc. and also in the section of line passing through the village, as finalised during detailed engineering. 11kV railway line crossing shall be constructed by using XLPE insulated armoured cable of 3Cx185 sq. mm. Aluminium conductor in UG location. For the purpose DP structure with PCC poles shall be erected at both ends of railway crossing. The incoming DP structure shall have AB switch arrangement. The cable shall be routed through GI pipe & clamped to the pole. The bidder should include the cost of DP structure with PCC pole along with all structural material, channel, clamps, connectors, hardware & accessories like anticlimbing device, danger board, earthling arrangement, insulators, AB switch & support structures for AB switch etc. The cost of cable shall include the cable cost along with the cost for termination kits. 11kV lines shall have the configurations as given in the Table-2 below. Table-2: 11kV Line Configuration Sl. Type of Conductor No. line Support Average Purpose Span in mtr 70 For feeder bifurcation & main line. For spur lines from existing main lines
2.06.02
2.06.03
1.
3 phase
(55sq mm, 7/3.15) 8 mtr./ AAAC 200KG PCC (34 sq.mm, 7/2.5) 8 mtr./ AAAC 200KG
2.
3 phase
90
Page 7 of 15
CLAUSE NO.
SCOPE OF WORKS PCC 3. 3 phase ABC(3x35+70) 8 mtr./ 200KG PCC 40 for village/habitation. For locations in spur line / Main line where adequate clearance is not available for bare conductrs.
2.07.00
11kV Spur line for village/habitation electrification Construction of 11 kV spur line from the existing or to be constructed lines for electrification of villages with habitations as given in Annexure to ChapterI Section E1 of Project Synopsis. Wherever clearance for bare conductor is not adequate 11KV, 3x35+70 sq. mm XLPE insulated ABC cable shall be used with the prior approval of employer.
2.07.01 2.07.02
These lines shall emanate from main lines and shall have provision of AB Switches at T-off points only where the spur line length exceeds 2 Km. Guarding arrangement, as detailed elsewhere in the technical specification, shall be provided in the 11kV Line (with AAAC conductor) at all the crossing i.e. road, telecommunication & power lines, railway line, nallah (drain/Canal) etc. and also in the section of line passing over the habitated area of the village, as finalised during detailed engineering While carrying out the route survey as detailed in Clause 2.01.00 above, the Contractor shall assess the actual requirement of the 11kV line configuration and approval of the same shall be obtained from the Employer/Engineer In-Charge prior to starting of construction activity.
2.07.03
2.10.00
Construction of Distribution Transformer Centres Construction of Distribution Transformer Centresi (DTC) using the type of transformers & configurations as given in the table below. Sl. Type of Voltage No. DT ratio(KV) 1 phase 1 phase 3 phase 11/0.250 11/0.250 11/0.415 Rating Arrangement (KVA) 10 16 25 8 mtr/200 Kg. PCC Single pole structure with DO fuse 8 mtr/200 Kg. PCC Single pole structure with DO fuse 8 mtr/200 kg. PCC Double pole structure with AB switch & HG fuse
Page 8 of 15
CLAUSE NO.
SCOPE OF WORKS The scope includes supply, installation, testing and commissioning the following i. Distribution Transformers fitted with LA protected by 11 kV AB Switch and HG fuse for 3-ph. 25KVA DTs and Drop out fuse for 1-Phase 10KVA and 16KVA DT on HT side, LT Distribution Box with MCCB & Energy Meter on LT side. ii. All structures, cables, earthing and all other items, not specifically mentioned but necessary for safe operation of the distribution transformer is included in scope. The cable from DT to DB and from DB to Overhead lines shall be run in GI pipe of proper size, duly clamped with poles for protection of cable. The supply of GI pipe and clamps shall be included in the quoted prices of structures. iii. LT Distribution Box with MCCB,0.5 class CT & Energy Meter on LT side of DT. The Distribution box shall have proper locking arrangement.
2.10.00 2.10.01 2.10.02
The contractor shall survey the area, fix the location of DT keeping in view that DT is as close as practically possible to the load centre of the area to be fed. Contractor shall obtain the owners approval for final DT location. The no. of LT feeders/ service connections to be connected to a particular DT shall be decided during detailed engineering. All distribution transformers shall be installed as per technical specification described elsewhere in Volume-II. For three phase DTs, Gang operated AB switches shall be mounted between 11 kV line dropper & HG fuse. Contractor has to make all arrangements for erection of AB Switch on DT poles. Construction of LT Lines The LT lines shall be of following configurations Sl. Type No. line of Conductor Support Average span in mtr 60
2.10.03
2.10.04
2.11.00 2.11.01
1 phase Aerial Bunched Cable (ABC) of 8 mtr/ ABC size1 x 16+25 sq.mm. 200KG PCC 3 phase Aerial Bunched Cable (ABC) of 8 mtr / ABC size 3 x 16+25 sq.mm. 200KG PCC
50
Page 9 of 15
CLAUSE NO.
SCOPE OF WORKS The LT Line using AB Cable shall be constructed on 8 mtr 200KG PCC Pole complete with eye hook, suspention/dead end clamp including belting of clamps etc. complete as required for supporting LT ABC conductor, earthing arrangement, anti climbing device, danger plate, stay sets, & Service Connection arrangement using piercing connector & connector as per REC Construction Standard E-38 etc. as required and any other hardware required to complete the work, as finalised during detailed engineering Service Connections The scope includes providing Service Connections to the Consumers of Below Poverty Line (BPL) Category, from LT poles based on identification by the bidder during their survey and subsequent confirmation by State Power Utility. Single light point house wiring & extension of service connection at consumer location shall be done for all BPL households. Only valid BPL consumers shall be considered for BPL house hold electrification. System Design and Engineering DC control voltage shall be 30 V un grounded two wire system. AC auxiliary supply shall be 1 Phase 230 V with neutral grounded & 3phase 415V AC wherever required. It is not the intent to specify all aspects of design and construction of equipment mentioned herein. The systems, sub-systems and equipment shall conform in all respect to high standards of engineering, design and workmanship, and shall be capable of performing in continuous commercial operation The Contractor shall be responsible for detailed design and engineering of overall system, sub-systems, elements, system facilities, equipments, auxiliary services, etc. It shall include proper definition and execution of all interfaces with systems, equipment, material and services of Owner for proper and correct design, performance and operation of the project.
2.11.02
2.12.00 2.11.03
3.01.03
Contractor shall provide complete engineering data, drawings, reports, manuals, etc. for Owners review, approval and records. The Contractor shall carry out earth resistivity measurements at the Sub Station site (based on four electrode method). Relay setting calculations shall be submitted by the Contractor and approved by Owner. For all civil and structural works, the Contractor shall carry out design calculations, prepare all the detailed construction and fabrication drawings. Project Management & Supervision
3.01.04
3.01.05
3.01.06
3.02.00
Page 10 of 15
CLAUSE NO.
SCOPE OF WORKS
3.02.01
The Contractor shall be responsible for the overall management and supervision of works. He shall provide experienced, skilled, knowledgeable, and competent personnel for all phases of the project, so as to provide the Owner with a high quality system. A project execution schedule called Master Network (MNW) in the form of PERT chart/network and based on Work break down structure shall be prepared by the Contractor for Owners approval. The MNW shall identify milestones of key events for each work/component in the areas of engineering, procurement, manufacture, despatch, erection and commissioning. Testing and Commissioning The scope includes testing and commissioning of all equipment, sub-systems and systems of the project and putting them into successful commercial operation. The scope shall include but not limited to the requirements given elsewhere in the specification. The Contractor shall be responsible to provide all necessary testing and commissioning personnel, tools and plant, test equipment, etc. Interface Coordination The Contractor shall identify all interface issues with Owner and other agencies, and shall be responsible for such interfacing, coordination and exchange of all necessary information. GENERAL REQUIREMENTS & INSTRUCTIONS For substation equipment the scope covers survey, structure, soil resistively measurements design, fabrication and supply of all type of 33 kV type tested structures and gantries including bolts, nuts and washers, hanger. Design, selecting type of foundation for different structures and gantries and casting of foundation for structure footing; and erection of structure, tack welding of bolts and nuts, supply and application of zinc rich paint, structure earthing, fixing of insulator string, stringing of conductors, earth wires along with all necessary line accessories and commissioning of the Sub Stations. All the raw materials such as steel, zinc for galvanizing, reinforcement steel and cement for foundation, coke and salt for earthing, bolts, nuts, washers, danger plates, phase plate, number plate etc. required for substation & its structures shall be included in the scope of supply. Bidders shall clearly indicate in their offer, the sources from where they propose to procure the raw materials and the components. In case of augmentation of existing sub-station, the Bidder shall visit site to ascertain the structures and foundations, dismantling and new construction of structures and
TECHNICAL SPECIFICATION VOL-II CHAPTER-I SECTION-E2 Scope of Works Page 11 of 15
3.02.02
3.03.00 3.03.01
3.03.02
3.04.00 3.04.01
4.00.00 4.01.00
4.02.00
4.03.00
CLAUSE NO.
SCOPE OF WORKS foundations works to be done before quoting. Bidder must furnish the design and drawings in support of the activities mentioned above that are to be carried out for augmentation of existing sub-station site.
4.04.00
For HT & LT line the scope covers detailed survey, pole spotting, optimization of pole location, pole design, testing, fabrication and supply of all type of transmission line poles including cross arms, angles, channels, braces, top brackets, stay sets, bolts, nuts and washers, D-shackle, all types of insulators, and all type of pole accessories like, phase plate, number plate, danger plate, anti-climbing device, stay sets. Guarding arrangements, etc.; design, selection of type of foundation for different poles and casting of foundation for pole footing; and erection of poles, supply and application of zinc rich paint, pole earthing, fixing of insulators, supply of conductors & accessories, stringing of conductors along with all necessary line accessories and testing and commissioning of the erected transmission lines. Bidder is required to follow statutory regulations stipulated in Electricity Act 2003, Indian telegraph act 1889, I.E. Act 1910, Electricity (Supply) Act 1948, Indian Electricity Rules 1956 with all amendments till date and other local rules and regulations referred in this specifications. The bidder shall comply with all the statutory rules and regulations prevailing in the state of concerned state including those related to safety of equipment and human beings. The successful bidder shall acquire electrical license from the concerned State Government / statutory body, as required for executing the works. The Bidder shall do complete coordination with all local & statutory agencies for execution of complete works including obtaining clearance for energising of the HT systems upon completion of erection. Bidder shall obtain approvals & clearances and right of way from all agencies involved. All lines shall generally be routed through public land / along the road. Tree cutting and compensation shall be completely avoided. The bidder shall be responsible for transportation to site of all the materials to be provided by the Contractor as well as proper storage and preservation of the same at his own cost, till such time the erected line is taken over by the Owner. Bidder shall set up required number of stores along the line and the exact location of such stores shall be discussed and agreed upon with NESCL. The Contractor shall submit to the Owner all drawings for review. He shall list the detailed requirements of interface between Contractors work and the material and services to be supplied by Owner
4.05.00
4.06.00
4.07.00
4.08.00
4.09.00
4.10.00
4.11.00
4.12.00
Page 12 of 15
CLAUSE NO.
SCOPE OF WORKS Any deviation or variation from the scope requirement and/or intent of this specification shall be clearly mentioned under Deviation Schedule of the Bid Proposal Sheets irrespective of the fact that such deviations/variations may be standard practice or a possible interpretation of the specification by the Bidder. Except for the deviations/variations which are accepted by the Owner before the award of the contract, it will be the responsibility of the Bidder to fully meet the intent and the requirements of the specification within the quoted price. No other departure from the specification except for the declared deviation indicated by the Bidder in his proposal shall be considered. The interpretation of the Owner in respect of the scope, details and services to be performed by the Bidder shall be binding, unless specifically clarified otherwise by the Owner in writing before the award of contract. The drawings enclosed as per list given in the bid document at Volume-II, Chapter-III and forming a part of the specification shall supplement the requirements specified herein. Drawings are divided into two parts i.e. Part-A and Part-B. Part-A are Standard Drawings for this Project which may be followed for erection of the lines No separate approval is envisaged for standard drawings Part-B are tender drawings. These are preliminary drawings for bidding purpose only and are subject to changes that may be necessary during detailed engineering after award keeping the basic parameters as specified. Failure of any equipment to meet the specified requirements of tests carried out at works or at site shall be sufficient cause for rejection of the equipment. Rejection of any equipment will not be held as a valid reason for delay in the completion of the works as per schedule. Contractor shall be responsible for removing all deficiencies, and supplying the equipment that meet the requirement. QUALIFYING REQUIREMENTS Qualifying Requirements are specified in Annexure-A of Special Condition of Contract, Volume-IA of bid document.
4.13.00
4.15.00
4.16.00
5.00.00
6.00.00 6.01.00
METHODOLOGY OF PROCUREMENT All 33 kV & 11 kV & LT equipments shall be sourced from reputed manufacturers only, who have designed, manufactured, routine & type tested (including short circuit test in case of power transformers) for relevant Indian Standards and supplied the equipment to various State Electricity Boards or other reputed utilities which are in trouble free service at minimum two different locations for a period of more than two (2) years as on the date of bid opening. Bidder shall confirm the same and provide documentary evidence in his bid for each of the equipment included in his offer. All the equipment of make, type, & rating to be supplied under the subject project package shall meet the above requirement of design & type testing & satisfactory operation. To establish the compliance, bidder shall furnish in the bid complete details of the identical equipment along with associated complete type test (including short
Page 13 of 15
CLAUSE NO.
SCOPE OF WORKS circuit test incase of power transformers) reports in each case carried out at national/NABL accredited laboratories within last five years. Incase the reports are more than five years old or found incomplete upon scrutiny by owner; the bidder shall carry out such tests at his own cost & risk.
7.00.00 7.01.00
QUALITY ASSURANCE, INSPECTION AND TESTS The bidder shall have a quality assurance Programme for the turnkey execution encompassing quality assurance at manufacturers works, storage, erection, testing and commissioning activities. Typical quality plans for manufacturing (MQP) and field (FQP) activities hve been included in the bid documents at Chapter IV. Bidder shall submit the individual quality plan for various equipment after placement of award and obtain approval of NESCL. Individual MQPs and FQPs pertaining to each equipment shall be submitted by bidder after award for review and approval by Owner. Bidder shall strictly adhere to the provisions or approved MQP & FQPs. The bidder shall offer proven and type tested equipment for the project. The type test certificates shall be complete as per the relevant I.S., carried out at independent third party laboratories like ERDA, CPRI etc. and shall not be older than 5 years as on the date of bid opening. The bidder shall submit complete type test reports for each of the equipments offered in his bid for approval of the owner and include one copy of all such test reports in the bid. In case during post award detail engineering stage if any equipment is found to be not type tested or partially type tested, as per I.S., the bidder shall carry out complete type test for the items at his own cost. All routine and acceptance tests shall be carried out as per approved MQP. The bidders shall arrange to give sufficient advance intimation of the manufacturing and testing schedules to facilitated timely inspection of the equipments by the purchasers. The bidder shall provide six sets of tests reports to Employer on successful completion of the tests. The Manufacturing Quality Plans for each equipment submitted by supplier shall cover detailed checks at various stages of raw material, bought out items, in process, final testing, etc. and packing, prior to dispatch. The submitted Quality Plan shall be in line with manufacturers plant standards, national/international standards, Approved Data Sheet and contract specification. This shall also contain statutory testing requirements, if any. CHP stages are identified by NESCL on MQP.
7.02.00
7.03.00
7.04.00
7.06.00
7.07.00
7.08.00
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CLAUSE NO.
SCOPE OF WORKS Field Quality Plan for each equipment shall be in line with the manufacturers practices, national/international standards, manuals, approved data sheet and contract specification. This shall also contain statutory testing requirements, if any. Field Quality Plan is intended to cover all activities at site from material receipt and storage, handling, pre-assembly, assembly up to completion of erection activities of equipment. BILL OF QUANTITY The Bill of Quantity for subject Scope of Works is indicated in the relevant Schedule of the Bid Proposal Sheet, Volume-IB of bid document. The bill of quantities indicated in the specifications is an estimate done by NESCL. However, it shall be the responsibility of the contractor to verify these in line with the requirement specified at Clause 2.01.00 above, within four months from the date of issue of LOI and estimate the actual quantities of all items that are required for completion of the listed scope of work based on relevant Indian Standards and Codes, and approval of the same shall be obtained from the Employer. The contractor shall be responsible to ensure satisfactory and timely completion of the scope of work. Pending estimation of the actual quantities by the contractor as described above, the contractor shall action initially for procurement of only part of the quantities as indicated in the specification, so that there is no excess quantity of materials/items at site on completion of the work. The contractor shall initiate timely action for balance quantities immediately on completion of the quantity estimation by the contractor. It shall be binding on the contractor to complete the work in accordance with the specification as per the actual quantity requirements and as per the rates quoted in the bid. Bidder shall note that the excess quantities shall be disposed/returned as per the relevant clauses of SCC.
7.09.00
7.10.00
8.00.00
9.00.00
WORK SCHEDULE For Work Schedule refer the relevant Schedule of the Bid Proposal Sheet
Page 15 of 15
CLAUSE NO.
GENERAL TECHNICAL CONDITIONS GENERAL INFORMATION The Rural Electrification works of the Project shall be undertaken through this specification. The project is being executed under Rajiv Gandhi Grameen Vidyutikaran Yojana (RGGVY) of Ministry of Power, Govt. of India. SCOPE Bill of Quantity for the works has been indicated in the relevant clause. Bidders scope shall include all items that are necessary for completion of the listed works based on Bid Documents and relevant Indian Standards & Codes and the various provision of Indian Electricity Act etc., all works shall be executed by the Bidder in complete compliance to the specifications except incase any specific deviation sought in the bid, which is subsequently discussed and agreed to by the Owner. The materials/equipment covered under this package shall be supplied complete in all respects, including all components, fittings and accessories that are necessary their efficient performance and satisfactory maintenance under the various operating and atmospheric conditions. Such parts shall be deemed to be within the scope of the Contract, whether specifically included or not in the Specification or in the Contract Schedules. The Contractor shall not be eligible for any extra charges for such fittings, etc. The details of the materials / equipment required have been indicated in Bid Proposal Sheets (BPS), Volume-IB of the bid document. GENERAL TECHNICAL CONDITIONS Bidders are requested to carefully examine and understand the specifications and seek clarifications, if required, to ensure that they have understood the specifications. Such clarifications should be sought at least 15 days before the scheduled date of the opening of the bids. The bid should not include any sections like clarifications, interpretations and/or assumptions. If the Bidder feels that, in his opinion, certain features brought out in his offer are superior to what has been specified, these may be highlighted separately.
1.00.00 1.01.00
2.00.00 2.01.00
2.02.00
3.00.00
3.01.00
Whenever a material or article is specified or described by the name of a particular brand, manufacturer or trade mark, the specific item shall be understood as establishing type, function and quality desired. Products of other manufacturers may also be considered, provided sufficient information is furnished so as to enable the Owner to determine that the products are equivalent to those named. Engineering Data to be furnished in the bid Bidder shall enclose with his bid one set of technical documents, for each of the material under his scope, comprising of guaranteed technical particulars & data sheets, engineering drawings, type and routine tests reports etc. which shall be in confirmation with the type, make & rating of the equipment indicated in the offer.
TECHNICAL SPECIFICATION VOL-II CHAPTER-I SECTION-E1 General Technical Conditions Page 1 of 22
3.02.00 3.02.01
CLAUSE NO.
GENERAL TECHNICAL CONDITIONS Engineering Data to be firmed up at the time Award of Contract In case of successful bidder, the Guaranteed Technical Particulars and Data Sheets furnished in the bid shall be firmed up at the time of award. Bidder shall furnish design documents and engineering drawings of individual equipment as applicable for the subject package, for review and approval by Owner. A drawing submission / approval schedule, keeping in view the overall work schedule, shall be finalised at the time of award. All engineering data submitted by the Contractor after final process including review and approval by the NESCL 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 NESCL in writing. Arrangement by the Contractor Contractor shall make his own necessary arrangements for the following and for those not listed anywhere else: a) b) c) d) e) f) Construction power supply at all work areas Construction water. Construction office and store (open & covered) Construction workshop and material/field testing laboratory Boarding & lodging arrangement for their personnel. Fire protection and security arrangements during construction stage
3.03.00 3.03.01
3.03.02
3.04.00
4.00.00 4.01.00 4.01.01
SPARES Commissioning Spares The Contractor shall supply spares which he expects to consume during installation testing and commissioning of system. The quantity of these spares shall be decided based on his previous experience, such that site works shall not be hampered due to non-availability of these spares. Contractor shall submit a complete list of such spares along with the bid, the cost of which shall be deemed to have been included in the lump sum proposal price of the package. Tools & Tackles The Contractor shall also supply at site one set of all special tool & tackles, etc. which are required by the Owners maintenance staff to maintain the works
5.00.00
CHAPTER-I SECTION-E1 General Technical Conditions
Page 2 of 22
CLAUSE NO.
GENERAL TECHNICAL CONDITIONS successfully at no extra cost. The list of such tools and tackles shall be enclosed with the offer.
5.02.00 5.02.01
Drawings All drawings submitted by the Contractor including those submitted at the time of bid shall be in sufficient detail to indicate the type, size, arrangement, dimensions, material description, Bill of Materials, weight of each component, break-up for packing and shipment, fixing arrangement required, the dimensions required for installation and any other information specifically requested in the Specifications. Each drawing submitted by the Contractor shall be clearly marked with the name of the Purchaser, the unit designation, the Specification title, the Specification number and the name of the Project. All titles, noting, markings and writings on the drawing shall be in English. All the dimensions should be to the scale and in metric units. The drawings submitted by the Contractor shall be reviewed by NESCL and shall be modified by the Contractor if any modifications and /or corrections are required by NESCL. The Contractor shall incorporate such modifications and or corrections and submit the final drawings for approval. Any delays arising out of failure by the Contractor to rectify the drawings in good time shall not alter the completion date. The drawings submitted for approval to NESCL shall be in quadruplicate. One print of such drawings shall be returned to the Contractor by NESCL marked approved / approved with corrections. The Contractor shall thereupon furnish NESCL additional print as stipulated in Technical Specification along with one reproducible in original of the drawings after incorporating all corrections. Further work by the Contractor shall be strictly in accordance with these drawings and no deviation shall be permitted without the written approval of the Purchaser, if so required. NESCLs review of data/drawings furnished by the bidder will cover only general conformance of the data to the specifications and drawings. This review by NESCL may not indicate a thorough review of all dimensions, quantities and details of the equipments, materials, any devices or items indicated or the accuracy of the information submitted. This review and/or approval by NESCL shall not be considered by the Contractor, as limiting any of his responsibilities and liabilities for mistakes and deviations from the requirements, specified under these Specifications and documents. All manufacturing and fabrication work in connection with the equipments / materials prior to the approval of the drawings shall be at the Contractors risk. The Contractor may make any changes in the design which are necessary to make the equipments conform to the provisions and intent of the Contract and such changes will again be subject to approval by NESCL. Approval of Contractors drawing or
5.02.02
5.02.03
5.02.04
5.02.05
5.02.06
5.02.07
CLAUSE NO.
GENERAL TECHNICAL CONDITIONS work by NESCL shall not relieve the Contractor of any of his responsibilities and liabilities under the Contract.
5.02.08
The drawings and data specific to the subject project package shall become owners property. Under no circumstances, the Contractor shall use/offer above designs/ drawings/data sheets to any other authority. Detailed drawing for erection of equipment showing dimensions and items proposed to be used shall be furnished for reference. The following is the general list of the documents and drawings that are to be approved by the Employer after award of contract: i) ii) Work Schedule (Master Network) Plan. All equipment drawings like switchgear, breakers, switches, isolators, surge arrestors, insulators, conductors, cables, transformers, control & relay panels, ACDB, DCDB, LTDB, connectors & clamps, poles etc. Sub-Station layout drawings. Typical General Arrangement and foundation drawings for all equipments pertaining to Sub-Stations. Detailed survey report showing ground clearance, pole locations with type and number of poles and corresponding stays, angle of deviation, road crossing etc., length of line of each type i.e. HT/LT with their conductor, etc. as confirmed in the field. Typical drawings for pole erection with arrangement of V-Cross arm, bracings, clamps, hardware, stays, foundation etc. to be adopted for different configurations of poles (8/9 mtr PCC poles, PCC poles with extension arrangements) on single as well as double pole structures for 33/11 kV/LT Lines, Distribution Transformer Stations (DTC) etc. Quality Plan for individual equipment for both manufacturing and Field Quality Assurance.
5.02.09
5.02.10
iii) iv)
iv)
v)
vi)
vii) Detailed Guaranteed Particulars and Data Sheets for individual equipments with make, type and rating. viii) Erection of various types of poles (Single, Double, Rail) for normal Soil, swampy/paddy field. ix) Road Crossing Poles
Page 4 of 22
CLAUSE NO.
GENERAL TECHNICAL CONDITIONS x) Railway Line (25 kV Traction) Crossing Arrangement of 33 kV line, below track. Earthing of all the above pole structures to be shown in respective drawings.
xi)
xii) Stay set fixing drawings. 5.02.11 The final schedule indicating location of poles, angle of deviation, road crossing and other details shall be submitted for the approval of the NESCL. After approval, the Contractor shall submit four sets of the approved drawings and documents along with one set of reproducible of drawings to NESCL for record purpose. Further, after completion of the works, bidder shall prepare and furnish six sets of as-built drawings of the complete 33 & 11 kV System for Owners reference & record. Bidder shall also prepare a project completion report enclosing the above as-built documents and submit to owner for reference & record. Design Co-ordination The Contractor shall be responsible for the selection and design of appropriate materials/items to provide the best coordinated performance of the entire system. The basic design requirements are detailed out in this Specification. The design of various components, sub-assemblies and assemblies shall be so done that it facilitates easy field assembly and maintenance. 5.04.00 Manufacturing Schedule The Contractor shall submit to NESCL his manufacturing, testing and delivery schedules of various items within two weeks from the date of the Letter of Award in accordance with the delivery requirements stipulated. Schedules shall also include the materials and items purchased from outside Contractors, if any. 5.05.00 5.05.01 Reference Standards The Codes and/or Standards referred to in Specifications shall govern, in all cases wherever such references are made. In case of a conflict between such Codes and/or Standards and the specifications, latter shall govern. Such Codes and/or Standards, referred to shall mean the latest revisions, amendments/changes adopted and published by the relevant agencies. Other internationally acceptable Standards that ensure equivalent or better performance than those specified shall also be accepted.
5.03.00
5.05.02
Page 5 of 22
CLAUSE NO.
GENERAL TECHNICAL CONDITIONS List of Standards

Sl. No. Title Indian Standards International & Internationally Recognized Standards IEC : 62271-100, IEC : 427 , IEC:56 IEC : 129 IEC : 185, BS : 3938 IEC : 99-4 IEC : 694 IS : 2544 IS : 3589, IS : 1239 IS : 209 IS : 406 IS : 731 BS:137 (Part-I&II) IEC:274, IEC:385 IEC : 168
5.06.00
1 2 3 4 5 6 7 8 9 10
Circuit Breaker Isolator Current Transformer Surge Arrestor Common clauses for Switchgear Post Insulator Degree of Protection Specification for Zinc Methods of Chemical Analysis Porcelain Insulators for Overhead Power Lines with a nominal voltage greater than 1000 volts Methods of high voltage testing Specification for conductor and earthwire accessories for overhead power line armour rods, binding wires, and tapes for conductor Specification for Insulators fittings for Overhead Power lines with a nominal voltage greater than 1000V - General Requirements and - Dimensional Requirement - Locking Devices
IS : 13118 IS : 9921 IS : 2705 IS : 3070
11 12
IS : 2071 IS : 2821 (Part-I)
13
IS : 2486
14 15 16
IS : 2486 Part-I IS : 2486 Part-II IS : 2486 Part-III
BS : 3288 IEC-120 IEC-372
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CLAUSE NO.
GENERAL TECHNICAL CONDITIONS

17 Recommended practice for hot dip galvanization of iron and steel Testing of uniformity of zinc coated articles Hexagonal Bolts and Nuts Characteristics of string insulator units ISO Metric Screw Threads Determination of weight of coating on zinc coated iron & steel articles Methods of RIV test on HV Insulators Methods for Switching Impulse test on HV Insulators Thermal Mechanical Performance test on String Insulators units Radio Interference Voltage of high voltage Apparatus Method of measurements Electrical relays for power system protections Indicating Instruments Energy Meters General requirements for switchgear and control gear for voltage not exceeding 1 kV Marking and arrangements for switchgear busbars, main connection and auxiliary Specification for static protection relay IS : 8263/NEMA Publication No. 107/1964, CISPR IS : 3231 IS : 1248, IS : 2419 IS : 722 IS : 4237 IEC-255 Part-I to III, BS : 142 BS-89, IEC : 5 BS : 5585, IEC : 521 IS : 2629
18 19 20 21 22
IS : 2633 IS : 2633 IS : 3188 IS : 4218 IS : 6745 ISO : R947 & ISO : R272 ISO : R68, SR-26, R-262, R-965
23 24
IEC : 437 IEC : 506
25
IEC : 575
26
27 28 29 30
31
IS : 375
32
IS : 8686
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CLAUSE NO.

33 Cross link polythelene PVC cable for working voltage upto and including 1100 Volts Conductors for insulated electrical cables and flexible cords Recommended current rating for cables PVC Insulation and sheath of electrical cables Mild steel wires, strips and tapes for armouring of cables PVC insulated electric cables for voltages upto and including 1100 Volts 7096 (Part-I)
34
IS : 8130
35 36 37
IS : 3961 IS : 5831 IS : 3975
38
IS : 1554 (Part-I), IS : 894
39
Joints and Terminations of Polymeric Cables for Working Voltages from 6.6 kV up to and Including 33 kV
IS 13573
IEEE : 383, ASTMD : 2893
40
Power Cables IS 12909 Dimensions for Moulds for Cast Resin Based Outdoor Terminations for Voltages Above 1100 Volts and up to and Including 11000 Volts
Glands Rigid steel conduits for electrical wiring Flexible steel conduits for electrical wiring Fitting for rigid steel conduits for elec. Wiring Accessories for rigid steel conduits for electrical wiring IS:9537 (Part-2) IS : 3480 IS : 2667 IS : 3837 BS : 6121
41 42 43 44 45
Page 8 of 22
CLAUSE NO.

46 47 48 Mild Steel Tube Specification for concrete pipes Guide for safety procedures and practices in practices in electrical works MS wire for general engineering purpose Compression type tubular terminal end for aluminium conductors insulated cables Cold rolled carbon sheet steel Indian Electricity Act Indian Electricity Rules National Electricity Safety Code Installation & Maintenance of cables Colours for ready mixed paints & enamels Code of practice for earthing Code of practice for protection of building and allied structure against lightning Specification for bushings Requirements for boxes, cabinets Degree of protection provided by enclosures for motors Test on motors Ferrules Specifications for fuses IS : 1255 IS : 5 IS : 3043 IS : 2309 IEEE : 80 IS : 1239 IS : 458 IS : 5216
49 50
IS : 280 IS : 8309
51 52 53 54 55 56 57 58
IS : 513 IS : 513
59 60 61
IS : 2099 IS : 5133 IS : 4691
IEC : 137 IEC : 137
62 63 64
IS:325, IS : 12075 IS : 10942 IS:9224, IS: 8724
Page 9 of 22
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65 66 67 68 Requirements for electric power connectors GLS Lamps Adopters for flexible steel conduits Specification for structural steel standard quality Method of chemical analysis of pig iron, cast iron, plain carbon and low alloy steel Code of practice for use of steel tubes in general building construction Code of practice for Ultrasonic testing by pulse Echo method Specification for hot dip coating on structural steel and other allied products Specification for hot dip galvanized coatings on fasteners Specification for hexagon bolts for steel structure Specification for Rolled Steel Specification for covered electrodes for metal arc welding of structural steel Code of practice for manual metal arc welding for general construction in mild steel Code of practice for manual metal arc welding of mild steel Specification for steel tubes for structural purposes IS : 5561 IS : 418 IS : 4649 IS : 226
69
IS : 228
70
IS : 806
71
IS : 3664
72
IS : 4759
73
IS : 1367
74 75 76
IS : 6639 IS : 808 IS : 814
77
IS : 816
78
IS : 9595
79
IS : 1161
Page 10 of 22
CLAUSE NO.

80 Specification for hexagonal bolts, screws nuts and lock nuts grade C Specification for bolts, screws, nuts and lock nuts (Grade A&B) Technical supply conditions for threaded steel fasteners Code for practice for finishing of Ferrous Method of Tensile Testing of steel products other than sheet, wire and Tube Method of Tensile Testing of steel products other than strip, wire and tube Plugs and sockets Switches for domestic and similar purposes Code of practice for elect. Wiring installation Code of practice for general construction in steel Industrial luminaire with metal reflectors Industrial lighting fitting with plastic reflectors Specification for flood light Specification for new insulating oils Ready mixed paint, air drying, red oxide, zinc chrome priming IS : 1363
81
IS : 1364
82
IS : 1367
83 84
IS : 1477 IS : 1608
85
IS : 1599
86 87 88 89
IS : 1293 IS : 3854 IS : 732 IS : 800
90 91 92 93 94
IS : 1777 IS : 3287 IS : 10322 IS : 335 IS : 2074
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95 Spacers and spacer dampers for twin horizontal bundle conductors Method of measurement of building and civil engineering works Part-I earthwork Safety code for excavation wok Specification for paving Bitumen Ordinary and low heat Portland cement Coarse and fine aggregates from natural sources for concrete Code of practice for plain and reinforced concrete Methods of test for strength of concrete Methods of sampling and analysis of concrete General requirements for concrete vibrators immersion type Screed board concrete vibrators Concrete vibrating tables Methods of sampling and test (physical and chemical) for water used in industry) Code of practice for concrete structures for the storage of liquids Methods of tests for routine control for water used in industry Admixture of concrete IS : 10162
96
IS : 1200
97 98 99 100
IS : 3764 IS : 73 IS : 269 IS : 383
101 102 103 104
IS : 456 IS : 516 IS : 1199 IS : 2505
105 106 107
IS : 2506 IS : 2514 IS : 3025
108
IS : 3370
109
IS : 3342
110
IS : 9103
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CLAUSE NO.

111 Cold worked steel high strength deformed bars to concrete reinforcement Code of practice for bending and fixing of bars for concrete reinforcement Integral cement water proofing compound Planning of (single side band) power line carrier system Specification for static protective relays Surge withstand capability & dielectric strength Control switches (LV switching devices for control and auxiliary circuits) Transducers PCC Poles Methods of test for concrete poles for overhead power & telecom lines Code of practice for selection, handling & erection of concrete4 poles for overhead power & telecommunication line Aluminium conductors for overhead transmission purpose Specification for porecelain insulators for overhead power lines with nominal voltage greater than 1000V IS:1678 IS:2905 IS : 8686 IS : 1786
112
IS : 2502
113 114
IS : 2645 IEC : 663
115 116
IEC-255 (Part-5 & 6) ANSI, IEEEC37.90
117
IEC : 337
118 119 120
IEC : 688-1
121
IS: 7321
122
IS:398
123
IS:731
124
Porecelain insulators for overhead power lines
IS:1445 CHAPTER-I SECTION-E1 General Technical Conditions Page 13 of 22
CLAUSE NO.

with nominal voltage upto & including 1000V 125 Insulator fittings for overhead power lines with nominal voltage upto & including 1000V Metal fittings for insulators for overhesd overhead power lines with nominal voltage greater than 1000V, general requirements & tests Insulators fittings for overhesd overhead power lines with nominal voltage greater than 1000V, Dimensional requirements Porecelain post insulators for systems with nominal voltage greater than 1000V Specification for porecelain guy strain insulators Specification for aerial bunched cables for working voltages upto & including 1100V Power transformer Outdoor three phase distribution transformer High voltage switches AB Switches Specification for alternating current disconnector(Isolator) Static watthour meter class-1 & 2 Capacitor Series Reactor IS:7935
126
IS:2486(Pt.-1)
127
IS:2486(Pt.-2)
128
IS:2544
129
IS:5300
130
IS:14255
131 132 133 134
IS: 2026 IS: 1180 IS:9920 IS:9921
135 136 137
13779 13925 5553
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CLAUSE NO.
GENERAL TECHNICAL CONDITIONS Quality Assurance To ensure that the equipments under the scope of this Contract whether manufactured within the Contractors Works or at his Sub-Contractors premises is in accordance with the specifications, the Contractor shall adopt suitable Quality Assurance Programme to control such activities at all points necessary. Indicative quality plans of manufacturing & Field activities for some of the items are attached with the bid document. Field quality plan shall necessarily cover the procedure and precautions to be adhered by the field personnel during erection of equipment Bidders may also bring out in case their proposed MQP/FQP is in variance with the indicative Quality plans provided in Chapter-V of Vol-IIB(Standard Technical Specification). Bidder shall submit detailed MQP & FQPs of individual equipment supplied. for which standard QP has not been provided, after award of contract for approval of Employer. Such Programme shall be outlined by the Contractor and shall be finally accepted by NESCL after discussions before the award of Sub-Contract. A Quality Assurance Programme of the Contractor shall generally cover but not limited to the following. (a) His organization structure for the management and implementation of the proposed Quality Assurance Programme. Documentation control system. Qualification data for key personnel; The procedure for purchases of materials. Parts/components and selection of Sub-Contractors services including vendor analysis, source inspection, incoming raw material inspection, verification of material purchases etc. System for shop manufacturing including process controls. Control of non-conforming items and system for corrective action. Control of calibration and testing of measuring and testing equipments. Inspection and test procedure for manufacture. System for indication and appraisal of inspection status. System for quality audits. System for authorizing release of manufactured product to the Purchaser. System for maintenance of records.
5.07.00 5.07.01
5.07.02
5.07.03
(b) (c) (d)
(e) (f) (g) (h) (i) (j) (k) (l)
CLAUSE NO.
GENERAL TECHNICAL CONDITIONS (m) System for handling storage and delivery and (n) A Quality Plan detailing out the specific quality control procedure adopted for controlling the quality characteristics of the product.
The Quality Plan shall be mutually discussed and approved by the NESCL after incorporating necessary corrections by the Contractor as may be required. 5.08.00 Quality Assurance Documents The Contractor shall submit all the Quality Assurance Documents as stipulated in the Quality Plan at the time of NESCLs inspection. NESCLs duly authorized representatives reserves the right to carry out Quality Audit and Quality surveillance of the systems and procedures of the Contractors/his sub-vendors Quality Management and Control Activities. 5.09.00 5.09.01 NESCLs Supervision The manufacturing of the product shall be carried out in accordance with the specifications. The scope of the rights of the NESCLs pursuant to the contract, will include but not be limited to the following: (a) Interpretation of all the terms and conditions of these Documents and Specifications. Review and interpretation of all the Contractors drawings, engineering data etc. Witness or authorize his representative to witness tests at the manufacturers works or at site, or at any place where work is performed under the Contract. Inspect, accept or reject any equipment, material and work under the Contract, in accordance with the Specifications & approved MQP. Issue certificate of acceptance and/or progressive payment and final payment certificate. Review and suggest modification and improvement in completion schedules from time to time; and Supervise the Quality Assurance Programme implementation at all stages of the Works.
(b)
(c)
(d)
(e)
(f)
(g)
Page 16 of 22
CLAUSE NO.
GENERAL TECHNICAL CONDITIONS Inspection, Testing and Inspection Certificate NESCLs duly authorized representative and/or outside inspection agency acting on behalf of NESCL shall have at all reasonable times access to the Contractors/Subcontractors premises or works and shall have the power at all reasonable times to inspect and examine the materials and workmanship of the product during its manufacture and if part of the product is being manufactured or assembled at other premises or works, the Contractor shall obtain from NESCL and/or his duly authorized representative permission to inspect as if the equipment/materials were manufactured or assembled on the Contractors own premises or works. The Contractor shall give NESCLs Inspector fifteen (15) days written notice of any material being ready for testing. Such tests shall be to the Contractors account except for the expenses of the Inspector. NESCLs Inspector, unless witnessing of the tests is virtually waived, will attend such tests within fifteen (15) days of the date of which the equipment is notified as being ready for test/inspection or on a mutually agreed date, failing which the Contractor may proceed with the test which shall be deemed to have been made in the Inspectors presence and he shall forthwith forward to the Inspector duly certified copies of tests in triplicate. NESCLs Inspector shall, within fifteen (15) days from the date of inspection as defined herein give notice in writing to the Contractor, of any objection to any drawing and all or any equipment and workmanship which in his opinion is not in accordance with the Contract. The Contractor shall give due consideration to such objections and shall make the modifications that may be necessary to meet the said objections. When the factory tests have been completed at the Contractors or Sub-Contractors works, NESCLs Inspector shall issue a certificate to this effect within fifteen (15) days after completion of tests but if the tests are not witnessed by NESCLs Inspector, the certificate shall be issued within fifteen (15) days of receipt of the Contractors Test Certificate by NESCLs Inspector. The completion of these tests or the issue of the certificate shall not bind NESCL to accept the equipment should it, on further tests after erection, be found not to comply with the Contract. In all cases where the Contract provides for tests whether at the premises or works of the Contractor or of any Sub-Contractor, the Contractor except where otherwise specified shall provide free of charge such item as labour, materials, electricity, fuel, water, stores, apparatus and instruments as may be reasonable demanded by NESCL/ Inspector or his authorized representative to carry out effectively such tests of the equipment in accordance with the Contract and shall give facilities to NESCL/ Inspector or to his authorized representative to accomplish testing. The inspection by NESCL and issue of Inspection Certificate thereon shall in no way limit the liabilities and responsibilities of the Contractor in respect of the agreed Quality Assurance Programme forming a part of the Contract.
5.10.00 5.10.01
5.10.02
5.10.03
5.10.04
5.10.05
5.10.06
CLAUSE NO.
GENERAL TECHNICAL CONDITIONS Testing Expenses Type test charges, if any shall be borne by the bidder except for those which have been specifically listed in the bid proposal sheets for the subject contract. The charges so incurred shall not be reimbursed / paid by NESCL. Bidders shall indicate the Govt. approved & National test 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 and as per the requirement of specifications guaranteed by them. The entire cost of testing for the acceptance test and routine tests and tests during manufacture specified in the technical specifications for materials/equipment shall be treated as included in the quoted unit price except for the expenses of the Inspector / NESCLs representative. In case of failure in any type test, repeat type tests are required to be conducted, then all the expenses for deputation of Inspector/NESCLs representative shall be deducted from the contract price. Also if on receipt of the Contractors notice of testing NESCLs representative/Inspector does not find plant to be ready for testing. The expenses incurred by NESCL for re-deputation shall be deducted from the contract price. ELECTRICAL SYSTEM DATA Sl. No. 1. 2. 3. 4. 5. (i) (ii) 6. 7. (i) Description of the Parameter System Operating Voltage Maximum operating voltage of the system (rms) Rated frequency No. of phases Rated Insulation levels Full wave impulse withstand voltage (1.2/50 micro sec.) One minute power frequency dry and wet withstand voltage (rms) Min. creepage distance (For SubStation equipment) Min. clearances Phase to earth
5.11.00 5.11.01
5.11.02
5.11.03
5.11.04
6.00.00
33 kV System 33 kV 36 kV 50 Hz 3
11 kV System 11 kV 12 kV 50 Hz 3
170 kVp 75 kV 25 mm/kV (900 mm)
75 kVp 28 kV 25 mm/kV (300 mm)
320 mm
140 mm( for out

Page 18 of 22
CLAUSE NO.
GENERAL TECHNICAL CONDITIONS door) (ii) (iii) 8. Phase to phase Sectional clearances Rated short circuit current 640 mm As per standard 25 kA for 1 sec. 280 mm( for out door) As per standard 25 kA for 1 sec. (13.1kA for 1 sec. for out door system) Solidly earthed
9. 7.00.00 7.01.00
System neutral earthing
Solidly earthed
GUARANTEED TECHNICAL PARTICULARS(GTP) Standard guaranteed technical particulars for most of the equipments have been provided in Chapter-III. Bidders are instructed to submit these standard GTPs & GTPs for other equipments for which standard GTP has not been enclosed , duly signed by them in one original and four (4) copies along with the bid as per the formats provided. Any deviation to the standard GTP provided may be brought out in the signed GTP to be submitted with the bid. In case the bidder does not submit the duly signed standard GTP along with the bid it shall be inferred that the standard GTP has been accepted by the bidder. The Bidder shall also furnish any other schedule information as in their opinion is needed to give full description and details to judge the item(s) offered by them. The data furnished in Guaranteed Technical Particulars should be the minimum or maximum value (as per the requirement of the specification) required. A Bidder may guarantee a value more stringent than the specification requirement. However, for testing purpose or from performance point of view, the material shall be considered performed successfully if it achieves the minimum/maximum value required as per the technical specification. No preference whatsoever shall be given to the bidder offering better/more stringent values than those required as per specification. Equipment Performance Guarantee The performance requirements of the items are detailed separately in this Specification. These guarantees shall supplement the general performance guarantee provisions covered under General Terms and Conditions of Contract in clause entitled Guarantee. Successful bidder shall complete the guarantee data sheet, duly signed by his authorised representative during finalisation of contract documents. The data shall form part of contract agreement and shall be refused, in case of any variation of parameter, during testing, inspection and final commissioning checks.
7.02.00
7.03.00 7.03.01
7.03.02
Page 19 of 22
CLAUSE NO.
GENERAL TECHNICAL CONDITIONS Liquidated damages for not meeting specified performance shall be assessed and recovered from the Contractor. Such liquidated damages shall be without any limitation whatsoever and shall be in addition to damages, if any payable under any other clause of Conditions of Contract. Responsibility of the Contractor shall be on total basis for all the item and at no instance of the Contract, the responsibility shall pass on as to Sub-Vendor/SubSupplier. DATA CHECK LIST FOR SUBMISSION Bidder shall enclose all the documents required by the bid document in proper format for information at evaluation of the bids. An indicative check list showing items for which various data are to be furnished in the prescribed format is enclosed. PACKING a) Bolts, nuts, washers and other attachments shall be packed in double gunny bags accurately tagged in accordance with the contents. The packing shall be properly done to avoid losses/damages during transit. Each bundle or package shall be appropriately marked.
7.03.03
7.03.04
8.00.00 8.01.00
8.02.00
9.00.00
b)
10.00.00
CHECK LIST The following check list is given for the benefit of bidder to complete his bid document in line with the specification requirements.
Sl. No.
Item
Guaranteed Technical Particulars & Data Sheet + + + +
Drawings
Type Test Reports
1. 2. 3. 4.
33/11 kV, 5 MVA Power Transformers 33/11 kV, 3.15 MVA Power Transformers 33/11 kV, 1.6 MVA Power Transformers 33 kV Vacuum Circuit
+ + + +
+ + + +
Page 20 of 22
CLAUSE NO.
GENERAL TECHNICAL CONDITIONS Breaker 5. 6. 7. 8. 9. 33 kV Isolators 33 kV PT 33 kV CT 33 kV Surge Arrestors 33 kV XLPE Cable + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + -
10. 11 kV Vacuum Circuit Breaker 11. 11 kV Isolators 12. 11 kV Surge Arrestors 13. 11 kV PT 14. 11 kV CT 15. P.C.C. Poles 16. 33 kV Insulators 17. 11 kV Insulators 18. LT & guy insulators 19. 11 kV AB Switch 20. 11 kV DO Fuse 21. 11 kV HG Fuse 22. 11 kV XLPE Cable 23. 11 kV AB Cable 24. Control Cable 25. Energy Meter (3 Ph) CT & PT operated 0.5 class 26. Energy meter CT operated(1 Ph), 0.5 class 27. Energy meter whole current (1 Ph), class- 1
RGGVY WORKS STANDARD TECHNICAL SPECIFICATION (REV.- 03) TECHNICAL SPECIFICATION VOL-II
+ + + +
+ + + +
+ + +
Page 21 of 22
CLAUSE NO.
GENERAL TECHNICAL CONDITIONS 28. 10kVA 1phase 11/240V Distribution Transformer 29. 16kVA 1phase 11/240V Distribution Transformer 30. 16kVA 3phase 11/433V Distribution Transformer 31. 25kVA 3phase 11/415V Distribution Transformer 32. Common Mtere Reading Instrument(CMRI) 33. LT ABC 34. AAAC/ AAC/ACSR conductor 35. Piercing connector, UDC 36. LT Power cable 37. Capacitor 38. Battery & Charger 39. Control Panel 40. ACDB & DCDB + : : To be submitted with the bid. Not Required. + + +
+ + + + + + + +
+ + + + + + + +
+ + + + + + + +
Page 22 of 22
CLAUSE NO.
GENERAL CONSTRUCTIONAL PRACTICES (SERVICE CONNECTION)
1.01.00
L.T. CONSUMER CONNECTION FROM SERVICE POLE The contractor shall provide the service connections to the identified households. The service connection shall be complete with energy meters in consumers premises. Service Connection shall be provided with PVC insulated 650/1100 V grade, twin core Aluminum solid Conductors of size 2.5 sq.mm (3/22 cu equivalent) these wires shall be supported by a bearer GI wire (3.15 mm) as per REC Spec. No. 45/1986. Cable shall be tied to bearer wire with an insulated (Porcelain) ring of adequate size and strength. REC construction standard H-1 shall be followed for extending service connection. The bidder shall provide his own arrangements for anchoring the bearer wire at the premises of customers in case of BPL households.
1.02.00
Consumer Connection Where lines with ABC Locations on L.T. main lines (both single and 3 phase - 4 wire) having ABC, where consumer connections (or service connection) is to be provided, following arrangement shall be adopted, depending upon the number of connections / consumers to be served from one pole.
1.03.00 1.03.01
HOUSE WIRING For all the identified BPL households, the contractor shall carry out complete works of house wiring with installation of energy meter as per enclosed drawing ISI marked Double Pole MCB of 5/6Amp rating with breaking capacity of 9/10KA shall be used . ISI marked PVC conduit with single core 2.5 sq mm. ISI marked aluminum wire shall be used for house wiring. Single point wiring for a lighting point shall include one piano type ISI marked 5A switch, Bakelite/plastic holder, one no of ISI marked 11Watt CFL Lamp. Earthing terminal on the meter board shall be connected to the pole earthing through the GI support wire for service connection Consumer connection from AB cable shall be through suitable piercing connector. Consumer connection from bare conductor phase and neutral shall be tapped using LTservice connectors as per REC standard E-38
1.03.02
1.03.03 1.03.04
1.03.05 1.03.06
TECHNICAL SPECIFICATION VOL-II (Part-D)
CHAPTER-II SECTION-E0
GENERAL CONSTRUCTIONAL PRACTICES (SERVICE CONNECTION)
Page 1 of 2
CLAUSE NO.
SINGLE PHASE WHOLE CURRENT ENERGY METER SCOPE This specification covers design, engineering, manufacture, inspection, testing at manufacturers works including type testing before dispatch, supply and delivery of electronic single phase whole current Active Energy meters for installation at premises of BPL consumers.
1.00.00
2.00.00
APPLICABLE STANDARDS Energy Meters shall completely meet the stipulated requirements of following standards: 1. IS-13779, with latest amendment
2.01.00 2.01.02
General Requirements Climatic Conditions i) ii) iii) iv) Temperature Humidity Average Annual Rainfall Max. Altitude above MSL : : : : 10oC to 55o C (in shade) Upto 95% RH non-condensing 150 cm (if not specified otherwise) 500 meters
3.00.00 3.00.01
DESIGN AND CONSTRUCTIONAL FEATURES Location The Energy meters shall be supplied suitable for out door installation.
3.01.00 3.01.01
Design The meters shall be suitably designed (for a long normal operating life), treated for normal life and satisfactory operation under the hot and hazardous tropical climate conditions and shall be dust and vermin proof. All the parts and surface, which are subject to corrosion, shall either be made of such material or shall be provided with such protective finish which provides suitable protection to them from any injurious effect of excessive humidity. The offered energy meter shall meet the requirements of IP 51 degree of protection. (IS: 12063). The case, winding, voltage circuit, sealing arrangement, registers, terminal block, terminal cover and nameplate etc. shall be in accordance with IS: 13779 (latest version). The meter shall be compact and reliable in design, easy to transport and immune to vibration and shock involved in transportation and handling. The construction of the meter shall ensure consistent performance under all conditions
RGGVY WORKS TECHNICAL SPECIFICATION VOL-II (Part-D) CHAPTER-II SECTION-E1
SINGLE PHASE WHOLE CURRENT ENERGY METER
3.01.02
STANDARD TECHNICAL
SPECIFICATION (REV.- 03)
Page 1 of 17
CLAUSE NO.
SINGLE PHASE WHOLE CURRENT ENERGY METER especially during dust storm/heavy rains/very hot weather. The insulating material used in the meter should be non-hygroscopic, non-ageing and of tested quality. The meter should be sealed in such a way that the internal parts of the meter are inaccessible.
3.01.03
The meter shall be based on digital measuring and sampling technique and shall employ latest technology such as Hybrid Micro Circuit or Application Specific Integrating Circuit (ASIC) to ensure reliable performance. The process of mounting components on the PCB (Printed Circuit Board) shall be SMT (Surface Mounted Technology). The integrated circuits used in the meter shall be sourced from reputed international manufacturers, tested and validated/certified to international standards such as Stack/0001 for quality & reliability and shall carry validation certificate from the original designer. All inward flow of major components and sub assembly parts shall have batch and source identification. Multi-layer PCB assembly with PTH using surface mounted component shall have adequate track clearance for power circuits. Complete assembled and soldered PCB should under go functional testing using computerized Automatic Test Equipment Testing at intermediate and final stage to be carried out with testing instruments, duly calibrated with reference standard, with trace ability of source and date. The electronic components used in the meter shall be industrial grade, reputed make and conforming to relevant to international standards such as VDE, IEC, BS, IEEE etc., tropicalized and operated below their thermal and electrical rating under combination of environmental, power supply variations and transient conditions and meet with high quality, performance & reliability standards to ensure trouble free operation in the field. There shall be no drift in the accuracy of the meter at least up to 10 years. Calibration of Meter Meters shall be factory calibrated using high accuracy (0.5 class or better), software based test bench. Energy Meter shall have test output device, accessible from the front, and be capable of being monitored with suitable testing equipment while in operation at site. Resolution of the device shall enable the starting current test in less than 10 minutes.
3.01.04
3.02.00
3.03.00 3.03.01
Construction Meter Case and Cover a) To ensure high reliability, long trouble free life, safety against electric shock, spread of fire and effects of excessive temperature, the meter casing and cover shall be made of high quality industrial grade polycarbonate material having adequate strength, which is unbreakable, corrosion resistant & inert to chemicals, flame retardant, immune to ultra violet radiation and meet UV ageing test as per relevant ASTM standards.
TECHNICAL SPECIFICATION VOL-II (Part-D) CHAPTER-II SECTION-E1
RGGVY WORKS
STANDARD TECHNICAL
Page 2 of 17
CLAUSE NO.
SINGLE PHASE WHOLE CURRENT ENERGY METER b) The bidder shall indicate hardness, melting temperature and tensile yield strength of the material and necessary test certificate of the same shall be furnished. The polycarbonate material used shall conform to the test requirement of heat deflection test as per ISO 75 and glow wire test as per the relevant Standard. The meter shall be provided with adequate shielding to withstand external magnetic influence from all directions as per latest amendments of IS 13779 Meter cover shall be continuously ultra sonically welded with meter base from all sides. Suitable locking arrangement shall be provided between the base and cover of the meter.
c)
d)
e)
3.04.00
Sealing Arrangement Meter cover shall be continuously ultra sonically welded with meter base from all sides. so that once the meter is manufactured and tested at factory, it should not be possible to open the cover at site except the terminal cover ..Necesssary provision shall be kept for fixing the utility seal on the terminal cover. The bidder shall supply the utility seal for the terminal cover. Terminal Block and Cover
3.05.01
The terminal block shall have adequate insulating properties and mechanical strength. The terminal block shall be made from best quality non-hygroscopic, flame retardant polycarbonate material (capable of passing the flammability tests give in IS : 11731) with nickel-plated brass studs for connecting terminals. The terminal block is to be enclosed in a metallic housing of steel plate of sufficient thickness to cover its back and sides and provide enough strength for the purpose of tightening of screws. Clamping screws should be provided inside the terminal cover and should have metallic sleeve moulded within the block to avoid damage during tightening of the screws. The terminals in the terminal block shall be of long socket type suitable for connection of cables with aluminium conductors along with suitable lugs (lugs to be provided by the supplier) having upto 16sq. mm cross sectional area, with adequate length. Double screw arrangement shall be provided to achieve adequate termination. All terminals and connecting screws and washers shall be of tinned / nickel plated brass material. The terminal cover shall be transparent with minimum thickness 2.5 mm and the material shall be same as that of meter case. It shall be of extended type and accommodate, in addition to the terminal block, a suitable length of external cable along with its insulation.
3.05.02
3.05.03
3.05.04
RGGVY WORKS
STANDARD TECHNICAL
Page 3 of 17
CLAUSE NO.
SINGLE PHASE WHOLE CURRENT ENERGY METER Name Plate and Marking 3.06.01 Every meter shall have nameplate clearly visible and indelible and distinctly marked in accordance with IS : 13779 (latest version). The following information shall appear on a nameplate preferably placed within the meter. Manufacturers name & trade-mark and place of manufacture. Serial number and year of manufacture. Designation of type. Number of phases and number of wires for which the meter is suitable. Guarantee period. Owners name & meter number. Principal unit in which the meter records. Reference voltage & frequency in Hz. Basic current and rated maximum current. Meter constant. Class index. Project Name : RGGVY ISI marking as per statutory requirement
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 3.07.00
Fixing Arrangement Every meter shall have three fixing holes one at the top and two at the bottom. Display Module The measured value(s) shall be displayed on a Liquid Crystal display (LCD) register. The height of the digit shall be minimum 8.5 mm. The KWh energy registration shall take place with 6 complete digits. The display shall have backlit capability for easy reading.
4.01.00.
Measuring Parameters 1) 2) 3) 4) Real time & date Instantaneous voltage Instantaneous current Instantaneous active load
RGGVY WORKS
STANDARD TECHNICAL
Page 4 of 17
CLAUSE NO.
SINGLE PHASE WHOLE CURRENT ENERGY METER 5) 6) Active Energy Maximum demand with date & time
4.02.00
DISPLAY SEQUENCE The meter shall display the required parameters in two different modes as follows: A) Auto Display Mode:
The following parameters shall be displayed in an auto-cycle mode, in the following sequence:1. 2. 3. 4. 5 6. 7. LCD Test Real Time Date Cumulative Active energy (forwarded) reading (kWh) Instantaneous Load (KW) Last month Maximum demand (kW) with its occurring date and time Meter ID
Each parameter shall be on meter display for 10 seconds B) Push Button Mode:In addition to the auto display mode parameters, the following parameters shall be displayed on pressing the push button 1. 2. 3. 4. 5. 6. LCD Test Real Time Date Instantaneous voltage, current Last Month Active Forwarded energy(kWh) Maximum demand kW for Current month with its occurring date and time
RGGVY WORKS
STANDARD TECHNICAL
Page 5 of 17
CLAUSE NO.
SINGLE PHASE WHOLE CURRENT ENERGY METER 7. 8. Supply Frequency Meter ID
4.03.00
STORAGE AND DOWNLOADING FEATURES The data should be stored in non-volatile memory (NVM) with a data storage capacity of at least 60 days with all data captured by the meter including tampers. The nonvolatile memory should retain data for a period of not less than 5 years under unpowered condition. Battery backup memory will not be considered as NVM. In addition to providing serial number of the meter on the display plate, the meter serial number shall also be programmed into meter memory for identification through communication port for CMRI/meter reading print out.
4.03.01
Downloading parameters it should be possible to also download the following data through optical port. 1. Cumulative Active energy (KWh) for each Calender month for previous six months Maximum demand (KW) in a Calender month for previous six months with occurring date and time Cumulative Active Energy during each time zone (KWh) for each calendar month for previous six months. Maximum demand in kW in a calendar month during each time zone for each calendar month for previous six months. Half Hourly logging of kW,kVA, and voltage. Half Hourly logging of kWh (cumulative). Duration Of power availability or power outage in minutes during each half hour duration.
2.
3.
4.
5. 6. 7.
4.03.02
CUMULATIVE ENERGY REGISTER Meter should have provision for automatic recording of cumulative Active energy & MD in Active Power (MW) at 24.00 hours on the last day of the month for each of the past six calendar months and same to be stored in the register/memory. The maximum demand shall automatically reset at 24:00 hrs. of the last date of each calendar month .
RGGVY WORKS
STANDARD TECHNICAL
Page 6 of 17
CLAUSE NO.
SINGLE PHASE WHOLE CURRENT ENERGY METER LOAD PROFILE RECORDING The meter shall be capable of monitoring and recording load profile information for KW demand for every 30 minutes interval for at least 30 days duration.
4.03.03
5.00.00
REAL TIME CLOCK (RTC) RTC shall be pre-programmed for 30 Years Day/date without any necessity for correction. Maximum drift shall not exceed +/- 300 Seconds per year. Time & date setting shall only be possible through .Common Meter Reading Instrument (CMRI)
5.01.00
RTC CLOCK DAY/DATE SYNCHRONISATION Synchronisation of Energy Meter RTC shall be done thru CMRI with password protection.
6.00.00
MAXIMUM DEMAND INTEGRATION PERIOD Energy Meter shall continuously monitor and calculate the average maximum demand for each demand interval time of 30 minutes and maximum of these in a calendar month shall be stored along with date and time when it occurred.It shall however be possible to change the demand integration period (DIP), from 30 to 15 minutes at site, through CMRI or laptop with proper security. The Maximum demand of past six months shall be stored in the memory with date and time. It shall be possible to retrieve this data through communication port and CMRI or MRI.There shall be no resetting button for MDI data and resetting shall be possible, on request, via CMRI connection with password enabled access only.
7.00.00
COMMUNICATION FACILITIES & STANDARDS Manufacturers to provide Application Program Interface (API) suitable for the meter for interoperability software. The Interoperability software shall provide common framework for data collection and conversion to XML format. The media copy of software, required for down loading the information to a user friendly Windows/LINUX based operating system, of Purchasers billing computer system (BCS), Substation data logger PC system thro CMRI shall be furnished in required number of copies (On CD) without any additional cost to the Purchaser.
RGGVY WORKS
STANDARD TECHNICAL
Page 7 of 17
CLAUSE NO.
SINGLE PHASE WHOLE CURRENT ENERGY METER PORT AND CONNECTION ARRANGEMENT LOCAL COMMUNICATION PORT i. The energy meter shall have a galvanically isolated optical communication port as per ICC 62056 -21 or any other internationally accepted port, located in front of the meter, for data transfer to or from a hand held data Collection Device (Common Meter Reading Instrument- CMRI-conforming to CBIP technical report-111) with proper security and without error.
8.00.00 8.01.00
9.00.00
CMRI/MRI REQUIREMENT Meter data should be downloaded/uploaded through CMRI specified for DT meter.
10.00.00
EVENT RECORD The meter should have features to detect the occurrence and restoration of the magnetic influence more than 0.2T with date & time stamping & shall be available on demand. Last twenty events shall be available on First came first out basis. The meter shall be capable of recording the following tamper events in memory (minimum 5 each) with date and time stamp along with snapshots of V, I, and Kwh. -Current reversal -Neutral Disturbance The meter shall also have provision for detection and logging of opening of meter cover.
11.00.00 11.01.00
ANTI TAMPER FEATURES Meters shall at least be immune to tampers elaborated in the Attached diagram (Annexure B) Successful bidder / his manufacturer / Supplier shall demonstrate then features during type testing of the meters in his works on reputed Lab. INFLUENCE QUANTITIES The meter shall work satisfactory with guaranteed accuracy as per limit of IS: 13779 (with latest amendments) under presence of the following quantities: 1.
RGGVY WORKS
11.02.00
12.00.00 12.01.00
External magnetic field

STANDARD TECHNICAL
Page 8 of 17
CLAUSE NO.
SINGLE PHASE WHOLE CURRENT ENERGY METER 2. 3. 4. 5. 6. 7. 8. Electromagnetic field Radio frequency interference Vibration Harmonic wave form Voltage fluctuation Electromagnetic high frequency field DC component input supply
12.02.00
The following LED indications visible from the front are mandatory: i. Power on indication / Test output pulse
13.00.00
ACCURACY In case any drift is noticed in the accuracy of the meter, which is beyond the permissible limits, the concerned meter shall be with drawn from service and Bidder shall supply a new meter without any extra cost as a replacement (with in one month of receipt from owner), during the guarantee period i.e. 5 years from supply.
14.00.00
INSPECTION, TESTING AND DISPATCH Bidder shall submit a detailed Quality plan along with his bid (with customer hold points), to be implemented for owners review and approval. A sample of manufacturers quality plan document is enclosed in this specifications. The contractor shall carry out all routine and acceptance tests in presence of owners representative. For carrying out acceptance tests as per the IS the sample plan shall be as per IS 13779
14.01.00
Type Tests (Table 20 of IS: 13779) The Type Test Certificate of meter having identical design (Display, recording,logging,tamper protection etc.) shall not be more than 2 years old. The testing should have been as per IS: 13779. (as per latest amendments) and carried out at an independent Govt. recognized ,NABL accredited test laboratory in India. The Type Test Reports shall clearly indicate the constructional features of the type tested meters The type test report should contain the make of major component used in meter subjected to type test i.e, ASIC, CT, Display module, LCD, Shunt, Memory chips, Communication module ,optical port, Power supply and Battery etc. failing to which
RGGVY WORKS TECHNICAL SPECIFICATION VOL-II (Part-D) CHAPTER-II SECTION-E1
STANDARD TECHNICAL
Page 9 of 17
CLAUSE NO.
SINGLE PHASE WHOLE CURRENT ENERGY METER owner reserves the right to send samples for type test from offered lot without any additional cost implication.
14.02.00
Acceptance and Routine Tests ( Table 20 of IS: 13779) Tests as prescribed in IS:13779 Test certificate for each energy meter with details of meter along with corresponding test results shall be issued by the manufacturer. One copy of test certificate shall be kept in the individual meter package for customers reference and another copy shall be given to the owner. A soft copy in the form of CD with test certificates for all meters, shall be provided to the owner at the end of delivery of all the meters.
15.00.00 15.01.00
INSTALLATION & COMMISSIONING The static energy meters specified above shall be installed at the premises of various consumers, located in Project Area (List of consumers to be provided by the purchaser after award of work). The exact location and time-table for Installation shall be finalized by the owner and furnished to the bidder. The bidder shall be responsible for total installation of the meters. Mounting of the meters, connection of input & output cables to the meters including required wiring, commissioning and handing over shall be the responsibility of the bidder. The Bidders personnel shall carry the necessary tools, equipment, materials and consumables (including insulated wires, lugs, ferrules, hardware etc.). QUALITY ASSURANCE PLAN The bidder (manufacturer) shall have a comprehensive quality assurance program at all stages of manufacture for ensuring products giving reliable, trouble free performance. The bidders (manufacturers) quality assurance plan shall be submitted along with bid document, which would be reviewed in detail by the owner in case of award and accepted with modifications, as felt necessary. The sub-bidders quality assurance programme shall generally cover the following. i) Bidder organization structure for the management implementation of the proposed quality assurance programme. Quality System Manual Design Control System Documentation Control System and
15.02.00
16.00.00 16.01.00
16.02.00
ii) iii) iv)
RGGVY WORKS
STANDARD TECHNICAL
Page 10 of 17
CLAUSE NO.
SINGLE PHASE WHOLE CURRENT ENERGY METER v) The procedure for purchase of materials, parts, components, source inspection, incoming raw-material inspection, verification of materials purchased etc. System for process controls and fabrication and assembly controls Inspection and test procedure both for manufacture and field activities Control of calibration and testing of measuring/testing equipments. System for Quality Audits. System for handling storage and delivery.
vi) vii) viii) ix) x) 16.03.00
The sub-Bidder is meter manufacturer shall accordingly furnish along with the bid i) A comprehensive quality assurance plan which is in practice (for both product & process). A detailed list of bought out items with name of the manufacturer and details about in coming quality control. Quality assurance plan of bidders collaborators in case of foreign collaborators.
ii)
iii)
16.04.00
Owner reserves the right to carry out quality audit and quality surveillance of the systems and procedure of the bidders quality management & control activities. The bidders shall provide all necessary assistance to enable the owner to carry out such audit & surveillance. MANUFACTURING AND TESTING FACILITIES The following Manufacturing and testing facilities shall be available. * * The factory shall be completely dust proof. The testing rooms shall be temperature and humidity controlled as per relevant Standards. The testing and calibrating equipment should be automatic and all test equipment shall have their valid calibration certificates Power supplies used in testing equipment shall be distortion free with sinusoidal waveforms and maintaining constant voltage current and frequency as per the relevant Standards.
17.00.00
RGGVY WORKS
STANDARD TECHNICAL
Page 11 of 17
CLAUSE NO.
SINGLE PHASE WHOLE CURRENT ENERGY METER During the manufacturing of the meters following minimum checks shall be carried out. a) b) Meter frame dimension tolerance shall be minimum. The pressure coil shall be made totally encapsulated and care shall be taken to avoid ingress of dust and moisture inside the coil. The assembly of parts shall be done with the help of jigs and fixtures so that human errors are eliminated. The meters shall be batch tested on automatic, computerized test bench and the results shall be printed directly without any human errors. The current coil shall be made with the help of jigs and fixtures. The potential coil shall be made with automatic computerized machine
17.01.00
c)
d)
e) f)
17.02.00
The meter shall be supplied as per the standard Guaranteed Technical Parameter enclosed at Annexure-C
RGGVY WORKS
STANDARD TECHNICAL
Page 12 of 17
CLAUSE NO.
SINGLE PHASE WHOLE CURRENT ENERGY METER ANNEXURE-A SPECIFICATION FOR POLY CARBONATE SEALS REQUIRED FOR SEALING OF ENERGY METER
1.00.00
Specification of Poly carbonate seals required for sealing of single phase energy meters Seal should be made of polycarbonate with ultra violet additive & should not be affected by boiling water & acid. The seal should withstand temperature up to 1470C. Seal should be available in Clear / Red / Blue / Yellow / Amber / Green / Grey colour and should be transparent. Every seal should have 6 inch long, 20 gauge, twisted strand stainless steel wire. Seal should have facility to print mono gram / name of company. Every Seals should have a unique seven-digit number. Numbers shall be printed on seal which shall not be erased using any tool or by any chemical reaction. both the seven digit seal numbers should be visible separately after closing the seal. Seals should have tamper proof, internal anchor locking mechanism that permanently secures the wire upon closing. The mechanism should be designed in such a way that its original position cant be restored after any effort of tamper or breaking of seals. Sealing mechanism shall be designed in such a way that it can be sealed without using any pliers or tools. Seal should be constructed of two parts, first the main body (female type) & second the anchor (male type) having locking mechanism. Both the part should be designed in such a way that once the seal is closed the two parts cant be separated. Seal should be patented. Copy of patent shall be submitted along with offer. Packaging : Seals shall be supplied in packet of 100 seals. Each packet shall be labelled for following information. * * * Client Name Purchase Order Number & Date Serial number range in the form of bar coding.
1.01.00
1.02.00 1.03.00
1.04.00 1.05.00 1.06.00
1.07.00
1.08.00
1.09.00
1.10.00 1.11.00
RGGVY WORKS
STANDARD TECHNICAL
Page 13 of 17
CLAUSE NO.
SINGLE PHASE WHOLE CURRENT ENERGY METER ANNEXURE-B
RGGVY WORKS
STANDARD TECHNICAL
Page 14 of 17
CLAUSE NO.
RGGVY WORKS
STANDARD TECHNICAL
Page 15 of 17
CLAUSE NO.
SINGLE PHASE WHOLE CURRENT ENERGY METER ANNEXURE-C Guaranteed Technical particulars for single phase consumer meter
Sr No
Description
1 Type Standard to which the meter 3 conforms IS 13779:1999 4 Rated Voltage 5 Rated Current 7 Frequency 8 Power Factor Completely type tested to 9 lS13779 Minimum starting current 10 in % of Base Current Maximum Continuous 11 Current Power consumption in 12 current and voltage circuit 13 Accuracy class. 14 Change in error due to
Particular Single Phase Static Whole Current Type with Mechanical Counter
1 Ph 240 V+20% to -40% 5A 50 Hz +/- 5% Zero to Unity(both Lagging and Leading) Yes 0.2% Of Ib 400% of Ib (20 A) As per IS 13779:1999 (with latest Amendment) 1 As per IS 13779:1999 (with latest Amendment)
a) Variation in frequency As per IS 13779:1999 (with latest Amendment) b) Variation in Temperature As per IS 13779:1999 (with latest Amendment) c) Variation in Voltage As per IS 13779:1999 (with latest Amendment) 15 Limit of accuracy One minute Power frequency withstand 16 Voltage Compliance to EMC&EMI 17 as per 18 Basic insulation level Current rating of the 19 terminal
RGGVY WORKS
As per IS 13779:1999 (with latest Amendment)
As per IS 13779:1999 (with latest Amendment) As per IS 13779:1999 (with latest Amendment) As per IS 13779:1999 (with latest Amendment)
STANDARD TECHNICAL
Page 16 of 17
CLAUSE NO.
SINGLE PHASE WHOLE CURRENT ENERGY METER 20 Maximum size of cable, which can be connected at terminals Terminal Block material
22
23
24 25
16 Sq mm The material of which the terminal block is made shall be capable of passing the test given in ISO 75-1(1993) and ISO 75-2(1993) for a temperature of 135C and a pressure of 1.8 Mpa(Method A) Resistance to Heat and Fire The test will be carried out accordinng to IS 11000 (Part2 /Sec-1)With the following temperature Terminal Block 960 15C, Terminal cover and Meter case 650 10C,Duration of Application 30 S 1S Degree of protection against dust and water IP-51 Type of display LCD (Backlit) 5+1 LED Yes
i. No. of digits 26 27 28 Test output type Ultrasonic welding of meter cover Whether provision for terminal cover sealing exists Number of digits up to which meter can register List of component used in meter shall be provided . Make shall be NESCL Corporate Quality Assurance(CQA) Approved
Yes 5+1 Yes
29 30 31
RGGVY WORKS
STANDARD TECHNICAL
Page 17 of 17
CLAUSE NO.
LT CABLES SCOPE This specification covers manufacture, design, testing and despatch of PVC Insulated LT cables for use as Service Cable
1.00.00
2.00.00
APPLICABLE STANDARDS The PVC insulated LT cables shall comply with the latest versions of the following Standards. Sl. No. A) i) Size Service cables Twin core unarmoured Al cable IS:694 (Part-II) (PVC Insulated Cables for working voltages upto and including 1100 V with aluminium conductors) Type Use
3.00.00 3.01.00
SIZE AND TYPE The size and type of PVC insulated LT cables for different applications under this project, shall be as in the following table: Sl. No. A I Size Service Cables 2.5 mm2 Twin-core (unarmoured) as per IS : 694-Pt-II Single-phase service connections upto 2 kW connected load Type Use
4.00.00
SHAPE OF CABLE All twin-core cables shall be of flat shape and single core cables of circular shape.
5.00.00 5.01.00 5.02.00 6.00.00
CONDUCTORS Aluminium conductor complying with IS:8130-1976 shall be used. The conductors of service cables shall be solid. TESTS All the type tests, acceptance tests and routine tests shall be carried out as per the relevant I.S.
TECHNICAL SPECIFICATION VOL-II (PART C)
CHAPTER-II SECTION-E6 LT CABLES
Page 1 of 3
CLAUSE NO.
LT CABLES PACKING Service cables shall be packed in coils of 500 metres length each. Each coil shall be protected against damage by polythene wrapping. MARKING The following information shall be contained in a label attached to the coils in case of service cables : a) b) c) d) e) f) g) h) i) j) Manufacturers name, brand name or trade mark Type of cable and voltage grade Number of cores Nominal cross-sectional area of conductor Length of cable on reel/drum or coil Direction of rotation of drums (by means of an arrow) Approximate gross weight Country of manufacture Year of manufacture and RGGVY work by NTPC Electric Supply Co. Ltd., NOIDA.
7.00.00 7.01.00 8.00.00
9.00.00
INSPECTION All routine and acceptance tests and inspection shall be made at the place of manufacture. The manufacturer shall afford the inspector, representing the purchaser, all necessary facilities (without charge) to satisfy him that the material is being supplied in accordance with the Specification.
Page 2 of 3
CLAUSE NO.
LT CABLES
10.00.00
GAURANTEED TECHNICAL PARAMETERS The following gauranteed technical parameters shall be applicable
S.No 1 Particulars Size Type Applicable standards Voltage Grade (Volts) Conductor Material Flexibility class as per IS:8130/84 Form of conductor Nominal Corss-sectional Area of Conductor (sq mm.) No. of strand / min. strand dia (mm) Max. D. C resistance of conductor at 200 C(ohm/km) Number of cores (Nos.) Identifcation of power cores Insulation Material Nominal Insulaton thickness(mm) Outer Sheath Material Nominal Thickness (mm) Application Colour 7 i ii iii 8 Continious Current rating of Cable (amperes) In Ground in Duct In Air Maximum Overall Diameter of cable VALUE 2CX2.5 Twin Core Flat AYY IS:694/90, IS:8130/84,IS:5831/84 1100 Aluminium EC Grade (H2/H4) Class-1 Solid circular 2.5 1/1.78 12.1 2 Red& Black PVC Compound Type-A 0.7 PVC Compound Type-ST1 1.00 Extruded Black (As per IS 3961 Table-3) 25 21 21 10 x 6.4 mm 500 + / - 5% ( Non standard length of the cable shall be supplied in one reel) IS:694/90 Yes
2 3 4 i ii iii iv v vi vii viii 5 i ii 6 i ii iii iv
9 10 11
Standard Length of Cable (meter) Packing and Marking progressive marking for every 1 meter length
Type test reports (all mentioned in relevant clause)
COMPLIED
Make shall be NESCL Corporate Quality Assurance (CQA) approved.
Page 3 of 3
CLAUSE NO.
GENERAL CONSTRUCTIONAL PRACTICES SURVEY AND GEO TECHNICAL INVESTIGATION The bidder shall carry out detailed survey and Geo Technical Investigation of the area as per specification given else where in this document for finalization of the following: a) The lay out of the sub-station as per the enclosed single line diagram, boundary Fencing location of 33 and 11 kV bays control room, incoming and outgoing 33/11kV lines, culverts, roads etc. Design the foundation of control room building and foundation of various equipments. To design the earth grid system for the sub-station. Herel profile of new sub station aria with relation elevate making of existing road or other existing place surface,
1.00.00 1.01.00
b) c) d) 2.00.00 2.01.00
STRUCTURAL All the supports shall be of GI lattice structure of suitable cross section for new 33/11kV Substation. Augmentation of existing 33/11kV Substations by adding new bays shall be with MSJoist structures. Minimum strength of structural concrete shall be M20 conforming to IS :456. Blinding concrete below foundations, cable trenches, shall be PCC of minimum grade M-7.5. Blinding concrete under brick foundations shall be minimum 150 mm thick in PCC of minimum grade M-10. SPECIFIC REQUIREMENT FOR EARTHING SYSTEMS Each earthing lead from the neutral of the power transformer shall be directly connected to two pipe electrodes in treated earth pits, which in turn and shall be connected to station earthing grid. Earthing of all equipment support structures, equipment, switchyard fence etc. shall be made through rod electrodes shall be buried in cement concrete pit with a cast iron cover hinged to a cast iron frame to have an access to the joints. Earthing terminal of each lightning arrester, and lightning down conductors shall be directly connected to pipe electrode with treated pit which in turn shall be connected to station earthing grid.
2.02.00
2.03.00 2.04.00 2.05.00
3.00.00 3.01.00
3.02.00
RGGVY WORKS STANDARD TECHNICAL SPECIFICATION (REV.- 03) PRACTICES
TECHNICAL CHAPTER-II SPECIFICATION SECTION-E0 VOL-II (PART B) GENERAL CONSTRUCTIONAL
Page 1 of 11
CLAUSE NO.
GENERAL CONSTRUCTIONAL PRACTICES LIGHTNING PROTECTION Lightning protection system installation shall be in strict accordance with the latest editions of Indian Electricity Rules, Indian Standards and codes of Practice and Regulations existing in the locality where the system is installed. Direct stroke lightning protection (DSLP) shall be provided in the switchyard by GI wire of suitable size mounted on switchyard structures. 25 mm dia. 1000 mm long GI rod electrode shall be provided with each lightning mast. Lightning protection system down conductors (insulated 1.1kV grade PVC cable of 1Cx6 sq.mm shall not be connected to conductors of earthing grid above ground level. Connection between each down conductor and rod electrodes shall be made via joints located approximately 1500 mm from ground level. The joints shall be directly connected to the earthing system. Down conductors shall be cleated at the structures at 1000 mm interval. BAY EQUIPMENT AND LAYOUT The disposition of major equipments is shown in enclosed single line diagram. The equipment connections are to be with ACSR panther conductor(Bus) conforming to relevant IS.The equipment spacing shall be so chosen that adequate safety clearances as well as working clearances are available and all requirements of codes and standards indicated elsewhere are complied with. In case of bay addition in existing sub station the Bus conductor shall match the existing conductor type & size of the substaion. EQUIPMENT ERECTION All support insulators, circuit breaker interrupters and other fragile equipment shall preferably be handled with cranes with 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. For cleaning the insulators only muslin or leather cloth shall be used. Handling equipment, sling ropes etc. should be tested before erection and periodically for strength.
4.00.00 4.01.00
4.02.00
4.03.00
4.04.00
4.05.00
4.05.00 5.00.00 5.01.00
5.02.00
6.00.00 6.01.00
6.02.00
6.03.00 6.04.00
Page 2 of 11
CLAUSE NO.
GENERAL CONSTRUCTIONAL PRACTICES The Contractor shall arrange at site all the equipment, instruments and auxiliaries required for testing and commissioning of equipment. STORAGE OF EQUIPMENT The Contractor shall provide and construct adequate storage shed for proper storage of equipment. Weather sensitive equipment shall be stored indoors. All equipment during storage shall be protected against damage due to acts of nature or accidents. The storage instruction of the equipment manufacturer/Owner shall be strictly adhered to.
6.05.00
7.00.00
8.00.00 8.01.00
INSTALLATION OF CABLES 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. a) b) Power cables on top tiers. Control cables in bottom tiers.
8.02.00
All power cables shall be laid with a minimum center to center distance equal to twice the diameter of the cable. Power and control cables shall be securely fixed to the supports. Cables shall not be bent below the minimum permissible limit. The minimum bending radius of power cables shall be 12D and that of control cables shall be 10D, where D is overall diameter of cable. Where cables cross roads, drains and rail tacks, the cables shall be laid in reinforced spun or steel pipes, buried at not less than one meter depth. In each cable run some extra length shall be kept at a suitable point to enable one (for LT Cables) or two (for H.T. cables) straight through joints to be made, should the cable develop fault at a later date. Selection of cable drums for each run shall be so planned as to avoid using straight through joints & splicing. Control cable terminations inside equipment enclosures shall have sufficient lengths so that switching of termination in terminal 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.
8.03.00 8.04.00
8.05.00
8.06.00
8.07.00
8.08.00
8.09.00
Page 3 of 11
CLAUSE NO.
GENERAL CONSTRUCTIONAL PRACTICES All due care shall be taken during unreeling, laying and termination of cable to avoid damage due to twist, kink, 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 or practices. Wherever cables pass through floor or through wall openings or other partitions, wall sleeves with bushes having a smooth curved internal surface shall be used so as not to damage the cables.These sleeves shall be supplied, installed and properly sealed at no extra charges. The erection work shall be carried out in a neat workmanlike manner and the areas of work shall be cleaned of all scrap materials after the completion of work in each area every day. Contractor shall remove the RCC/steel trench covers before taking up the work and shall replace all the trench covers after the erection work in that particular area is completed or when further work is not likely to be taken up for some time. In case the outer sheath of a cable is damaged during handling/installation, the Contractor shall repair it at his own cost, and to the satisfaction of the Engineer-inCharge. In case any other part of a cable is damaged, the same shall be replaced by a healthy cable, at no extra cost i.e. the Contractor shall not be paid for supply, 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 type, sleeve or paint. CONDUITS, PIPES AND DUCT INSTALLATION Contractor shall supply and install conduits, pipes as specified and as shown in detailed drawings. Flexible conduit should be used between fixed conduit and equipment terminal boxes. Where vibration is anticipated, the flexible conduit shall be as per the relevant IS. Contractor shall have his own facility for bending cutting and threading the conduits at site. Cold bending should be used. All conduit/pipes shall be extended on both sides of wall/floor/openings. Exposed conduits/pipes shall be adequately clamped at an interval of about 2 m. The fabrication and installation of supports and the clamping are included in the scope of work. For underground runs, Contractor shall excavate and back fill as necessary.
TECHNICAL CHAPTER-II SPECIFICATION SECTION-E0 VOL-II (PART B) GENERAL CONSTRUCTIONAL Page 4 of 11
8.10.00
8.12.00 8.13.00
8.14.00
8.15.00
8.16.00
8.17.00
9.00.00 9.01.00
9.02.00
9.03.00
9.04.00
CLAUSE NO.
GENERAL CONSTRUCTIONAL PRACTICES JUNCTION BOXES Contractor shall supply and install, wherever required, junction boxes complete with terminals as required. The brackets, bolts, nuts and screws required for the erection shall be included in the installation price.
10.00.00
11.00.00 11.01.00
INDOOR & OUTDOOR LIGHTING Average lux level measured at equipment level to be maintained in various areas and type of fittings to be use are given as under` 1 Location Street light Sub-Station outdoor Control/Switchgear room Battery room Emergency DC Control room 20 Incandascent Lamp Avg. Lux level 10 20 150 150 Type of Fixture HPSV HPSV Fluorescent lamp Fluorescent lamp
Street light shall be provided by mounting fixtures on structures/use of 9mtr swan poles. Indoor lighting shall be provided by use of 36 watt slim type fluorescent lamp fittings. Yard lighting shall be provided on the substation gantry/ towers. Substation having augmentation with power transformers shall be provided with light fixture on the existing/new structure.
12.00.00 12.01.00
FIRE FIGHTING EQUIPMENT Fire Buckets Filled With Sand Buckets filled with sand shall be installed at two place in new substation 1 In control room 2 In switchyard near power transformer. There shall be 3 no. of buckets at each location in a substation. The buckets shall be hanging on a steel stand. The buckets and the stand shall be as per relevant standards and will be filled with sand
12.02.00
Fire Extinguishers Fire extinguishers of the following types shall be provided in the control room of new substation. 1. Carbon dioxide type 1nos -22.5Kg capacity mounted on trolley 2. Dry chemical powder type- 2nos- 5Kg portable type
Page 5 of 11
CLAUSE NO.
GENERAL CONSTRUCTIONAL PRACTICES Portable type extinguishers shall be provided with suitable clamps for mounting on walls or columns for dry chemical powder type. All extinguishers shall be painted with durable enamel paint of fire red colour conforming to relevant Indian Standards. Carbon dioxide (CO2, type) extinguisher shall conform to IS: 2878.Dry chemical powder type extinguisher shall conform to IS:2171. The trolley mounted carbon dioxide mobile fire extinguisher shall operate in the vertical position, mounted on solid rubber tyre trolley wheels.
13.00.00
SIGN BOARD A sign board of size 4ftx3ft of 2.5mm thick MS sheet shall be fitted near or at the main gate with the following details inscribed on it with suitable letter size. - Rural Electrification Project under Rajiv Gandhi Grameen Vidyuti Karan Yojana of Government of India. -Scheme Implemented by- NTPC Electric Supply Company Ltd. For Name of State Utility -Name of District -Date of Commissioning -Other physical details. The drawing of this board shall be submitted for approval.
14.00.00 15.00.00 15.01.01
EARTHING General Exact location of earthing conductor, earth electrodes and test pits and earthing connections shall be designed to suit the site conditions. Soil resistivity measurements to be taken. Neutral points of system of different voltages, metallic enclosures and frame works associated with all current carrying equipment and extraneous metal works associated with electric systems shall be connected to a single earthing system unless stipulated otherwise. Earthing system installation shall be strict in accordance with the latest edition of Indian Electricity Rules, relevant Indian Standards and codes of practice and regulations existing in the locality where the system is installed : a) b) c) Code of practice for earthing Code of practice for protection of building and allied structures against lightning. Indian Electricity Rules 1956
15.01.02
15.01.03
IS:3043 IS:2309
CLAUSE NO.
GENERAL CONSTRUCTIONAL PRACTICES DETAILS OF EARTHING SYSTEM Item Size Material 25 mm dia rod 50x6mm GS Flat Mild steel Galvanised
16.00.00
Main earthing conductor Conductor above ground and mild steel earthing leads (for equipment structures etc.) Rod Electrode 16.01.00 16.03.00 16.03.01 16.03.02 16.03.03
25 mm dia
Mild steel
The resistance of earthing system shall be less than 1.0 ohm. The step & touch potential shall be within safe limits. Earthing Conductor Layout Earthing conductors in outdoor area shall be buried at least 600 mm below finished ground level unless stated otherwise. Minimum 600 mm spacing between rod electrodes shall be provided unless stipulated otherwise. Wherever earthing conductors cross cable trenches, underground service products, 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 the equipment/structure if the equipment is available at the time of laying the grid. Otherwise earth insert with temporary wooden cover or earth riser shall be provided near the equipment foundation/pedestal for future connections to the equipment earthing terminals. Earthing conductors along their run on cable trench ladder columns, beams, walls, etc. shall be supported by suitable welding/cleating at intervals of 750 mm. Earthing conductors along cable trenches shall be the wall nearer to the equipment. Wherever it passes through walls, floors, etc. glavanized iron sleeves shall be provided for the passage of the conductor. Both ends of the sleeve 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. In outdoor area, tap connections shall be brought 300 mm above ground level or laid at greater depth to suit conditions. Earthing conductors embedded in the concrete fiber shall have approximately 50 mm concrete cover.
16.03.04
16.03.05
16.03.06
16.03.07 16.03.08
Page 7 of 11
CLAUSE NO.
GENERAL CONSTRUCTIONAL PRACTICES Equipment and Structure Earthing Earthing pads shall be provided by the supplier of apparatus/equipment at accessible position. The connection between earthing pads and the earthing gird shall be made by short and direct earthing leads free from kinks and splices. In case earthing pads are to be provided on the item to be earthed, same shall be provided in consultation with Engineer-in-charge. Whether specifically shown in drawings or not, steel/ RCC columns, metallic stairs etc. shall be connected to the nearby earthing grid conductor by 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 bounded to ensure electrical continuity and connected to earthing conductors at regular interval. Apart from intermediate connections, beginning points shall also be connected to earthing system. 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, lightning conduits, etc. Wherever earthing conductor crosses or runs along metallic structures such as gas, steam, conduits, pipe 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 earthling conductor running along the supply cable which, in turn, shall be connected to the earth in grid conductor at minimum two points, whether specifically shown or not. Railway tracks within switchyard areas shall be bonded across fish plates and connected to earthling grid at several locations. At the point where track leaves the plant area, the rail section shall be provided with insulated joint at both ends. Earthling conductor shall be buried 2000 mm outside the switchyard fence. Every alternate post of the fence and gates shall be connected to earthing grid to ensure continuity. Flexible earthling connectors shall be provided where flexible conduits are connected to ensure continuity. JOINTING Earthling connections with equipment earthling pads shall be bolted type and joint faces shall be galvanized. 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 earthling lead and main earthling conductors, and between main earthling conductors shall be welded/brazed type. For rust protection, the welds should be treated with red lead and afterwards thickly coated with bitumen compound to prevent corrosion.
16.04.00 16.04.01
16.04.02
16.04.03
16.04.04 16.04.05 16.04.06
16.04.07
16.04.08
16.04.09
16.04.10 17.00.00 17.01.01
17.01.02
CLAUSE NO.
GENERAL CONSTRUCTIONAL PRACTICES 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 are welding. All welded joints shall be allowed to cool down gradually to atmospheric temperature before putting any load on it. Artificial cooling shall not be allowed. Bending of large diameter rod/thick conductor shall be done preferably by gas heating. All arc welding with large diameter conductors shall be done with low hydrogen content electrodes. Power Cable Earthing Metallic sheaths and amour of all multicore power cables shall be earthed at both equipment and switchgear end. Sheath and armour of single core power cables shall be earthed at switchgear end only. Specific Requirement for Earthling Systems Each earthing lead from the neutral of the transformer shall be directly connected to two pipe electrodes in treated earth pits, which in turn and shall be connected to station earthing grid. All the rod electrodes shall be buried in cement concrete pit with a cast iron cover hinged to a cast iron frame to have an access to the joints. Earthing terminal of each lightning arrester, and lightning down conductors shall be directly connected to rod electrode which in turn shall be connected to station earthing grid. An auxiliary earthing mat of overall size 1500 mm x 1500 mm, comprising of closely spaced (300 mm x 300 mm) and 300 mm deep conductor shall be provided below the operating handles of the isolator/earthing switch shall be directly connected to the earthing mat. CABLING Cables inside the switchyard shall be laid on angle supports at 600 mm spacing with separate tiers for control and power cables. Cables shall be generally located adjoining the electrical equipment through the pipe insert 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 radii as recommended by the cable supplier shall be maintained. Guidelines for selection of control cable core combination and cable grouping for control and protection application: a) Core size not less than 5 sq.mm shall be used for: i) ii) DC supply circuits All trip connections
17.01.03 17.01.04 17.01.05
17.01.06 17.01.07 18.00.00 18.01.00
18.02.00 18.03.00
18.04.00
18.05.00
19.00.00 19.01.00 19.02.00
19.03.00
CLAUSE NO.
GENERAL CONSTRUCTIONAL PRACTICES b) Connections from CT cores to protection panel shall be through independent cables for each core.
19.04.00 19.05.00 19.06.00
Cables Tags and Markers Each cable and conduit run shall be tagged with numbers that appear in the cables and conduit schedule. The tag shall be of aluminum with the number punched on it and securely attached to the cable conduit by not less than two turns of 20 SWG GI wire conforming to IS:280. Cable tags shall be of rectangular shape for power cables and of circular shape for control cables. The marker shall project 150 mm above ground and shall be spaced at analysis interval 30 meters and at every change in direction. They shall also be located on both sides of road and drain crossings. Specific requirements for cabling for cabling, wiring, ferrules as covered in respective equipment section shall also be complied with. Storage and Handling of Cable Drums Cable drums shall be unloaded, handled and stored in an approved manner. Rolling of drums shall be avoided as far as practicable. For short distances, the drums may be rolled provided they are rolled slowly and in proper direction as marked on the drum. In absence of any indication the drums may be rolled in the same direction it was rolled during taking up the cables. Cable Supports and Mounting Arrangements a) Cable trenches in the control room are normally provided with embedded steel inserts on concrete floors/walls. The Contractor shall secure supports by welding to these inserts or available building steel structures. However, in cases where no such embedded steel inserts are available, the contractor shall have to secure the supports on walls or floors by suitable anchoring to no extra cost to the Owner. Details of fixing steel plates by anchor fasteners shall be decided during detailed engineering stage. 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 Owner. 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. Cost of all consumable material shall be included in the erection rates quoted. The equipment will be generally provided with undrilled gland plates for cables/conduit entry. The Contractor shall be responsible for drilling of gland plates, painting, and touching up. Holes shall not be made by gas cutting.
TECHNICAL CHAPTER-II Page SPECIFICATION SECTION-E0 10 of 11 VOL-II (PART B) GENERAL CONSTRUCTIONAL
19.07.00
19.08.00 19.09.00 19.01.01
19.01.02
b)
19.01.03
Cable Terminations and Connections a)
b)
c) d)
CLAUSE NO.
GENERAL CONSTRUCTIONAL PRACTICES e) The Contractor shall tag/ferrule the control cable cores at all terminations, as instructed by the Owner. In panels where a large number of cables are to be terminated and cable identification may be difficult, each core ferrule may include the complete cable number as well. Spare cores shall be similarly tagged with cable numbers and coiled up. Control cables shall have stranded copper conductor. Bare portion of the solid conductors shall be tinned after removing the insulation and shall be terminated directly without using cable lugs. All cable entry points shall be sealed and made vermin and dust proof. Unused openings shall be effectively closed. If the cable-end box or terminal enclosure provided on the equipment is found unsuitable and requires modification, the same shall be carried out by the Contractor with the approval of the Owner.
f)
g) h)
19.01.04
CABLE (HT AND POWER)AT SUB-SECTION The Contractor shall construct the cable trenches required for directly buried cables. The scope of work and rates for construction of cable trenches for cables shall include excavation, preparation of sand bedding, soil cover, supply and installation of brick or concrete protective cover, back filling and reaming, supply and installation of route markers and joint markers. The Bidder shall ascertain the soil conditions prevailing at site, before quoting the rates. Laying the cable and providing protective covering shall be as per approved drawing.
19.02.00
Cable laying at augmentation sub-section shall be making with existing cabling practice ( )
TECHNICAL CHAPTER-II Page SPECIFICATION SECTION-E0 11 of 11 VOL-II (PART B) GENERAL CONSTRUCTIONAL
CLAUSE NO.
33kV/11kV ISOLATORS
SCOPE This specification covers the design, manufacture, assembly, shop testing / inspection before dispatch, packing, forwarding, transportation to site, insurance (during transit, storage and erection), storage, erection, supervision, site testing and commissioning of 33 kV & 11kV Isolators for 33/11 kV substations GENERAL The isolators and accessories shall conform in general to IS: 9921 or IEC: 129 except to the extent explicitly modified in specification. Earth switches shall be provided on 33kV isolators as per the SLD. The isolators and earth switches shall be manually operated type. Complete isolator with all the necessary items for successful operation shall be supplied. 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 system in their closed position. They shall be constructed such that they do not open under influence of short circuit current and wind pressure together. The earth switches wherever provided shall be constructional interlocked so that the earth switches can be operated only when the isolator is open and vice-versa. The earthing switches shall be capable of discharging trapped charges of the associated lines. Isolator and earth switches shall be able to bear on the terminals the total forces including wind loading and electrodynamics forces on the attached conductor without impairing reliability or current carrying capacity. CONSTRUCTIONAL FEATURES The isolators shall be provided with high pressure current carrying contacts on the hinge/jaw ends and all contact surface shall be silver plated. The thickness of silver plating should not be less than 25 microns. The contacts shall be accurately machined and self aligned. The isolator shall be provided with a galvanized steel base provided with holes and designed for mounting on a lattice /joist pole/ PCC pole support structure . The base shall be rigid and self supporting. The position of movable contact system (main blades) of each of the isolator and earthing switch shall be indicated by a mechanical indicator at the lower end of the vertical rod of shaft for the isolator and earthling switch. The indicator shall be of metal and shall be visible from operating level. All metal parts shall be of non-rusting and non-corroding metal. Current carrying parts shall be from high conductivity electrolytic copper/Aluminium. Bolts, screwed pins shall be provided with lock washers. Keys or equivalent locking facilities, if provided on current carrying parts, shall be made of copper silicon alloy or equivalent. The bolts or pins used in current carrying parts shall be made of copper silicon alloy or equivalent. The bolts or pins
TECHNICAL SPECIFICATION VOL-II (PART-B) CHAPTER-II SECTION-E1 33kV & 11kV ISOLATORS Page 1 of 4
1.00.00 1.01.00
2.00.00 2.01.00
2.02.00 2.03.00 2.04.00 3.00.00 3.01.00
3.02.00
3.03.00
4.00.00 4.01.00
4.02.00
4.03.00
RGGVY-WORKS STANDARD TECHNICAL SPECIFICATION (REV.- 03)
CLAUSE NO.
33kV/11kV ISOLATORS
used in current carrying parts shall be made of non-ferrous and non-corroding material. The live parts shall be designed to eliminate sharp joints, edges and other corona producing surfaces.
4.04.00
Data & technical requirements for the insulators to be used for the isolators shall be as per the 33&11kV post insulator discussed in chapter-II of this specification The switch-isolator shall be manually-operated, triple-pole, centre-post-rotating type with double-break operation. It shall be suitable for horizontal mounting arrangement. Central break type horizontal isolator can also be considered. All current carrying parts shall be made of silver faced 90%electrolytic copper. The arcing contacts shall be made of phosphor bronze. The isolator shall be provided with required number of 24 KV post insulators per pole conforming to IS:2544 and IS:5350 (Pt .III) or 36kV post insulators. Six bimetallic connectors shall be provided on the incoming and outgoing sides to directly receive ACSR of required size without the use of lugs. The frame of each solator shall be provided with a separate earthing terminal for connection to an earthing conductor having a clamping bolt of not less than 12 mm dia. The terminal shall be marked with Earth symbol. The Isolator shall have a pad-lock arrangement both for ON and OFF positions. The vertical operating rod shall comprise of 40 mm (nominal bore) Galvanised Steel Tube (medium class) as per IS:1161-1979. Length of the operating rod shall depend upon the mounting position of the isolator (exact length of the rod to be specified by the purchaser). Operating handle shall be fixed to the concrete structures approx. 1 metre above the ground level. Provision shall be made for the earthing of operating handle only through the flexible copper strap connected to the supporting metallic structure. The switch-isolator shall open when operating handle is pulled downwards and the switch-isolator shall close when the operating handle is moved upwards. The rotating parts, i.e. bell crank lever and fork etc. shall be either forged or made of mild steel (cast-components shall not be used).. Tubes shall be galvanised in accordance with IS:4736-1968 and other metal parts shall be hot dip galvanised. Phase clearance i.e. centre-to-centre distance between the insulators of adjacent phases in the assembled position of the isolator shall be as per IE Rules. The centre-to-centre distance between insulators of the adjacent poles of the same phase in the assembled position of the switch shall be as per IE Rules. All the post insulator stacks, except the central rotating stacks, shall be provided with arcing horns.
TECHNICAL SPECIFICATION VOL-II (PART-B) CHAPTER-II SECTION-E1 33kV & 11kV ISOLATORS Page 2 of 4
4.05.00
4.06.00
4.07.00
4.07.01
4.08.00
4.09.00 4.10.00
4.11.00
4.12.00 4.13.00
4.14.00
4.15.00
4.16.00
4.17.00
CLAUSE NO.
33kV/11kV ISOLATORS
All similar materials and removable parts of similar equipment shall be interchangeable with each other. The isolator shall be provided with a suitable mechanical interlocking arrangement with the associated equipments in the sub-station. EARTHING SWITCHES Where earthling switches are specified these shall include the complete operating mechanism and auxiliary contacts. The earthing switches shall form an integral part of the isolator and shall be mounted on the base frame of the isolator. Earthing switches shall be suitable for local manual operation only. The earthing switches shall be constructional interlocked with the isolator so that the earthing switches can be operated only when isolator is open and vice versa. OPERATING MECHANISM AND CONTROL The Contractor shall offer, hand operated switches having padlock arrangement on both ON and OFF positions. Limit switches (2NO+2NC) for control shall be fitted on the isolator/earth switch shaft, within the cabinet to sense the open and close positions of the isolators and earth switches. 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 allow improper functioning of the isolator when the isolator is opened or closed at any speed. OPERATION Isolator shall be gang operated for main blades and earth switches. The operation of the three poles shall be well synchronised and interlocked. The design shall be such as to provide maximum reliability under all service conditions. All operating linkages carrying mechanical loads shall be designed for negligible deflection. The length of inter insulator and interpole operating rods shall be capable of adjustments. The design of linkages and gears be such so as to allow one man to operate the handle with ease for isolator and earth switch. TESTS The isolator along with operating mechanism shall conform to the type tests and shall be subjected to routine tests and acceptance tests in accordance with IS-9921. Power frequency voltage withstand tests (routine test) shall be performed on one completely assembled isolator pole. Minimum 50 nos. mechanical operations will be carried out on 1 (one) isolator assembled completely with all accessories as acceptance test. During final testing of isolator sequential closing/opening of earth switch shall also be checked only after isolator is fully open/close. Acceptance test shall be carried out with relevant operating box. The insulator shall conform all type, routine and acceptance tests, as per relevant Indian standard.
4.18.00
4.19.00
5.00.00 5.01.00
6.00.00 6.01.00
6.02.00
6.03.00
7.00.00 7.01.00
7.02.00
7.03.00
8.00.00 8.01.00
8.02.00
TECHNICAL SPECIFICATION VOL-II (PART-B)
CHAPTER-II SECTION-E1 33kV & 11kV ISOLATORS
Page 3 of 4
CLAUSE NO.
33kV/11kV ISOLATORS
GAURANTEED TECHNICAL PARAMETERS The following gauranteed technical parameters shall be applicable. PART-A Sl.. Parameter No. 1. Standard 2. Operating mechanism of Isolator and Earth Switch 3. Nominal System Voltage 4. 5. 6. 7. Highest System Voltage System Frequency 33kV Isolator IS:9921 Manually operated 33 kV 36 kV 50 Hz Outdoor 400 A 25kA(rms) for 1 sec. 63 kA (peak) 170 kVp to earth & 195 kVp across isolating distance 70 kV (rms) to earth /80 kV(rms) between isolating distance As per Table-IV of IS:9921 II for rated Ambient temp 900 mm 2NO+2NC for each Isolator 2NO + 2NC for each earth switch Silver plated electrolytic copper flat COMPLIED 11kV Isolator IS:9921 Manually operated 11 kV 12 kV 50 Hz Outdoor 400 A 13.1kA(rms) for 1 sec. 33 kA (peak) 75 kVp to earth & 85 kVp across isolating distance 28 kV (rms) to earth & 32kV(rms) between isolating distance As per Table-IV of IS:9921 II for rated Ambient temp 320 mm 2NO+2NC for each Isolator 2NO + 2NC for each earth switch Silver plated electrolytic copper flat COMPLIED
9.00.00
Type Rated current at rated ambient temperature 8. Rated Short Circuit Current of Isolator 9. Rated Dynamic Short Circuit Withstand Current of Isolator 10. Rated Insulation Levels Impulse Withstand Voltage with 1.2/50 Micro Sec. Wave 11. One minute power frequency withstand voltage
12. Temperature rise
13. Creepage Distance (Total) 14. No. of Auxiliary Contacts
15. Material of fixed contact & moving blade 16. Type test reports (all mentioned in relevant) clause
Make shall be NESCL Corporate Quality Assurance (CQA) approved .
CHAPTER-II SECTION-E1 33kV & 11kV ISOLATORS
Page 4 of 4
CLAUSE NO.
INSTRUMENT TRANSFORMERS GENERAL The instrument transformers and accessories shall conform to the latest version of the standards specified except to the extent explicitly modified in the specification. The CTs and PT/VT shall be capable of withstanding meteorological and short circuit forces when installed in a layout arrangement described in the specification. The instrument transformers shall be complete with its secondary terminal box. They shall be suitable for upright mounting on lattice/pipe type support structures. Each set of three phase current transformers shall be supplied with one CTMB The instrument transformer tank along with top metallic shall be hot dip galvanised or painted as per IS:5 shade 697. The Contractor shall furnish the impregnation details along with tests/checks to ensure successful completion of impregnation cycle for approval. Bellows if used for expansion of transformer oil shall be tested for pressure/leak test, springing test, permanent set test. The details of the same shall be finalised during engineering. CONSTRUCTIONAL FEATURES Bushing/Insulator a) Instrument transformers shall be oil filled, with shaded porcelain insulators suitable for outdoor service. The insulator for CT shall be one piece without any metallic flange joint. Instrument transformers shall be provided with filling and drain plugs oil sight glass for CT and for electro-magnetic unit of VT. The insulator of instrument transformers shall have cantilever strength of not less than 500 Kg. Instrument transformers shall be hermetically sealed unit. Contractor shall furnish the details of site tests to check the effectiveness of hermetic sealing for approval. Polarity marks shall indelibly be marked on each instrument transformer and at the lead terminals at the associated terminal block. Marshalling box, terminal box & terminal connectors to be provided shall conform to requirements. Insulating oil to be used for instrument transformers shall conform to IS:335 required for first filling. CTs must have adequate provision for taking oil samples from the bottom of the CT without exposure to atmosphere.
1.00.00 1.01.00 1.02.00 1.03.00 1.04.00 1.05.00 1.06.00 1.07.00
2.00.00 2.01.00
b)
c)
d) e) 2.02.00
Instrument Oil a) b)
3.00.00 3.01.00
CURRENT TRANSFORMERS Current transformers shall be single primary top dead tank type design. Secondary terminals shall be brought out in a weather proof (IP:55) terminal box at the bottom.
TECHNICAL SPECIFICATION VOL-II (PART-A) CHAPTER-II SECTION-E2
INSTRUMENT TRANSFORMER
Page 1 of 6
CLAUSE NO.
INSTRUMENT TRANSFORMERS These secondary terminals shall be terminated to stud type non-disconnecting terminal blocks inside the terminal box.
3.02.00 3.03.00 3.04.00 3.05.00
The core lamination shall be of cold rolled grain oriented silicon steel or other equivalent alloys. Different ratios, if specified, shall be achieved by secondary taps only, and primary reconnections shall not be accepted. Current transformers guaranteed burdens and accuracy class are to be intended as simultaneous for all cores. The instrument security factor at all ratios shall be less than five (5) for metering core. If any auxiliary CTs/Reactors are used in the current transformers then all parameters specified shall have to be met treating auxiliary CTs/reactors as an integral part of the current transformer. The wiring diagram, for the interconnection of the three single phase CTs shall be provided inside the central control cabinet in such a manner so that it does not deteriorate with time. Facilities shall be provided at terminal blocks in the marshalling box for star/delta formation, short circuiting and grounding of CT secondary terminals. VOLTAGE TRANSFORMERS Voltage transformers (VT) shall be oil immersed electromagnetic type conforming to IS:3156. It shall be thermally and dielectrically safe when secondary terminals are loaded with guaranteed thermal burdens. Secondary terminals shall be accessible without any danger of access to high voltage circuit. Oil level indicator shall be such that level of oil is clearly visible under normal temperature variations. A danger level of oil indicating the leakage of oil shall be clearly marked for detection by maintenance personnel. Each secondary shall be protected by HRC cartridge type fuses. Secondary terminals shall be terminated on stud type non-disconnecting terminal blocks in secondary box via the fuse. TESTS The current transformers shall conform to type tests and shall be subjected to routine tests in accordance with IS:2705. Also the CTs shall be subjected to the following routine tests in addition to routine tests as per IEC/IS. a) b) c) d) e) Measurement of capacitance (only for 33kV CTs) High voltage power frequency withstand test on secondary winding Over voltage inter turn test Oil leakage test (procedure to be mutually agreed) Measurement of tan delta at 0.3, 0.7 1.0 and 1.1 Um. (only for 33kV CTs)
3.06.00
3.7.00 4.00.00 4.01.00
4.02.00 4.03.00
4.04.00
5.00.00 5.01.00
TECHNICAL SPECIFICATION VOL-II (PART-A)
Page 2 of 6
CLAUSE NO.
INSTRUMENT TRANSFORMERS The VTs shall conform to type tests and shall be subjected to routine tests in accordance with IS: 3156. GAURANTEED TECHNIACL PARAMETERS Current Transformer Parameters The following gauranteed technical parameters shall be applicable. PART-A Sl. No. 1. 2. 3. 4. 5. Parameters Highest System Voltage(kV) Rated Frequency Installation Rated continuous current extended 33kV CT 36 50 Out door primary As per IS 25 kA rms for 1 Sec 63kA rms for 1 sec 11kV CT 12 50 Outdoor As per IS 13.1 kA rms for 1 Sec 33kA rms for 1 sec 75 kVp 28 (rms) kV
5.02.00 6.00.00 6.01.00
Rated short time thermal current
6. 7. 8. 9.
Rated dynamic withstand currents
1.2 / 50 micro second impulse withstand 170 kVp Voltage One minute dry withstand Voltage power frequency 70 kV (rms) As per IS 900 Class-A As per IS
Max. temp. rise over ambient temp.
As per IS 320 Class-A As per IS
10. Creepage distance (total)(mm) 11. Type of insulation 12. Power frequency over voltage withstand requirements of secondary windings 13. Number of cores
2 (1 for 2 (1 for protection and 1 protection and 1 for for metering) metering with REF
Page 3 of 6
CLAUSE NO.
INSTRUMENT TRANSFORMERS protection (3rd core will be PS class as per Clause 6.02.02) 14. Current ratio 400-200-100/ 1-1 A 400-200-100/ 1-1 A for Transformer CT and 200-100-50/ 1-1 A for 11 kV feeder 15. Output burden of each core 16. Accuracy class of protection core 17. Accuracy class & ISF of metering core 18. Number of TB ways in central control cabinet 10VA 5P15 0.5, <5 All terminals of cores are to be wired up to marshaling box plus 30% spare. 10VA 5P15 0.5, <5 All terminals of cores are to be wired up to marshaling box plus 30% spare. 0.3g (horizontal) COMPLIED
19. Seismic acceleration 20. Type test reports (all mentioned in relevant clause)
0.3g (horizontal) COMPLIED
Make shall be NESCL Corporate Quality Assurance (CQA) approved. 6.02.01 6.02.02 CTs for indoor use (for 11kV indoor switchgear) (Resin cast type) PS Class CTs provided on neutral only in case of 5MVA, 33/11 kV transformers for REF protection with the following parameters CTR Min. Vk Max. Ik Rct : 400-200/1 A : 400 V : <= 60-120 mA : <= 2.5 - 5 ohm
Page 4 of 6
CLAUSE NO.
INSTRUMENT TRANSFORMERS Voltage Transformer Parameters (Part-A) The following gauranteed technical parameters shall be applicable. Sl. No 1. Parameters Highest Voltage(kV) Rated Frequency Installation System Neutral Earthing System Fault Level(kA) 1.2 / 50 micro second impulse withstand Voltage(kVp) System 36 33kV 12 11kV
2. 3. 4. 5. 6.
50 Out door Effectively earthed 25 170
50 Outdoor Effectively earthed 13.1 75
7.
One minute dry power 70 frequency withstand Voltage kV (rms)
28
8. Creepage distance (total)(mm) 900 9. Power Freq. withstand requirements of secondary side windings 2 kV (rms)
320 2 kV (rms)
10. Max. Temp. rise over ambient 11. Number cores of secondary
As per relevant IS
As per relevant IS
One (1) [for metering]One (1) [for metering] 33/3 kV 110/3 V 0.5 50VA 11/3 kV 110/3 V 0.5 50VA
12. Rated primary voltage 13. Rated Secondary Voltage and Winding 14. Accuracy class metering core of
15. Rated Secondary Burden/ winding

Page 5 of 6
CLAUSE NO.
INSTRUMENT TRANSFORMERS 16. Rated Voltage Factor 17. Seismic Acceleration 18. Type test reports (all mentioned in relevant clause) 1.2 Continuous; 1.5 for 30 secs. 0.3 g COMPLIED 1.2 Continuous; 1.5 for 30 secs. 0.3 g COMPLIED
Page 6 of 6
CLAUSE NO.
33/11KV SURGE ARRESTERS SCOPE This specification covers the design, manufacture, assembly, shop testing/inspection before dispatch, packing, forwarding, transportation to site, 36/11 KV outdoor type surge arresters at 33/11 kV substations. GENERAL The Surge Arresters (SAs) shall conform in general to IEC 99.4 or IS:3070 as well as IEC document TC-37. Arresters shall be of hermatically sealed units, self supporting construction, suitable for mounting on lattice type support structures. DUTY REQUIREMENTS The SAs shall be of heavy duty station class and gapless Metal Oxide type without any series or shunt gaps. The SAs shall be capable of discharging over-voltages occurring during switching of unloaded transformers, and long lines. The reference current of the arresters shall be high enough to eliminate the influence of grading and stray capacitance on the measured reference voltage. The arrester shall be fully stabilized thermally to give a life expectancy of 100 years under site conditions and shall take care of the effect of solar radiation. The surge arresters shall be capable of withstanding meteorological and short circuit forces when installed in layout arrangement as described in the specification. The duty cycle of circuit breaker installed in the system shall be 0-0.3 sec-CO-3 min-CO. The SA shall be suitable for such circuit breaker duties in the system. Surge arresters shall be capable of discharging severe re-energisation switching surges on 33 kV lines upto 25 km. length. Surge arrester shall be capable of discharging energy equivalent to class-2 of IEC of a 33 kV system of two successive operations. CONSTUCTIONAL FEATURES The non-linear blocks shall be of intered metal oxide material. These shall be provided in such a way as to obtain robust construction, with excellent stable mechanical and electrical properties even after repeated operations. The surge arresters shall be fitted with pressure relief devices and arc diverting ports suitable for preventing shattering of porcelain housing.
TECHNICAL SPECIFICATION SURGE ARRESTERS CHAPTER-II SECTION-E4 Page 1 of 5
1.00.00 1.01.01
2.00.00 2.01.00
2.02.00
3.00.00 3.01.00
3.02.00
3.03.00
3.04.00
3.05.00
3.06.00
3.07.00
4.00.00 4.01.00
4.02.00
CLAUSE NO.
33/11KV SURGE ARRESTERS The arresters shall not fail due to porcelain contamination. Seals shall be provided in such a way that these are always effectively maintained even when discharging rated lightning current. Outer insulator shall be porcelain conforming to requirements of Chapter-E14. Porcelain housing shall be so co-ordinated that external flashover will not occur due to application of any impulse or switching surge voltage upto the maximum design value for arrester. The end fittings shall be made of non-magnetic and corrosion proof material. The Contractor shall furnish the following: The heat treatment cycle detail along with necessary quality checks used for individual blocks along with insulation formed across each block. Metalizing coating thickness for reduced resistance between adjacent disc along with procedure for checking the same. Details of thermal stability test for uniform distribution of current on individual disc. Detailed energy calculations to prove thermal capability of discs. The base of the SA shall be provided with two separate terminals distinctly marked for connection to earth. FITTINGS AND ACCESSORIES Arresters shall be complete with separate mounting base and structure.. Suitable leakage current meters should also be supplied. The reading of millimeter and counters shall be visible through an inspection glass panel. A pressure relief device vent/other suitable provision shall be made so as to prevent excessive pressure build-up/shattering of view glass. TESTS The surge arrestors shall conform to type tests and shall be subjected to routine and acceptance tests in accordance with IEC document. Each metal oxide block of surge arrester shall be tested for the guaranteed specific energy capability in addition to the routine/acceptance tests as per IEC-99-4.
4.03.00 4.04.00
4.05.00 4.06.00
4.07.00 4.08.00 4.09.00
4.10.00
4.11.00
4.12.00 4.13.00
5.00.00 5.01.00 5.02.00
6.00.00
TECHNICAL SPECIFICATION SURGE ARRESTERS
Page 2 of 5
CLAUSE NO.
33/11KV SURGE ARRESTERS Acceptance Tests Measurement of power frequency reference voltage of the arrester units. Lightning impulse residual voltage at nominal discharge current on arrester. Galvanising test on exposed steel parts. Routine Tests Measurement of reference voltage. Residual voltage test at nominal discharge current on arrester. Sealing test Test on Surge Monitors The surge monitors shall also be connected in series with the test specimens during residual voltage and current Impulse withstand tests to verify efficiency of the same. Additional routine/functional tests with one 10 kA and 100 kA current impulse (8/20 micro-sec) shall also be performed on the surge monitor. GAURANTEED TECHNICAL PARAMETERS The following gauranteed technical parameters shall be applicable.
6.01.00 6.01.01 6.01.02 6.01.03 6.02.00 6.02.01 6.02.02 6.03.00 6.04.00 6.04.01
7.00.00
Sl. No
DESCRIPTION
VALUES
a)
Rated system voltage
33 kV
11 kV
b)
Rated Arrester Voltage rms
30 kV
9 kV
c)
Nominal discharge current
10 kA of 8/20 micro-sec wave
10 kA of 8/20 micro-sec wave

Deleted: 5 Deleted: 10 Ka of 8/20 micro-sec wave
Page 3 of 5
CLAUSE NO.
33/11KV SURGE ARRESTERS d) Minimum discharge capability 5 kJ/kV (referred to rated arrester Voltage corresponding to min. discharge characteristics)
e)
Maximum continuous operating voltage at 50 deg C. Max. Residual Voltage (1 kA)
24 kV rms
7.2 kV
f)
70 kVp
28 kVp
g)
Max. residual voltage at 10kA nominal discharge current (8/20 micro-sec wave)
85 kVp
34 kVp
h)
Max. switching impulse residual Voltage at 500A Peak
70 kVp
28 kVp
i)
Max. Steep Current Residual Voltage
93 kVp at 10kA/38 kVp at Nom. Disch. Current
27.3 kVp at 10kA/38 kVp at Nom. Disch. Current

Deleted: 2 Deleted: 1
j)
Long duration discharge class
k)
High current short duration test value (4/10 Micro-Sec Wave)
100 kAp
100 kAp
l)
Long duration current impulse withstand
>=800A - 2000s
>=800A 2000s
m)
Partial Discharge (Max.)
50pc
50pc
l)
Current for Pressure Relief
25 kA rms
25 kA rms
CHAPTER-II SECTION-E4 Page 4 of 5
CLAUSE NO.
33/11KV SURGE ARRESTERS Test
m)
Low current long duration test value (2000 micro-sec)
As per IEC
As per IEC
n)
Prospective symmetrical fault current
25 kA for 1 sec.
13.1 kA for 1 sec.
o)
Pressure relief class as per IEC 99
p)
Dry & Wet Power Frequency
70 kV rms
35 kV rms
q)
Lightning Impulse
170 kVp
75 kVp
r)
Nominal Creapage Discharge
900mm
300mm
r)
COMPLIED
COMPLIE D
Deleted:
Formatted: Indent: Left: 0"
Page 5 of 5
CLAUSE NO.
CONTROL & PROTECTION PANELS SCOPE Control/relay board shall be supplied completely assembled and wired as per approved schematics with all necessary items as detailed. Applicable statndards Standard IS 3231 IS 8686 IEC-60255 IS:13947 part1 IS:13871:1993 IS:6005 IS:3043 IS: 13703 /IEC 60269 IS: 11353 IS:134947 Item Relay characteristics ,performance and accuracy test Static Relay Relay characteristics ,performance and accuracy test Specification for low-voltage Switchgear and control gear Degree of protection for enclosures. Powder coating paint Code of practice for phosphate iron and steel Code of practice for earthing HRC cartridge fuses Guide for uniform system of making identification of conductor and appratus terminal Air Break switches<air break disconnectors, for voltage not exceeding 1000 V
1.01.00 1.02.00
1.03.00
1.04.00
Control panel shall be of simplex design with all control switches, indicating lamps, semaphore indicators, name plates, relays, auxiliary relays, timers, annunciators and instruments mounted on front face of the panel with hinged door at the back with lock and key type handle. Single panel door shall be provided on rear side for service and maintenance of relay instruments. Panels shall be provided with double leaf door in case the width is more than 800 mm. Control panel shall be free standing, floor mounting type and shall comprise of structural frames enclosed completely with smooth finished, cold rolled sheet steel of thickness not less than 3 mm for weight bearing members of the panel and 2 mm for sides and top. Doors, cutouts etc. shall be provided with neoprene rubber gasket and degree of protection shall be IP: 31 for indoor panel and IP-54 for outdoor control panel. Ventilating louvers (As per customer requirement), if provided shall have screens and filter made of brass/GI wire mesh.
1.05.00
2.00.00 2.01.00
OUTDOOR CONTROL PANEL In cases where no control room building is available in existing substation or space is unavailable in existing control room, Outdoor type Control and Relay panel shall be used for Transformer, and Feeder control and protection .Self energized type (DC control Supply) ( i.e. Control & Protection panel shall hve a
CONTROL & PROTECTION PANELS
Page 1 of 11
CLAUSE NO.
CONTROL & PROTECTION PANELS power supply unit (Power pack) with Out door type maintenance free Ni-Cd battery back up ) Outdoor control panel shall be provided with IP-54 protection against ingress of Dust and moisture. The battery shall have Amp-hr capacity as per details given in Chapter-II Part-A for satisfactory operation of control panel and associate Circuit Breaker .Substation having augmentation of only 11 kV feeder may have unit type control cubicle with protection ,metering, control ,battery with charger for outdoor application as discussed here. The panel shall have suitable construction for outdoor application having adequate protection for against Rain, thunder, cyclone, sand storm and sunlight protection.panel shall be mounted on plinth (pcc) with provision of bottom entry of cables. Mounting of relays, energy meter and instruments in outdoor panel shall be such that the wiring and setting of relay is accessible either from front or rear side.Double door panel with swing frame for mounting of control and realy is acceptable.The design of panel with realay mounted internally is acceptable for protection panel.
3.00.00 3.00.01
CONTROL SUPPLY Wherever DC control supply is available from control room same shall be used for control supply of panel. But in case where control supply is not available in substation or existing DC battery bank does not have adequate capacity to supply control panel, Control panel shall be supplied with self supplied 24 Volt DC for control panel. Small, maintenance free completely enclosed Ni-Cad battery housed inside control panel shall be used. The battery shall have adequate Amp-hr capacity for satisfactory operation of control panel and associate Circuit Breakerfor 10 hour outage with capacity to meet the total station load even at1.8 volt/cell. Panel shall not be more than 2100 mm high and shall be provided with: a) b) c) d) e) f) g) h) Removable glands, gland plates (screwed type made of brass) for bottom entry cables. Terminal blocks for external connection. Lifting lugs/eye bolts. Space heater with on/off switches, thermostat & MCB. Incandescent panel lamp with door switch 5A, 240 V, 3 pin socket outlet Provision for locking doors Door handles
3.00.02
4.00.00
PAINTING All sheet work shall be pretreated, in tanks, in accordance to IS: 6005.Degreasing shall be done by alkaline cleaning. Rust and scales shall be removed by pickling
Page 2 of 11
CLAUSE NO.
CONTROL & PROTECTION PANELS with acid. After pickiling,the parts shall be washed in running water. Then these shall be rinsed in slightly alkaline water and dried. Powder coated paint shade 692 as per IS: 5 shall be used as per IS 13871The Phosphate coating shall be Class C as specified in 13871.The phosphate surface shall be passivated and electrostatic Powder Painting shall be used. The paint thickness shall not be less than 50 microns. Finished parts shall be coated by pealable compound by spraying method to protect finished surfaces from scratching, grease, dirts and oily spotsduring testing, transportation, handling and erection.
5.00.00 5.00.01
MOUNTING Metal channels with anchor bolts and necessary hardware shall be furnished with dispatch of panels, so that they can be installed and leveled when concrete foundations of control room are poured. Panels shall have additional rolled channel plinth at the bottom with smooth bearing surface. Panels shall be fixed on the embedded foundation channels with intervening layers of anti-vibration strips made of shock absorbing materials which shall be supplied by the Contractor. All equipment on and in panels shall be mounted and completely wired to the terminal blocks ready for external connection. The equipment on front of panels shall be flush mounted. No equipment shall be mounted on panels doors. The lowest mounting plate shall be not less than 350 mm from bottom of the panel and the center lines of operating handles of control/selector switches. Push buttons, etc., shall be not less than 750 mm and not more than 1600 mm from bottom of the panel. A mimic diagram showing the single line representation of the system shall be incorporated on panel front. Mimic shall be made of 12.5 mm. wide and 3 mm thick enamel painted aluminum strips. It shall be fastened with pins or screws and nuts on the panel. Following colour coding shall be followed for the mimic diagram : 33 kV 11 kV Neutral Signal red - shade 537 of IS:5 Salmon pink - shade 443 of IS:5 Black
5.00.02
5.00.03
5.00.04
6.00.00 6.00.01
EARTHING An earth bus of copper flat of 25X6 mm section shall be provided. When several panels are mounted adjoining each other, the earth bus shall be made continuous and necessary connectors/clamps for this purpose shall be included in the scope of supply.Door shall be properly earthed by braided copper conductor of suitable cross sanction and Gland plate shall be connected to earth bus. Steel structure of the cubicle and non-current carrying metallic parts of all panel mounted devices shall be suitably earthed.
Page 3 of 11
CLAUSE NO.
CONTROL & PROTECTION PANELS The colour code of earthing wires shall be green. Earthing wire shall be connected on terminals with suitable clamp connectors and soldering shall not be permitted. Looping of earth connection which would result in loss of earth connection to other devices when the loop is broken shall not be permitted.
6.00.02
6.00.03.01 CT and VT secondary neutral and common lead shall be earthed at one place only at the terminal blocks where they enter the panel. Such earthing shall be made through links so that earthing may be removed from one group without disturbing continuity of the earthing system for other groups. The earthing scheme shall be approved by the Owner. 7.00.00 7.01.00 Control and Selector Switches Control switch for circuit breaker and isolator shall be spring return to neutral type with pistol grip handle. They shall be rotary type with escutcheon plates clearly marked to show the function and position. The switch shall be of sturdy construction suitable for mounting on panel front. The contact rating shall be suitable for the application. Miniaturised or discrepancy type of control switches for circuit breaker operation are also acceptable. These shall include necessary auxiliary relays having indicators and its contacts shall be adequately rated for the function as desired. Ammeter and Volmeter selector switches shall have four stay put position with adequate number of contacts for 3 phase 4 wire system.Ammeter selector switches shall have make before break type contact to prevent open circuiting of CT secondaries. 8.00.00 8.00.01 INDICATING LAMP Indicating Lamp shall beCLUSTER LED Type.The lamp scutcheonplates marked with its function wherever necessary. shall have
8.01.01
Indication lamps shall be ultra bright LED based. synthetic lens .& translucent lamp cover.Control switch for breaker shall have three indication lamps. Red for breaker condition, Green for breaker condition ,White for breaker Auto Trip condition.BLUE for all healthy condition(e.g control supply and also for BREAKER SPRING CHARGED) Indicating lamp should be located just above the associated Push button/Control switches.RED lamp shall Invariably located to the right of Green lamps.In case a White lamp is also provided,it shall be placed between the Red and Green lamp along the centre line of Control switch/Push button pair.Blue should normally be located above the Red and Green lamp. All indicating lamp shall be suitable for continous operation at 90% to 110% of their rated voltage.
8.01.02
8.01.03
Page 4 of 11
CLAUSE NO.
CONTROL & PROTECTION PANELS Position indicators of semaphore type shall be provided as part of the mimic diagrams on panels for indicating the position of isolator / earthing switches. Their strips shall be the same colour as the associated mimic. Position indicator shall be suitable for either AC or DC operation as specified, not exceeding 2.5W and shall withstand 120% of rated voltage continuously. RELAYS All protective relays shall be flush mounted on panel with connections made from inside. They shall have transparent dust tight cover removable from front. All protective relays shall have a draw out construction for easy replacement from the front. They shall either have built-in test facilities or shall be provided with necessary test blocks and test switches located immediately below each relay. The auxiliary relays may be furnished in non-draw out cases. The contact multiplying auxiliary relays may be located inside the auxiliary compartment and may be of fixed type. All ac relays shall be suitable for operation at 50 Hz.110V VT secondaries and 1 amp CT secondaries, DC auxiliary relays and timer shall be designed for dc voltage specified and shall operate satisfactorily between 70% and 110% of rated voltage. The protective relays shall be suitable for efficient and reliable operation of the protecting scheme described in the specification. Necessary auxiliary relays and timers required for interlocking schemes for multiplying of contacts suiting contact duties of protective relays, monitoring of control supplies and circuits, lockout relays, monitoring of control supplies & circuits, etc. and also required for the complete protection scheme described in the specification, shall be provided. The protective relays shall have at least two potential free output contacts. Auxiliary relays and timers shall have contacts required to complete the scheme. Contacts shall be silver faced and shall have spring action. Adequate number of terminals shall be made available on the relay cases for applicable relaying scheme. All the spare contacts shall be wired to terminal blocks. All protective relay shall type tested be in accordance to IS: 3231.
8.01.04
9.00.00 9.01.00
10.00.00
TERMINAL BLOCK AND INTERNAL WIRING Terminal blocks shall be 1100 V grade 10 Amps rated one piece moulded complete with insulating barriers, clip on type terminals, washers, nuts, identification strips leads shall be provided with isolating links and shorting links. 20% spare terminals shall be provided in the panel. All panel wiring for external connections shall terminate on separate terminal blocks, which shall be suitable for terminating stranded copper conductors of 2.5 sq.mm. from each side.
Page 5 of 11
CLAUSE NO.
CONTROL & PROTECTION PANELS Disconnecting type terminal blocks for CT and PT secondary leads shall provided. Also CT secondary leads shall be provided with short circuiting earthing facilities. be and
The minimum size of the multi-stranded copper conductor used for internal wiring shall be as follows: All circuits except current transformer circuits and voltage transfer circuits meant for energy metering one on 1.5mm sq. per lead. All current transformer circuits one no 2.5sqmm per lead. Voltage transformer circuit (for energy meters): Two 2.5 sqmm. Per lead. Unless otherwise specified, terminal blocks shall be suitable for connecting the following conductors of external cable on each side. All CT & PT circuits: minimum of two of 2.5mm sq. copper. AC/Dc Power Supply Circuits: One of 6mm sq. Aluminium. All other circuits: minimum of one of 2.5mm sq. copper. 11.00.00 NAME PLATES AND MARKING All equipment mounted on front and rear side as well as equipment mounted inside the panels shall be provide with individual name plates with equipment designation engraved. Also on the top of each panel on front as well as rear side, large and bold name plates shall be proved for circuit/feeder designation. All front mounted equipment shall also be provided at the rear with individual name plates engraved with tag numbers corresponding to the one shown in the panel internal wiring to facilitate easy tracing of the wiring. Each instrument and meter shall be prominently marked with the quantity measured e.g. KV, A, MW, etc. All relays and other devices shall be clearly marked with manufacturers name, manufacturers type, serial number and electrical rating data. Name Plates shall be made of non-rusting metal or 3 ply lamicoid. Nameplates shall be white engraving lettering with black background. All the panels shall be provided with nameplate mounted inside the panel bearing LOA No & Date. Name of the substation & feeder and drawing number. Caution name plate caution Live terminalshall be provided at all points where the terminals are likely to remain live and isolation is possible at remote end. Alarm annunciation of back-lighted name plate type with flasher and bell shall be provided on the panel for drawing attention of operators during faults or abnormal operating conditions. Alarming conditions shall cover the following
RGGVY WORKS STANDARD TECHNICAL SPECIFICATION (REV.- 03) TECHNICAL SPECIFICATION VOL-II (PART-A) CHAPTER-II SECTION-E4
Page 6 of 11
CLAUSE NO.
CONTROL & PROTECTION PANELS a) b) c) d) e) f) g) h) g) Circuit breaker auto trip Trip annunciation Trip & annunciation Trip & annunciation Trip & Alarm annunciation Alarm annunciation Alarm annunciation Alarm annunciation Alarm annunciation Alarm annunciation
Transformers buchholz alarm Transformer winding temp. alarm Transformer oil temp. alarm Transformer oil level low DC fail alarm Trip circuit Supervision unhealthy Over current relay operated E/F relay operated
Annunciation system shall be of solid state type mounted on top of control panel. Window engravings shall be in black on milk white translucent cover. Each window shall have two indicating lamps. Annunciation system shall incorporate push buttons for acknowledge, reset and test purposes. Operating sequence of alarm shall be as follows: Condition Normal Fault occurs Acknowledge Reset before normal Fault cleared Reset after normal Lamp Test Status of Visual Alarm Off Off Flashing Steady on Steady on Steady on Off Steady on Status of Audible Alarm On Off Off Off Off Off
Each device mounted on the control panel shall be identified by name plate All the relays shall be provided with hand reset operation indicators (flags). The relays shall be of reputed make and proven type and shall be subject to Owners approval before procurement by Contractor. Failure of a control supply or auxiliary supply and de-energisation of a relay shall not initiate any circuit breaker operation. 12.00.00 PROTECTIONS The detailed description of each protection and the associated equipment are described below: DC operated, instantaneous, high speed tripping relays with hand re-setting type contacts and necessary supervisory relays.
Page 7 of 11
CLAUSE NO.
CONTROL & PROTECTION PANELS Hand reset auxiliary relays with flag indication and 4 NO/NC contacts each.
13.00.00
33/11 kV TRANSFORMER PROTECTION All the 33/11kV Transformers shall be provided with the following protection a) Non directional, highset instantaneous, three phase, Overcurrent relay (50) with setting range 500-2000% of rated current. Non directional, definite time delayed, (0.1to10sec)three phase, Overcurrent relay (51) with setting range 50-500% of rated current. Non directional inverse definite time delayed (0.1-1sec) single pole, Earth fault current relay (51N) with setting range 10 to 80% of rated current. Relays shall have low transient over reach and high drop off / pick up ratio. Earth switch shall have suitable interlocking with associated breaker and isolator for safe operation of equipment. Only for transformers rated 5MVA or above REF earth fault protection shall be provided on 11 KV side with current setting range from 10 to 80% of rated current.
b)
c)
d)
e)
f)
Transformer Restricted Earth Fault (REF) Protection shall 1) Be single pole type 2) Be of voltage operated high impedance type 3) Have a current setting range of 10-80% of rated current 4) Be tuned to system frequency 5) Have suitable non-linear resistor to limit the peak voltage 6) Shall have suitable stabilizing resistor The REF relay shall be mounted at the 33kV control & protection panel. where the 11kV breaker is of out door type.In In-door type 11kV breaker, it is to be mounted on the 11kV SWGR incomer panel. 13.00.01 33 Kv Feeder protection All the 33kV feeder shall be provided with the following protection a) Non directional, high setinstantaneous, three phase, over current relay (50) with setting range 200-3000% of rated current.
Page 8 of 11
CLAUSE NO.
CONTROL & PROTECTION PANELS b) Non directional, time delayed (0-1to10sec), three phase, earth fault relay (51) with setting range 50-200% of rated current. Non directional indefinite time delayed (0-1to10sec),single pole, earth fault relay (51N) with setting range 10 to 80% of rated current. Relays shall have low transient over reach and high drop off / pick up ratio. Earth switch shall have suitable interlocking with associated breaker and isolator for safe operation of equipment.
c)
d)
e)
13.00.02
11 Kv Feeder protection All the 11 feeder shall be provided with the following protection a) b) Non directional, instantaneous, three phase, over current relay (50) with setting range 200-3000% of rated current. Non directional, definite time delayed (0-1to10sec), three phase, Overcurrent relay (51) with setting range 50-200% of rated current. Non directional definite time delayed (0-1to10sec), single pole , earth fault relay (51N) with setting range 10 to 80% of rated current. Relays shall have low transient over reach and high drop off / pick up ratio. Earth switch shall have suitable interlocking with associated breaker and isolator for safe operation of equipment.
c)
d)
e)
If bidder is offering Auto Reclosing scheme as an alternative, than the available Auto Reclosing relay settings should be compatible to above requirement. 13.03.00 11kV Incomer protection All the 11 Incomer feeder shall be provided with the following protection a) b) Non directional, instantaneous, three phase, over current relay (50) with setting range 500-3000% of rated current. Non directional, definite time delayed (01to10sec), three phase, Over current relay (51) with setting range 50-200% of rated current. Non directional definite time delayed (0.5-5sec), single pole , earth fault relay (51N) with setting range 10 to 80% of rated current. Relays shall have low transient over reach and high drop off / pick up ratio.
c)
d)
Page 9 of 11
CLAUSE NO.
e)
Earth switch shall have suitable interlocking with associated breaker and isolator for safe operation of equipment.
13.04.00
High speed tripping relay (86) shall a) b) c) d) Be instantaneous (operating time not to exceed 10 milli-sec.) Have hand reset contacts (lockout) Be DC operated Have adequate contacts to meet the requirement of the scheme and additional pair of contacts for Owners use. e) f) g) Be provided with hand reset operation indicators for each element/coil. Have necessary supervision relays. Be provided preferable with single coil.
13.05.00
Flag relays shall have a) reset flag indication. b) elements/coils. c) least two NO and two NC contacts for each element.
13.06.00
DC Supply Supervision Relay The relay shall be capable of monitoring the failure of dc supply to which it is connected. It shall have adequate potential free contacts as per scheme requirement. The relay shall have a time delay on drop-off of not less than 100 milli-sec. and be provided with operation indicator/flag.
13.07.00
33 & 11 kV CONTROL PANELS Meters
13.08.00
Ammeters: 96 mm x 96 mm square,flush panel 240 deg. Radial, +/- 1 % full scale accuracy,suitable for 0-10A,Black case/white dial having facility of zero adjustment. Applicable standard IS:1248
Page 10 of 11
CLAUSE NO.
CONTROL & PROTECTION PANELS Voltmeter 96 mm x 96 mm square, flush panel 240 deg. Radial, +/- 1 % full scale accuracy,suitable for 0-10A ,suitable for PT secondary voltage of 63.5 phase to earth , Black case/white dial having facility of zero adjustment. Applicable standard IS:1248
13.09.00
13.10.00
Energy meter CT & PT operated Energy meter shall be as per specification provided elsewhere in this chapter.
13.11.00
Power factor meter CT & PT operated Power factor meter shall be 96 mm x 96 mm square, moving coil, flush panel 240 deg. radial, +/- 1% full scale accuracy, suitable for PT secondary voltage of 63.5 phase to earth & CT secondary current of 1 Amp., Black case/white dial having facility of zero adjustment. Applicable standard IS:1248 .Scale 0.5lag, Unity, 0.5 lead.
13.12.00
Semaphore indicators Flush mounting, 45deg. operation, 38mm size, suitable dc control supply voltage.
13.13.00
Control switches Pistol grip type, flush mounted, maximum voltage 660V AC/DC, 25A continuous, DC breaking 1A at220Vdc, AC breaking 26A at 440V, 0.3 lagging power factor, Kaycee make or equivalent, shall be provided with barrel locking facility having key removal only in neutral. 2 nos. of NO contacts each shall be available for the control switch positions of C, T, NAC and NAT.
13.14.00
Annunciation system Annunciation system shall be solid state, comprising of audio visual annunciation with the facility of test/accept/reset push-buttons (located in the panel), sequence module, logic card, lamp box, etc. For group alarms reflash card shall be provided to accommodate multiple field contact groups. Contact bounce filter shall be provided on all input cards. Lamp box size shall have 50mm x 75mm display area with 5mm size inscription. Annunciation system shall be suitable for 30 field inputs.
13.15.00
Contact Multiplication relay Conform to the standards and having operating DC voltage of that of station battery voltage.
Page 11 of 11
CLAUSE NO.
11 kV VACUUM CIRCUIT BREAKER SCOPE This specification covers three-pole, 50 Hz, 11 KV vacuum circuit breakers both for indoor and outdoor installations in rural electrification system. SERVICE CONDITONS The breakers and accessories to be supplied against this specification shall be suitable for satisfactory continuous operation under the tropical conditions described in General Technical Requirement & in Project Synopsis. APPLICABLE STANDARDS Unless otherwise modified in this specification, the vacuum circuit breakers shall comply with the following Indian Standards as amended from time to time . Sl. No. 1. IS IS-13118 (1991) IS-12729 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. IEC-17A Study Group Dec. 1981 IS-1554 IS : 5 IEC : 529 IEC-227 IS-2705 (1992) Is-3156 (1992) Is-3231 (1987) Is-1248 IS-375 IS: 14697 IS-3072 IS : 9135 IEC : 60
IEC-60687
1.00.00
2.00.00
3.00.00
IEC IECSwitchgear 62271-100 IEC-694
Item
Common clauses for high voltages switchgear and control gear standards Current Transformer Voltage Transformer Relays Ammeter & Voltmeter Arrangement of Breakers Bus Bars main connection and auxiliary wiring Static Energy Meter Installation and maintenance of switchgear Guide for testing of circuit breakers with respect to out of phase switching High voltage testing technique Sealing of interrupters/breakers PVC insulated cables upto and including 1000 volts Colors for ready mixed paints and enamels Degree of protection provided enclosure
CHAPTER-II SECTION-E6 11 kV Vacuum Circuit Breaker Page 1 of 13
RGGVY WORKS Standard Technical Specification
TECHNICAL SPECIFICATION VOL-II-B, (PART-A)
CLAUSE NO.
11 kV VACUUM CIRCUIT BREAKER 15. 16. 17 IS : 996 Is : 2629, 2633 IS 3427 IEC-34 Iso : 1460 IEC 298 AC Motors Hot Dip galvanising A.C. Metal Enclosed Switchgear and Controlgear for Rated Voltages Above 1 kV and Up to and Including 52 kV
4.00.00
RATED VOLTAGE The rated voltage for the circuit breaker shall be 12 KV. This represents the highest system voltage corresponding to the nominal system voltage of 11 KV. RATED CURRENT The standard rated normal current shall be 400A. The bus-bar rating of the indoor type vacuum circuit breaker shall be 400 A. & short time rating shall be 13.1KA for 1 second. RATED SHORT-CIRCUIT BREAKING CURRENT The rms value of the A.C. component of the rated short-circuit breaking current shall be 13.1 kA. The value of D.C. component shall be calculated in accordance with the recommendations contained in IS: 13118. RATED SHORT-CIRCUIT MAKING CURRENT The rated short-circuit making current of the circuit breakers shall be taken as 2.5 times the rms value of the A.C. component of the rated short-circuit breaking current. RATED VOLTAGE OF OPERATING DEVICES The standard DC voltage for the operating devices shall be 30/24/48V as specified in the Scope of Work Voll-2A VOLTAGE TRANSFORMER FOR METERING Voltage Ratio : The rated voltage ratio shall be 11000/110 V. The transformer shall be star-star connected and one of the secondary terminals shall be earthed. Rated Output: The standard rated output (burden) of the voltage transformer shall be 50VA per phase Accuracy Class : The standard accuracy class shall be 0.5. CURRENT TRANSFORMER FOR METERING & ROTECTION Transformer Ratio: The standard transformation ratio shall be :400-200/1A
5.00.00
6.00.00
7.00.00
8.00.00
9.00.00 9.01.00
9.02.00
10.00.00
CHAPTER-II SECTION-E6 11 kV Vacuum Circuit Breaker
Page 2 of 13
CLAUSE NO.
11 kV VACUUM CIRCUIT BREAKER Accuracy Class : Accuracy class for the purpose of metering shall be 0.5 and for the purpose of protection shall be 5P with an Accuracy Limit Factor of 15. Rated Output : The rated output (burden) of the current transformers for both protection & metering cores shall be 10VA. METERING AND PROTECTION Meters/instruments on the incoming and outgoing circuit breaker panels shall be provided in accordance with relevant clauses of the chapter shall be as specified in the relevant clause of chapter Control & Protection Panel CONSTRUCTIONAL FEATURES(Indoor) Indoor Application : The 11 kV HT Switch board shall be totally enclosed dust and vermin proof, sheet metal clad, floor mounted, free standing, indoor type and shall house circuit breakers, busbars, control equipments, cable termination, current transformers, potential transformers, instruments, relays and other accessories. All HT panels shall be with fully draw out type breaker carriages, compartmentalized design with cold rolled sheet steel (thickness 2.0 mm for non load bearing and 3.0mm for load bearing parts) and with IP-52 class of enclosure. The Circuit Breaker compartment, Busbar compartment, Cable compartment and LT compartment shall have its own pressure relief flaps/vents with a view to release pressure which would develop in the unlikely event of fault. The vents shall not allow entry of vermin in any case. Bus bar, metering, circuit breaker chamber, cables and cable box chamber should have proper access for maintenance, proper interlocks should be provided. All instruments shall be non-draw out type and safe guard in every respect from damages and provided with mechanical indicator of connection and disconnection position. The switchgear shall be completed with all necessary wiring fuses, auxiliary contacts terminal boards etc. For each of the incoming and outgoing cubicles, the cable connection, HT bus bars and all low voltage control devices shall be housed in separate enclosures. These enclosures shall be necessarily isolated from that for main circuit breaker chamber to offer better safety and protection of working personnel. All doors other than cable chamber shall be of hinged and lockable type with Neoprene gaskets at all joints and the cable chamber shall be fixed with nuts and bolts. Additional wire mesh guards and gaskets shall be provided for cable chamber. The arcing contacts and bus bar should be rated for 13.1KA for1 seconds. Bus bars shall be capable of connecting one switchgear panel to other through proper insulated arrangement, which does not decrease the insulation strength of the bus bar at the point of connection between two panels. The panels shall be modular in design. Breaker should have three distinct positions inside the cubical; i.e. service, test and isolated.
10.01.00
10.02.00
11.00.00 11.01.00
12.00.00 12.01.00
12.02.00
12.03.00
12.04.00
12.05.00
The switchboard shall be suitable to handle full rated capacity in the naturally ventilated atmosphere and it shall be able to control and contain the high short circuit
TECHNICAL SPECIFICATION VOL-II-B, (PART-A) CHAPTER-II SECTION-E6 11 kV Vacuum Circuit Breaker Page 3 of 13
CLAUSE NO.
11 kV VACUUM CIRCUIT BREAKER energy under internal arc conditions and ensure safety of the operating personnel in case of faults.
12.06.00
13.00.00
The cubicle door can be fully shut with breaker in ISOLATED position to stop ingress of dust and vermin. All switching operations shall be performed with the door closed. BUS BARS AND CONNECTORS i. Bus bars and all other electrical connection between various components shall be made of electrolytic copper of rectangular cross sections. The bus bars shall be able to carry the rated current of 400 Amp continuously without excessive heating and for adequately meeting the thermal and dynamic stresses in the case of short circuit in the system up to full MVA rating. ii. All bus bars connections shall be firmly and rigidly mounted on suitable insulators to withstand short circuit stresses and vibrations. iii. Adequate clearance between 11 KV point and earth and between phase shall be provided to ensure safety as per provision in Indian Electricity Rule 1956 and its amendment thereof and also in accordance with the relevant Indian standard specification and the same shall be capable of withstanding the specified high voltage tests as per IS-13118/IEC-62271-100 and amendment thereof.
14.00.0
Cable glands & Clamping arrangements Two nos, brass-wiping glands for each incomer and one no. Brass wiping gland for each outgoing panel of adequate dimension for XLPE cable of 3 crores up to 400 sq. mm size shall be supplied along with panels. For bus coupler no cable glands should be provided. v. Suitable cable boxes as per requirement of cable shall be arranged by the purchaser at his end. The panel shall however provide a flat of size 50x6 mm2 with suitable clamp made of 50x6 mm2 flat along with Nuts Bolts and Washers for holding the cable boxes. The flat should be fitted at a suitable height with allotted arrangement for adjustment of height from 300mm to 500mm at site. The clamp and flat shall have suitable stud type arrangement for earthing cable and cable box. vi. All control cable/wire entries shall be by means of suitable cable glands, such glands shall be of brass and tinned. iv.
13.00.0
PAINTING All metallic surface [except enameled and bright parts] exposed to weather shall be given suitable primer coat and two coats of first quality paint of approved color. The supplier shall also supply adequate quantities of paints, Varnish etc. for use of finished cost and for use of patching up any scratches received during transport, handling erection testing and commissioning.
Page 4 of 13
CLAUSE NO.
11 kV VACUUM CIRCUIT BREAKER
Instead of above proper powder coating after proper pre treatment is acceptable and in that case earlier condition will not applicable. 14.00.00 14.01.00 CONSTRUCTIONAL FEATURES(Outdoor Application) Vacuum circuit breakers for outdoor application shall have fixed type of construction and the vacuum interrupter units together with the HV connections shall be enclosed in a sealed housing (preferably of porcelain) conforming to IP-65 protection (IS:2147). The operating mechanism, links, etc. shall be housed in a suitable cubicle and should be accessible for maintenance. The relays, meters, indicators and operating handle etc. shall be provided on the front side with a hinged door and locking device. The door shall open upwards (with hinge at the top) for protection against rain (when in open position). Isolator shall be provided for outdoor breakers. AUXILIARY/CONTROL WIRING .All the secondary wiring in the panel shall have high quality PVC insulation and the same shall have conductor size of not less than 2.5 mm2 of copper Colors of the secondary/auxiliary wiring should confirm to IS 375/1963 and latest amendment thereof if any. All wiring shall be neatly run and group of wiring shall be securely fixed by clips so that wiring can be checked without necessity of removing the clamps. Wiring between fixed and moving portion of the panel shall be run in flexible tubes and the same shall be so mounted to avoid any damage to them due to mechanical movements. Ferrules with number shall be provided on both end of the wiring. 16.00.00 CLOSING/TRIPPING MECHANISM The circuit breakers shall be provided with 230 V single-phase AC motor for springclosing mechanism with provision for manual spring charging. circuit breakers shall have h solenoid closing mechanism suitable for operation with 30/24/48V DC battery as required. In the case of outdoor circuit breakers, it would be preferable to house the station battery in an outdoor kiosk instead of the control room to avoid excessive voltage drop in the long leads. Circuit breakers shall be provided with trip coil operated by 30/24/48V DC battery as required, using Shunt trip relays.
14.01.02 15.00.00
Page 5 of 13
CLAUSE NO.
11 kV VACUUM CIRCUIT BREAKER TESTS The circuit breakers, voltage transformers and current transformers shall be subjected to the following routine and type tests in accordance with the details specified in the relevant Indian standards, as amended from time to time.
17.00.00
17.01.00 17.01.01
Circuit Breakers - IS:13118-1991 Routine Tests i. ii. iii. iv. Power frequency voltage dry test on the main circuit Voltage test on control and auxiliary circuits Measurement of resistance of the main circuit Mechanical Operating test
17.01.02
Type Tests i) ii) iii) iv) v) vi) vii) viii) ix) x) Mechanical performance Mechanical operation Temperature rise Insulation resistance short-circuit making and breaking performance short-time current performance performance when breaking line-charging current performance when breaking cable-charging current performance when breaking single capacitor bank currents the performance when breaking small inductive currents
17.02.00 17.02.01
Voltage Transformers : - IS:3156 (Part-I)-1992 Routine Tests i) Verification of terminal markings and polarity ii) Power-frequency dry withstand tests on primary windings iii) Power-frequency dry withstand tests on secondary windings iv) Determination of errors for accuracy class Type Tests: i) ii) iii) iv) Verification of terminal markings and polarity Power-frequency dry withstand tests on primary windings Power-frequency dry withstand tests on secondary windings Determination of errors for accuracy class
TECHNICAL SPECIFICATION VOL-II-B, (PART-A) CHAPTER-II SECTION-E6 11 kV Vacuum Circuit Breaker Page 6 of 13
17.02.02
CLAUSE NO.
11 kV VACUUM CIRCUIT BREAKER v) Temperature-rise test vi) Impulse voltage tests Current Transformers - IS:2705 (Part-I)-1992 Routine Tests: i) ii) iii) iv) v) Verification of terminal markings and polarity High voltage power-frequency test on primary windings High voltage power-frequency test on secondary windings Over-voltage inter-turn test Determination of error for accuracy class
17.03.00 17.03.01
17.03.02
Type Tests: i) Verification of terminal markings and polarity ii) High voltage power frequency test on primary windings iii) High voltage power frequency test on secondary windings iv) Over-voltage inter-turn test v) Determination of error according to accuracy class vi) Short-time current test vii) Temperature-rise test viii) Impulse voltage test NAME PLATE AND DIAGRAM PLATES The firm shall affix a name plate on each Switchgear panel having following information: ix) x) xi) xii) xiii) xiv) xv) xvi) xvii) Manufacturers name and trade mark. Unique No. Type of Panel. CT Ratio. Rated Voltage. Rated Insulation Level Rated Frequency Rated Normal Current Rated Short Circuit Breaking Current.
18.00.00
xviii) Weight
RGGVY WORKS Standard Technical Specification TECHNICAL SPECIFICATION VOL-II-B, (PART-A) CHAPTER-II SECTION-E6 11 kV Vacuum Circuit Breaker Page 7 of 13
CLAUSE NO.
11 kV VACUUM CIRCUIT BREAKER
xix) xx) xxi) xxii) 19.00.00
Specification No. Order No. and Date Year of supply. RGGVY/NESCL works
INSPECTION i) All tests and inspection shall be made at the place of manufacture unless otherwise especially agreed upon by the manufacturer and purchaser at the time of purchase. The manufacturer shall afford the inspector representing the purchaser all reasonable facilities, without charge, to satisfy him that the material is being furnished in accordance with the specification. ii) The purchaser has the right to have the tests carried out at his own cost by an independent agency whenever there is dispute regarding the quality of supply.
20.00.00
Technical Parameters 11 kV Circuit Breakers Sl. No. i) ii) iii) iv) v) vi) vii) viii) ix) DESCRIPTION Rate Voltage (kV rms) Rated frequency (Hz) System neutral earthing Type of arc quenching medium Rated normal current at site conditions (Amps) Number of poles Installation Temperature rise Rated short circuit a) Interrupting capacity at : 13.1 kA
VALUES : : : : : : : : 11 kV 50 Solidly grounded system Vacuum 400 Amps 3 Outdoor/Indoor type As per IEC 62271-100
CLAUSE NO.
11 kV VACUUM CIRCUIT BREAKER 11 kV b) The percentage DC components c) Minimum number of Short Circuit operation the Circuit Breaker can withstand x) xi) xii) xiii) xiv) Rated short circuit making capacity First pole to clear factor Rated short time carrying capacity current : : As per IEC 62271-100 100
: : : : :
33kA 1.5 13.1 kA for 1 second 1 Seconds As per IS/IEC
Rated duration of short circuit Total break time for any current upto the rated breaking current with limiting condition of operating and quenching media pressure (ms) Closing time (rms) Standard value of rated transient recovery voltage for terminal fault Standard value of rated line Characteristics for short line faults RRRV Surge Peak Factor Impedance
xv) xvi)
: :
As per IS/IEC As per IEC-62271-100
xvii)
: : : : :
KV/ms=0.214 Factor K=1.6 A Z (ohms) = 450
xviii)
Rated operating a) Duty cycle
O-0.3 Second-CO-3 Minutes-CO
b) Auto reclosing xix) Rated insulation level under heavy pollution condition
: :
Suitable for three phase Auto reclosing duty 75 kV

CLAUSE NO.
11 kV VACUUM CIRCUIT BREAKER 1.2/50 micro second lightening Impulse withstand voltage (kV peak) to earth xx) Power frequency withstand voltage kV (rms) to earth (kV rms) Rated characteristic for out of Phase breaking a) Out of phase breaking capacity b) Standard values transient recovery c) Operating mechanism d) Power available operating mechanism(Spring charging) xxii) for of : 28 kV
xxi)
: : : : : 25% of rated breaking capacity As per IEC-62271-100 Spring operated, Anti pumping and Trip free mechanism Three phase 415 Volts 50 C/S or single phase 50 C/S 240 Volts
a) Rated supply voltage of closing and operating devices and auxiliary circuits b) Permissible voltage variation
1) 30/24/48 VDC for closing & tripping 2) 240 Volts AC 50 C/S single phase
1) In case of DC Power supply voltage variation shall be between 85% to 110% of normal voltage. 2) In case of AC power supply voltage variation shall be of the normal voltage as per IS-15% to +10%
c) Permissible frequency d) Combined variation of frequency and voltage xxiii) Number of auxiliary contacts
: : :
3% from normal 50 Hz as per IS : 2026 Part-I 1977 para 4.4 15% 4 NO and 4 NC on each pole Continuous current rating 10 Amps, DC breaking rating capacity shall be 2 Amps with circuit time constant less than 20 ms at 220 volts DC 2 (Two) trip coils and 1 close coil with
xxiv)
Number of coils
CLAUSE NO.
11 kV VACUUM CIRCUIT BREAKER anti-pumping arrangement xxv) Rated terminal load : 100 kg. Static. The breaker shall be designed to withstand the rated terminal load, wind, load, earthquake load and short circuit forces.
Page 11 of 13
CLAUSE NO.
11 kV VACUUM CIRCUIT BREAKER ANNEXURE CONFIGURATION OF DIFFERENT TYPE OF 11 KV INDOOR PANEL Sl. No. 1. 2. 3. Description of Relays 1 No. Fabricated sheet steel housing 1 No. Complete set of mechanical interlocks 1 No. Set of isolating plugs and sockets [6 nos. rated for 400 Amp. With automatic safety shutters and pad locking arrangements] 1 No. 400 Amp triple pole VCB fitted with isolating sockets, spring operated, manually as well motor charged, manually/electrically released spring closing mechanism with mechanical ON/OFF indicators 1 No. set of copper bus bars of not less than 400 Amp. Continuous rating Protection Relays for Incomer (Shall be as specified in the relevant clause of chapter Control & Protection Panel) 7. Protection Relays for feeder (Shall be as specified in the relevant clause of chapter Control & Protection Panel) 8. Static Trip Circuit supervision relays suitable for pre-closing and post-closing supervision of circuit breaker trip coil circuit Rated Voltage : 30/24/48 VDC 9. 10. Static, instantaneous 3 phase PT Fuse Failure Relays. Rated Voltage-110VAC Master Trip operation at Relays suitable for 30/24/48 VDC with
Incomer
Bus Coupler
Outgoing
4.
5. 6.
Page 12 of 13
CLAUSE NO.
11 kV VACUUM CIRCUIT BREAKER sufficient number and configuration of contacts 11. Auxiliary Relays for Anti-pumping, Density switch, Contact multiplier etc. as may be required Voltmeter with selector switch Ammeter with selector switch Power Factor meter Indication lamps for breaker on, Breaker off, auto trip, trip circuit healthy and spring charged Local remote selector switch Pistol grip switch Push buttons for Alarm accept/Reset/Lamp test Annunciation windows with annunciation relay Trivector Energy Meter CT (Metering core of accuracy 0.5 and protection core of type 5 P 15) 1 No. 3 phase resin cast, draw out type bus bar connected potential transformers of Ratio 11000/110 volts class 0.5 accuracy having 50 VA output per phase, complete with HT fuse and LT MCB with monitoring contacts 1 No. 80 watts continuously rated tubular/strip type heater with manual ON/OFF switch working on 230 VAC single phase supply 1 No. multi way plug box for secondary wiring between the fix and moving glands 1 No. set of independently operated automatic shutters for bus bar cable and
12. 13. 14. 15.
16. 17. 18. 19. 20. 21.
400/200/1
400/200/ 1 -
200/100/1 -
22.
23.
24.
25.
Page 13 of 13
CLAUSE NO.
11 kV VACUUM CIRCUIT BREAKER voltage transformers orifices, which shall be clearly leveled and individually pad-locked 26. 1 No. complete set of self contained inter connectors, foundation bolts, fine wiring, wiring terminals board, sundries to complete the unit Spring Charging Handle
27.
1 No. with each set of panel
Feature to be provided - Feature not to be provided
Page 14 of 13
CLAUSE NO.
CONTROL & POWER CABLES GENERAL All power and control cables will be armoured. They shall be designed to withstand all mechanical, electrical and thermal stresses under steady state and transient operating conditions. The cables shall be suitable for laying in racks, ducts trenches, conduits and underground buried installation with uncontrolled back fill and chances of flooding by water. The Aluminium/copper wires used for manufacturing the cables shall be true circular in shape before stranding and shall be uniformly good quality, free from defects. All Aluminium used in the cables shall be of H2 grade. The fillers and inner sheath shall be of non-hygroscopic, fire retardant material, softer than insulation and outer sheath shall be suitable for the operating temperature of the cable. Progressive sequential marking of the length of cable in metres at every one metre shall be provided on the outer sheath of all cables. . For control cables only round wire armouring shall be used. All the cables shall pass fire resistance test as per IS:5831. The cables shall have outer sheath of a material with an oxygen index of not less than 29 and a temperature index of not less than 250 Deg. C. The normal current rating of all PVC insulated cables shall be as per IS:3961. All cables shall conform to type test and shall be subjected to routine and acceptance tests listed in the relevant IS. Repaired cables shall not be accepted. Allowable tolerance on the overall diameter of the cables shall be plus or minus 2 mm. L.T. POWER CABLES The PVC insulated 1100 V grade cables shall conform to IS:1554 (Part-I)-1976 and its amendments, read along with this specification and shall be suitable for a steady conductor temperature of 70C. The conductor shall be stranded Aluminium. The insulation shall be extruded PVC to type-A of IS:5831. A distinct inner sheath shall be provided in all multicore cables. For multicore armoured cables, the inner sheath shall be of extruded PVC. The outer sheath shall be extruded PVC to Type ST-I of IS:5831 for all cables.
1.00.00 1.01.00
1.02.00
1.03.00
1.04.00
1.05.00
1.06.00 1.07.00
1.08.00 1.09.00
1.10.00 2.00.00
CONTROL & POWER CABLES
Page 1 of 5
CLAUSE NO.
CONTROL & POWER CABLES L.T. CONTROL CABLES The 1100 V grade control cables shall conform to IS:1554 (Part-I) 1976 and its amendments, read along with this specification. The conductor shall be stranded copper. The insulation shall be extruded PVC to type A of IS:5831. A distinct inner sheath of extruded PVC shall be provided in all cables. The outer sheath shall be of extruded PVC to type ST-I of IS:5831 and shall be Grey in colour except where specifically advised by the Owner to be black. Cores shall be identified as per IS:1554 (Part-I) for the cables upto five (5) cores & for cables with more than five (5) cores the identification of cores shall additionally be done by printing legible alphabets on all cores. The alphabets shall be white, and shall be printed at about 100 mm interval all along the cable length. Cables without such core identifications will not be accepted. CABLE DRUMS Cables shall be supplied in wooden or steel drums of heavy construction and drum shall be properly seasoned sound and free from defects. Wood preservative shall be applied to the entire drum. A layer of water proof paper shall be applied to the surface of the drums and over the outer most cable layer. A clear space of at least 40 mm shall be left between the cables and the logging. Each drum shall carry the manufacturers name, purchasers name and address, contract number, item number and type, size and length of the cable, net and gross weight stencilled on both sides of drum. A tag with same information shall also be attached to the leading end of the cable. An arrow and suitable wordings shall be marked on one end of the reel indicating the direction in which it should be rolled. Packing shall be sturdy and adequate to protect the cables, from any injury due to mishandling or other conditions encountered during transportation, handling and storage. Both cable ends shall be sealed with PVC/rubber caps so as to eliminate ingress of water during transportation and erection. TESTS All types and sizes of cables shall conform to type tests and shall be subjected to all routine and acceptance tests as per relevant IS /IEC. Guaranteed Technical parameters (GTP) The following gauranteed technical parameters shall be applicable.
3.00.00 3.01.00
3.02.00
4.00.00 4.01.00
4.02.00
4.03.00
4.04.00
5.00.00 5.01.00
6.00.00
Page 2 of 5
CLAUSE NO.
CONTROL & POWER CABLES . PART-A Sl.No. Particulars 1 Applicable standard Indian Standard Power conductor Material No. of strands Shape of Conductor Max.DC resistance at 20 deg C(Ohm/KM) Core Identification Insulation Type Nominal Thickness (mm) Laying of Core Inner Sheath Material Type Minimum thickness (mm) Armouring Material Nominal Size (mm) Armour Resistance Outer Sheath Type Minimum thickness (mm) Colour Minimum Oxygen Index ( Tested as per ASTDM-2863) MinimumTemprature Index Current rating (Amperes) Cable shall be fire resistant Standard Length Embossing/Marking Size of Drum 2.5 sq mm. Copper conductor(Control cable) IS:1554 Pt 1/88,IS8130/84,IS:5831/84,IS:3975/99 Stranded bare Cu Class-2 (IS:8130/84) 3 Stranded Circular 7.41 (IS:5831/84) IS:1554 Cl 10.1 Type A PVC compound 0.9 IS:1554 Cl 11 PVC Extruded 0.3 G.I Round Wire (IS:3975/99) As per IS 1554-P-I table-5 IS:1554 Table-6 PVC Compound Type ST-1 1.24 Grey 29 250 deg Celsius IS:3961 Pt-II Yes,complies with IS:5831 500 +/- 5% As per IS:1554 As per IS:10418
4 5
8 9 10 11
12
Progressive sequential marking of the length of cable in meter at every meter Type test reports (all COMPLIED mentioned in relevant clause)
Yes
13
Page 3 of 5
CLAUSE NO.
CONTROL & POWER CABLES Make shall be NESCL Corporate Quality Assurance (CQA) approved. The following gauranteed technical parameters shall be applicable.
PART-A Sl.No. Particulars 1 Applicable standard Indian Standard Power conductor Material No. of strands Shape of Conductor Max.DC resistance at 20 deg C(Ohm/KM) Core Identification Insulation Type Nominal Thickness (mm) Laying of Core Inner Sheath Material Type Minimum thickness (mm) Armouring Material Nominal Size (mm) Armour Resistance Outer Sheath Type Minimum thickness (mm) Colour Minimum Oxygen Index ( Tested as per ASTDM-2863) MinimumTemprature Index Current rating (Amperes) Cable shall be fire resistant Standard Length Embossing/Marking Size of Drum Progressive sequential marking of the length of cable in meter at every meter
2.5 sq mm. Aluminium conductor(Power cable) IS:1554 Pt 1/88,IS8130/84,IS:5831/84,IS:3975/99 Stranded Aluminium H2 Grade (IS:8130/84) 3 Stranded Circular 12.1 (IS:5831/84) IS:1554 Cl 10.1 Type A PVC compound 0.9 IS:1554 Cl 11 PVC Extruded 0.3 G.I Round Wire (IS:3975/99) As per IS 1554-P-I table-5 IS:1554 Table-6 PVC Compound Type ST-1 1.24 Grey 29 250 deg Celsius IS:3961 Pt-II Yes,complies with IS:5831 500 +/- 5% As per IS:1554 As per IS:10418
4 5
8 9 10 11
12
Yes
Page 4 of 5
CLAUSE NO.
CONTROL & POWER CABLES Type test reports (all COMPLIED mentioned in relevant clause)
13
Make shall be NESCL Corporate Quality Assurance (CQA) approved
Page 5 of 5
CLAUSE NO.
AUXILIARY ITEMS STRING INSULATORS & HADRWARE The technical parameters and other details of insulators shall conform to relevant indian standard. CONDUCTOR The bus conductor of the substation shall be ACSR PANTHER conductor .The conductor shall conform to relevant part of IS:398. CLAMPS & CONNECTORS Clamps & connectors shall conform to IS:5561. Constructional Features The clamps and connectors shall be made of materials listed below : a) For connecting ACSR conductors Aluminium alloy casting, conforming to designation A6 of IS:617 and shall be tested for all tests as per IS:617 Bimetallic connectors made of copper with ACSR conductors from aluminium alloy casting conforming to designation A6 of IS:617 with 2 mm thick Bimetallic liner and shall be tested as per IS:617. Galvanised mild steel Hot dip galvanised mildsteel for sizes M12 and above, and electro-galvanised for sizes below M12. Electro-galvanised mildsteel suitable for at least service condition 4 as per IS:1573.
1.00.00 1.01.00 2.00.00 2.01.00 3.00.00 3.01.00 3.02.00 3.02.01
b)
For connecting equipment terminals
c) d)
For connecting GS shield wire Bolts, Nuts & plain washers
e)
Spring washers for items a to c
3.02.02 3.02.03 3.02.04 3.02.05
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 current carrying part of a clamp or connector shall be less than 10 mm thick. They shall be designed and manufactured to have minimum contract resistance. For Bimetallic clamps or connectors, copper alloy liner of minimum 2 mm thickness shall be provided. Flexible connectors, braids or laminated strips made up of copper/aluminium for the terminal clamps for equipment, shall be suitable for both expansion or through (fixed/sliding) type connection of IPS Aluminium tube as required. In both the cases the clamp height (top of the mounting pad to center line of the tube) should be same. Size of the terminal/conductor for which the clamp/connector is suitable shall be embossed/punched (i.e. indelibly marked) on each components of the clamp/
TECHNICAL SPECIFICATION VOL-II (PART-A) CHAPTER-II SECTION-E7 AUXILIARY ITEMS Page 1 of 7
3.02.06
CLAUSE NO.
AUXILIARY ITEMS connector, except on the hardware.
3.02.07
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. Clamps and connector shall be designed corona controlled. EARTHING CONDUCTORS All conductors burred in earth and concrete shall be mild steel. All conductors above ground level and earthing leads shall be galvanized steel. The galvanizing shall conform with requirements stipulated in Sec. GTR. of this specification. Parameters Main Earthing Conductor a) Buried in Earth b) Above ground 25 mm M. S. dia rod (for Main mat) Rod electrode (25 mm dia 3m long MS) G.I. pipe (in treated earth pit) (25 mm and 3 m long perforated pipe). 50x6 GS Flat 50x6 mm GS Flat 50x6 mm GS Flat
3.02.08 4.00.00 4.01.00
4.03.00 4.03.01
4.04.00
Earthing Leads a) b) Columns and other auxiliary structures Cable trenches
4.05.00
Earthwire Earth wire of suitable size shall be used & the material of the wire shall conform to IS 12776: 2002 Specification for Galvanized Strand for Earthing
5.00.00 5.01.00
Cable Support Structures & Accessories The Contractor shall fabricate and install mounting arrangements for the support and installation of all the cables on angles & trays 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 general constructional practice. All nuts, bolts, washers etc. to be supplied by the Contractor shall be hot dip galvanized after fabrication. The Contractor shall perform all tests and inspection to ensure that material and workmanship are according to the relevant standards. The cable trench & trays shall be as per attached tender drawing
5.01.01 5.01.02 5.01.03
CHAPTER-II SECTION-E7 AUXILIARY ITEMS
Page 2 of 7
CLAUSE NO.
AUXILIARY ITEMS BUSHINGS, HOLLOW COLUMN INSULATORS AND DISC INSULATORS INSULATORS, SUPPORT
6.00.00 6.01.00
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 5284. The support insulators shall be manufactured and tested as per IS:2544/IEC 168/IEC-273. The insulators shall also conform to IEC 815 as applicable. 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. Porcelain used shall be homogenous, 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 form blisters, burns and other similar defects. When operating at normal rated voltage there shall be no electric discharge between conductor and insulators which would cause corrosion or injury to conductors or 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 be lead to deterioration. All ferrous parts shall be hot dip galvanized. Contractor shall make available data on all the essential features of design including the method of assembly of shells and metal parts, number of shells per insulator, the manner in which mechanical stresses are transmitted through shells to adjacent parts, provision for meeting expansion stresses, results of corona and thermal shock tests, recommended working strength and any special design or arrangement employed to increase life under service conditions. Post type insulators shall consist of a porcelain part permanently secured in metal base to be mounted on supporting structures. They shall be capable of being mounted upright. They shall be designed to withstand all shocks to which they may be subjected to during operation of the associated equipment. Bushing porcelain shall be robust and capable of withstanding the internal pressures likely to occur in service. The design and location of clamps, 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 galvanized and all joints shall be air tight. Surface of joints shall be trued, 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.
6.02.00
6.03.00
6.04.00 6.05.00
6.06.00
6.07.00
6.08.00
6.09.00
6.10.00
CLAUSE NO.
AUXILIARY ITEMS Parameters of bushings/Hollow column insulators/support insulators : a) b) c) d) e) Rated Voltage Impulse withstand voltage (Dry & Wet) kVp Power frequency withstand voltage (dry and wet) kV (rms) Total creepage distance Pollution level (as per IEC 71) 33 kV / 11 kV 170 / 75 75 / 35 900 mm/320 mm Class-III, Heavy
6.11.00
Insulator shall also meet requirement of IEC - 815 as applicable, having alternate long & short sheds. 7.00.00 7.01.00 7.02.00 CONTROL CABINETS, JUNCTION MARSHALLING BOX / KIOSK BOXES, TERMINAL BOX
All types of boxes, kiosks and cabinets shall generally conform to IS:5039/IS:8623, IEC 439 as applicable and as given below. The cabinets/boxes/kiosks shall be of sheet Steel/Aluminium and shall be dust, water and vermin proof. Sheet steel used shall be at least 2.0 mm thick cold rolled/ 2.5 mm thick 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 Aluminium enclosed box, the thickness of Aluminium shall be such that it provides adequate rigidity and long life as comparable with sheet steel of specified thickness. The enclosures of the cabinets/boxes/kiosks shall provide a degree of protection of not less than IP 55 as per IS:13947. The cabinets/boxes/kiosks shall be free standing floor mounting type or wall mounting type or pedestal mounting type as per requirements. The cabinets/boxes/kiosks shall be provided with at least double hinged doors with padlocking arrangement. The distance between two hinges shall be adequate to ensure uniform sealing pressure against atmosphere. All doors, removable covers and plates shall be gasketed all around with neoprene gaskets. The neoprene gasket shall be tested in the presence of Owners representative. All gasketted surfaces shall be smooth, straight and reinforced if necessary to minimise distortion and to make a tight seal. All cabinets/boxes/kiosks shall be designed for the entry of cable from bottom by means of weather proof and dust-proof connections. Boxes and cabinets shall be so designed with adequate clearances to avoid interference between the wiring entering from below and any terminal blocks or accessories mounted within the box or cabinet. Suitable cable gland plate on the base of the marshalling kiosk projecting at least 150mm above the base shall be provided for this purpose. Necessary number of Double Compression type cable glands of suitable sizes shall be supplied. This removable gasketted gland plate shall have provision for some glands if needs to be provided in the future. The glands shall project at least 25 mm above the gland plate to prevent the entry of moisture in the cable crutch.
7.03.00 7.04.00 7.05.00
7.06.00
7.07.00
CLAUSE NO.
AUXILIARY ITEMS Suitable A.C. heaters shall be provided in the cabinets/boxes/kiosks to prevent condensation. Heaters shall maintain cubicle temperature approximately 10C above the outside air temperature for which suitable thermostat shall be provided. On-off switch and fuse for this shall be provided. A 240V, single phase, 50 Hz ac plug and socket of industrial grade 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 cabinets a lamp with socket and a door operated switch shall be provided. 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/flat shall be terminated on to the earthing pad and secured by the use of star or self etching washers. Earthing of hinged door shall be done by using a separate earth wire. Terminal Block All internal wiring to be connected to the external equipment shall terminate on terminal blocks, preferably vertically mounted on the side of cabinet, junction box, terminal box and marshalling box. The terminal blocks shall be made of moulded, non-inflammable thermosetting plastic. The material of terminal block moulding shall not deteriorate because of varied conditions of heat, cold humidity, dryness etc. that would be anticipated at the location where the equipment is proposed to be installed. 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 terminal blocks shall be non-disconnecting stud type equivalent to Elmex type CAT-M4. The conducting part in contact with cable shall be tinned or silver plated. The terminal blocks shall be of extensible design. The terminal blocks shall be of 1100 V grade and shall be rated to carry continuously the maximum current that is expected to be carried by the terminals. The terminal blocks shall be fully enclosed with removable covers of transparent, non-deterioration 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. The terminals shall be provided with the marking tags for wiring identification. The boxes shall be provided with 20% spare terminals unless otherwise specified. Unless otherwise specified, terminal blocks shall be suitable for connecting the following conductors on each side. a) All circuits except CT/VT Minimum of two 2.5 sq.mm. copper flexible
CHAPTER-II SECTION-E7 AUXILIARY ITEMS Page 5 of 7
7.09.00
7.10.00
7.11.00 7.12.00 7.13.00
7.16.00 7.16.01
7.16.02
7.16.03
7.16.04 7.16.05 7.16.06 7.16.07
7.16.08 7.16.09
CLAUSE NO.
AUXILIARY ITEMS b) c) All CT/VT circuits AC/DC Power supply circuits Minimum of 4 nos. of 2.5 sq.mm copper flexible One of 16 sq. mm. aluminium.
7.16.10
There shall be a minimum clearance of 250 mm between the first row of terminal block and the cable gland plate or side of the box. Also the clearance between two rows of terminal blocks shall be a minimum of 150 mm. 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. Cabinet wiring should be suitable for 60 deg. C as the space heaters will keep the temperature 10 deg. C higher than the ambient. For the Control and Relay Panels the terminal blocks for current transformer and voltage transformer secondary lead shall be provided with test links and isolating facilities. Also current transformer secondary leads shall be provided with short circuiting and earthing facilities. Wiring All wiring shall be carried out with 1100 V grade stranded copper wires. The minimum size of the stranded conductor used for internal wiring shall be as follows: a) b) All circuits except CT circuits 2.5 sq.mm. CT circuits 4 sq.mm. (minimum number of strands shall be 3 per conductor).
7.16.11
7.16.12
7.17.00 7.17.01
7.17.02 7.17.03
All internal wiring shall be securely supported, neatly arranged readily accessible and connected to equipment terminals and terminal blocks. Wire terminations shall be made with solderless crimping type of tinned copper lugs which firmly grip the conductor and insulation. Insulated sleeves shall be provided at all the wire terminations. Engraved core identification plastic ferrules marked to correspond with the wiring diagram shall be fitted at both ends of each wire. Ferrules shall fit tightly on the wires shall not fall off when the wires and shall not fall off when the wire is disconnected from terminal blocks. All wires directly connected to trip circuit breaker shall be distinguished by the addition of a red coloured unlettered ferrule. Number 6 & 9 shall not be included for ferrules purposes. All terminals including spare terminals of auxiliary equipment shall be wired upto terminal blocks. Each equipment shall have its own central control cabinet in which all contacts including spare contacts from all poles shall be wired out. Interpole cabling for all equipments shall be carried out by the Contractor. CABLE GLANDS AND LUGS Cable glands shall be Double compression type, tinned/Nicked plated (coating thickness not less than 20 microns in case of tin and 10 to 15 microns in case of nickel) brass cable glands for all power and control cables. They shall provide dust and weather proof terminations. They shall comprise of heavy duty brass casting, machine finished and tinned to avoid corrosion and oxidation. Rubber components
7.17.04
7.17.05
8.00.00 8.01.00
CLAUSE NO.
AUXILIARY ITEMS used in cable glands shall be neoprene and off tested quality. Required number of packing glands to close unused openings in gland plates shall also be provided.
8.02.00
Cables lugs shall be tinned copper solder less crimping type conforming to IS:8309 and 8394 suitable for aluminum or copper conductor (as applicable). The cable lugs shall suit the type of terminals provided. The cable lugs shall be of Dowell make or equivalent. CONDUITS, PIPES AND ACCESSORIES The 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 reduces, enlargers, wooden plugs, coupling caps, nipples, gland sealing fittings, pull boxes, etc. Rigid conduits shall be flow-coat metal conduits. The outer surface of the conduits shall be coated with hot-dip zinc and chromate conversion coatings. The inner surface shall have silicone epoxy ester coating for easy cable pulling. Mild steel pipes shall be hot-dip galvanised. All rigid conduits/ pipes shall be of a reputed make. Flexible conduits shall be heat-resistant lead coated steel, water-leak, fire and rust proof, and be of PLICA make or equivalent.
9.00.00 9.01.00
9.02.00
9.03.00
CHAPTER-II SECTION-E7 AUXILIARY ITEMS
Page 7 of 7
CLAUSE NO.
SITE TESTING AND COMMISSIONING

INTRODUCTION An indicative list of tests is given below. Contractor shall perform any additional test based on specialties of the items as per the field QP/instructions of the equipment supplier or Owner without any extra cost to the Owner. The Contractor shall arrange all instruments required for conducting these tests along with calibration certificates and shall furnish the list of instruments to the Owner for approval. GENERAL CHECKS a) b) c) d) e) f) g) h) i) Check for physical damage. Visual examination of zinc coating/plating. Check from name plate that all items are as per order/specification. Check tightness of all bolts, clamps and connecting terminals using toque wrenches. For oil filled equipment check for oil leakage, if any. Also check oil level and top up. Check ground connections for quality of weld and application of zinc rich paint over weld joint of galvanized surfaces. Check cleanliness of insulator and bushings. All checks and tests specified by the manufactures in their drawings and manuals as well as all tests specified in the relevant code of erection. Pressure test on all pneumatic lines at 1.5 times the rated pressure shall be conducted. Insulation resistance of each pole. Check adjustments, if any, suggested by manufacturer. Breaker closing and tripping time. Slow and power closing operation and opening Trip free and anti pumping operation. Minimum pick up volts of coils Contact resistance Functional checking of compressed air plant and all accessories Functional checking of control circuits, interlocks, tripping through protective relays and auto-reclose operation. Insulation resistance of control circuits, motor etc. Resistance of closing and tripping coils. Insulation resistance of each pole Manual and electrical operation on interlocks Insulation resistance of control circuits and motors. Ground connections Contact resistance
1.00.00 1.01.00
2.00.00
3.00.00
CIRCUIT BREAKERS a) b) c) d) e) f) g) h) i) j) k)
4.00.00
ISOLATORS a) b) c) d) e)
Page 1 of 2
CLAUSE NO.

f) g) h) Proper alignment to minimise the vibration to the extreme possible during operation. Measurement of operating torque for isolator and Earth switch Resistance of operating and interlocking coils. Insulation Resistance Test Polarity test. Ratio identification test-checking of all ratios on all cores by primary injection of current. Dielectric test of oil (wherever applicable) Magnetising characteristics test. Insulation resistance test Polarity test Ratio test Dielectric test of oil (if applicable) Grading leakage current Resistance of ground connection.
5.00.00
CURRENT TRANSFORMERS a) b) c) d) e)
6.00.00
VOLTAGE TRANSFORMERS a) b) c) d)
7.00.00
SURGE ARRESTER a) b)
8.00.00 9.00.00
PHASING OUT The phasing out of all supplies in the Sub station system shall be carried out. STATION EARTHING a) b) c) d) e) Check soil resistivity Check continuity of grid wires Check earth resistance of the entire grid as well as various sections of the same. Check for weld joint and application of zinc rich paint on galvanised surface. Dip test on earth conductor prior to use.
10.00.00
CONDUCTOR STRINGING AND POWER CONNECTORS a) b) c) d) e) Physical check for finish Electrical clearance check Testing of torque by torque wrenches on all bus power connectors and other accessories. Milli volt drop test on all power connectors. Sag and tension check on conductors.
11.00.00
INSULATORS Visual examination for finish damage, creepage distance, etc.
Page 2 of 2
CLAUSE NO.
POWER TRANSFORMERS SCOPE This specification covers the design, manufacture, assembly, shop testing/inspection before dispatch, , packing, forwarding, transportation to site of 33/11 kV ONAN type outdoor power transformer for use in rural electrification system. STANDARD RATING The standard rating shall be 3150 KVA with off-circuit taps. CONSTRUCTIONAL DETAILS The features and constructional details of all transformers shall be in accordance with the requirements stated herein under:
1.00.00 1.01.00
2.00.00
3.00.00
3.01.00
Tank & Tank Accessories The Tank of the power transformer shall be as per details given below: i) The Transformer tank and cover shall be fabricated from high grade low carbon plate steel of tested quality. The tank and the cover shall be of welded construction. ii) Tank shall be designed to permit lifting by crane or jacks of the complete transformer assembly filled with oil. Suitable lugs and bosses shall be provided for this purpose. iii) All beams, flanges, lifting lugs, braces and permanent parts attached to the tank, shall be welded and where practicable, they shall be double welded. iv) The main tank body of the transformer, excluding tap changing compartments and radiators, shall be capable of withstanding pressure of 760 mm of Hg. v) Inspection hole(s) with welded flange(s) and bolted cover(s) shall be provided on the tank cover. The inspection hole(s) shall be of sufficient size to afford easy access to the lower ends of the bushings, terminals etc. vi) All bolted connections to the tank shall be fitted with suitable oil-tight gaskets which shall give satisfactory service under the operating conditions for complete life of the transformer. Special attention shall be given to the methods of making the hot oil-tight joints between the tank and the cover as also between the tank cover and the bushings and all outlets to ensure that the joint can be remade satisfactorily and with ease, with the help of semiskilled labour. Where compressible gaskets are used, steps shall be provided to prevent overcompression. vii) Suitable guides shall be provided for positioning the various parts during assembly or dismantling. Adequate space shall be provided between the
POWER TRANSFORMERS
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CLAUSE NO.
POWER TRANSFORMERS cores and windings and the bottom of the tank for collection of any sediment. The transformer top shall be provided with a detachable tank cover with bolted flanged gasket joint. Lifting lugs shall be provided for removing the cover. The surface of the cover shall be suitably sloped so that it does not retain rainwater.
3.02.00
Axle and Wheels The transformers shall be provided with flanged wheels suitable for use on a 1435 mm gauge track. These wheels shall be suitable for being turned through an angle of 90and locked in that position when the tank is jacked up. Other transformers shall be provided with bidirectional flat rollers suitable for use on a 1000mm gauge track.
3.03.00
Anti Earthquake Clamping Device To prevent transformer movement during earthquake, a clamping device should be provided for fixing the transformer to the foundation. The contractor shall supply necessary bolts for embedding in the concrete.
3.04.00
Oil Preservation System The transformer shall be provided with conventional single compartment conservator. The top of the conservator shall be connected to the atmosphere through a transparent type silica gel breather. Silica gel is isolated from atmosphere by an oil seal The Buchholz relay shall also be provided as specified.
3.05.00
Conservator Tank It shall have adequate capacity to accommodate oil preservation system and volumetric expansion of total transformer oil. The conservator shall be bolted into position so that it can be removed for cleaning purposes.
3.06.00
Buchholz Relay A double float type Buchholz relay conforming to IS: 3637 shall be provided. The relay shall be provided with a test cock suitable for a flexible pipe connection for checking its operation.. The device shall be provided with two electrically independent contacts, one for alarm on gas accumulation and the other for tripping on sudden rise of pressure.
3.07.00
Temperature Indicator i) Oil Temperature Indicator (OTI) All transformers shall be provided with a 150 mm dial type thermometer for top oil temperature indication. The transformer shall have adjustable, electrically independent alarm and trip contacts, maximum reading pointer and
POWER TRANSFORMERS
Page 2 of 21
CLAUSE NO.
POWER TRANSFORMERS resetting device and shall be mounted in the marshalling box. A temperature sensing elements suitably located in a pocket in top oil shall be furnished. This shall be connected to OTI by means of capillary tubing. Accuracy class of OTI shall be +2 deg. C or better. ii) Winding temperature indicator A device for measuring the hot spot temperature of the winding shall be provided. The accuracy class of winding temperature indicator shall be +2 deg. C or better. It shall comprise temperature sensing element, image coil and bushing current transformer, aux. CTs, if required to match the image coil, automatic ambient temperature compensation and 150 mm dial type indicating instrument with maximum reading pointer, mounted in marshalling box. The device shall have two adjustable electrically independent, alarm and trip contacts.
3.08.0
CORE The core shall be constructed from M4 or better grade non ageing, cold rolled grain oriented silicon steel laminations. The design of the magnetic circuit shall be such as to avoid static discharges, development of short circuit The Core of the power transformer shall be as per details given below: i) ii) The core shall be wound or stack type. Each lamination shall be insulated such that it will not deteriorate due to mechanical pressure and the action of hot transformer oil. The core shall be constructed either 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 and frequency variation of - 5% shall not exceed 1.9 Tesla. The bidder shall provide saturation curve of the core material proposed to be used. The bidder should offer the core for inspection and approval by the purchaser during the manufacturing stage. Bidders call notice for the purpose should be accompanied with the following documents as applicable as a proof towards use of prime core material: a) Invoice of the supplier b) Mills test certificate c) Packing list
iii)
iv)
POWER TRANSFORMERS
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CLAUSE NO.
POWER TRANSFORMERS d) Bill of lading e) Bill of entry certificate to customs v) Core material shall be directly procured either from the manufacturer or through their accredited marketing organization of repute and not through any agent. The laminations shall be free of all burrs and sharp projections. Each sheet shall have an insulating coating resistant to the action of hot oil. The insulation structure for the core to clamp plates, shall be such as to With stand 2000 V DC voltage for one minute. The completed core and coil shall be so assembled that the axis and the plane of the outer surface of the core assembly shall not deviate from the vertical plane by more than 25 mm. All steel sections used for supporting the core shall be thoroughly shot or Sand blasted, after cutting, drilling and welding. The finally assembled core with all the clamping structures shall be free from deformation and shall not vibrate during operation. The core clamping structure shall be designed to minimize eddy current loss. The framework and clamping arrangements shall be securely earthed. The core shall be carefully assembled and rigidly clamped to ensure adequate mechanical strength.
vi)
vii)
viii)
ix)
x)
xi)
xii) xiii)
xiv)
Oil ducts shall be provided, where necessary, to ensure adequate cooling inside the core. The welding structure and major insulation shall not obstruct the free flow of oil through such ducts. The design of magnetic circuit shall be such as to avoid static discharges, development of short circuit paths within itself or to the earthed clamping structure and production of flux component at right angle to the plane of the lamination, which may cause local heating. The supporting framework of the cores 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. The construction is to be of `core type. The core shall be provided with lugs suitable for lifting the complete core and coil assembly. The
POWER TRANSFORMERS
xv)
xvi)
Page 4 of 21
CLAUSE NO.
POWER TRANSFORMERS core and coil assembly shall be so fixed in the tank that shifting will not occur during transport or short circuits.
3.09.00
Windings The conductors shall be of electrolytic grade copper. All windings of all the transformers shall be fully insulated. The insulation of transformer windings and connections shall be free from insulating compounds
3.10.00
Off Circuit Tap change switch Off-circuit taps : Transformers with off-circuit taps shall have taps ranging from (+) 2.5% to (-) 10% in steps of 2.5% each on HV winding. Transformer with higher tap range on positive or negative sides or both which includes (+) 2.5% to (-) 10% range shall also be acceptable without any extra cost. The tap changing switch shall be located in a convenient position so that it can be operated from ground level. The switch handle will be provided with a locking arrangement along-with tap position indication, thus enabling the switch to be locked in position.
3.11.00
Radiators The radiators shall be detachable type, mounted on the tank with shut off valve at each point of connection to the tank, along with drain valve at the bottom and relief valve at the top.
3.12.00
Insulating Oil i) The new insulating oil before pouring into the transformer shall conform to the requirement of IS:335. No inhibitors shall be used in the oil. The oil samples taken from the transformer at site shall conform to the requirements of IS:1866 ii) The Contractor shall dispatch the transformer filled with oil. Sufficient quantity of oil required for first filling of tank, coolers and radiators at the proper level shall be supplied. Ten percent (10%) extra oil shall be supplied for topping up, in non-returnable containers suitable for outdoor storage. Terminal Arrangement i) The electrical characteristics of bushings shall be in accordance with IS:2099 & IS:3347 (relevant parts). Bushing terminals shall be provided with terminal connectors of approved type and size for connection to external parts. Bushings shall be of solid porcelain or oil communicating type.
POWER TRANSFORMERS
3.13.00
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CLAUSE NO.
POWER TRANSFORMERS ii) The neutral terminal of 11 kV winding shall be brought out on a separate bushing and shall be solidly earthed. Earthing strip from neutral bushing to the earth is to be insulated from the tank body and brought down to a suitable height to connect to earth. Neutral Bushing CT mounted internally shall be provided for transformers as specified under the heading Technical Parameters. The terminal marking and their physical position shall be in accordance with IS: 2026 unless specified otherwise.
iii) iv) 3.14.00
Marshalling Box A sheet steel, weather, vermin and dust proof marshalling box shall be furnished with each transformer to accommodate temperature indicators & terminal boards for incoming and outgoing cables. The temperature indicators shall be so mounted that the dials are not more than 1600 mm, from ground level. The marshalling box shall have a door with a cut out fitted with glass window of suitable size for convenience of temperature indicators reading.
3.15.00
Painting The paint material and procedure for the power transformer shall be as per details given below: i) Surface Preparation for tank, Pipes, etc. All surfaces of transformer tank, pipes, etc shall be thoroughly blast cleaned with sand or shot or grit in accordance with ISO 8501 Part 1 to a minimum standard of Sa2 to make the surface free from visible oil, grease & dirt, mill scale, rust, paint coatings and foreign matter. Machined areas and threaded components etc are to be covered during blasting to prevent damage. The air that is used for blasting should be dry and free from oil. The flanges, angles, tank curbs and other such areas shall be preferably blast cleaned prior to fabrication and paint these with one coat of primer. After adequate blast cleaning of each large surface where blasting time is more than three hours, an overall blast cleaning is to be done on the entire surface once more so that entire surface areas is exposed as fresh for first coat of primer paint. The first coat of primer paint should be applied not later than 3-4 hours after preparation of surface to avoid oxidation. ii) Surface Preparation for radiatorAll internal and external surfaces of radiator shall be thoroughly cleaned either by chemical cleaning or by blast with sand or shot or grit in accordance with ISO 8501 Part 1 to make the surface free from visible oil, grease & dirt, mill scale, rust, paint coatings and foreign matter. Suitable chemical should be used for chemical cleaning, if required. The air that is used for blasting should be dry and free from oil. After adequate surface cleaning, the first coat of primer paint / varnish should be applied not later than 3-4 hours after preparation of surface to avoid oxidation.
POWER TRANSFORMERS
Page 6 of 21
CLAUSE NO.
POWER TRANSFORMERS
iii) Painting- external & internal surfacesPainting shall be carried out in closed and dust free area. The external surface shall be coated with suitable layers of paint and to form an impermeable layer so that air and water cannot reach the substrate. The paint selected shall be stable in outdoor condition such as rain, sunlight, pollution etc. Paint used for primer, under coat and top or finish coat should be from the same manufacturer and compatible to each other. In case in the rare event, paint used for primer, under coat and finish coat are not from the same manufacturer the compatibility test of the paint from different source shall be carried out. Painting shall be applied as per the recommendation of the paint manufacturer. The number of coats shall be such that the minimum dry film thickness (DFT) specified is achieved. The DFT of painted surface shall be checked with a measuring gauge to ensure specified DFT. Complete painting scheme for the transformer is tabulated below: iv) Painting-Transformer tank, pipes, radiator etc.-
v)
Surface Preparation for Control cabinets/Marshalling Boxes-
a. Surface Preparation for all Transformer Control cabinets/Marshalling Boxes shall be carried out confirming to following Indian standard in dust free area: 1) IS: 3618: Degreasing by solvent wiping: Phosphate Treatment of Iron &Steel for Protection against corrosion.2) IS: 6005: Code of Practice for phosphating of Iron & Steel. b. Chemicals: Suitable chemicals should be used and concentration of chemicals /weight of Phosphate coating should be checked regularly as per recommendation of the chemical manufacturer and applicable IS.
POWER TRANSFORMERS
Page 7 of 21
CLAUSE NO.
POWER TRANSFORMERS
c. Inspection: The surface for application of paint should be dry, free from oil,dirt, acid & loose adhering powder and reasonably smooth in finish withoutuncovered areas, rusty surfaces and roughness. v) Painting- Control cabinets/Marshalling Boxes Enamel paint shall be used with total paint thickness as minimum 80 microns. 3.16.00 Bolts and Nuts All bolts and nuts exposed to weather shall be of galvanised steel steel. 3.17.00 Control Wiring i) All controls, alarms, indicating and relaying devices provided with the transformer shall be wired upto the terminal blocks inside the marshalling box. The contractor shall supply and install the required 1100 V grade heavy duty PVC insulated, armoured, PVC sheathed multicore cables with copper conductors of at least 2.5 sq.mm. conforming to IS : 1554. The cables shall be properly supported. All devices and terminal blocks within the marshalling Box shall be clearly identified by symbols corresponding to those used on applicable schematic or wiring diagrams. Not more than two wires shall be connected to one terminal. At least 20% spare terminals shall be provided. Each terminal shall be suitable for connecting two 2.5 sq.mm. standard copper conductors from each side.
ii)
iii)
3.18.00
FITTING The following fittings shall be provided with all the transformers, unless mentioned specifically otherwise. i. Conservator with oil filling hole and cap, isolating valve, drain valve, vent valve. ii. Magnetic oil level gauge with low level alarm contacts mounted on conservator. Transparent Dehydrating filter breather for conservator. Prismatic/toughened glass oil level gauge for transformer. Oil preservation system as specified. Buchholz relay, double float type with isolating valve bleeding pipe and alarm and trip contacts.
POWER TRANSFORMERS
iii. iv. v. vi.
Page 8 of 21
CLAUSE NO.
POWER TRANSFORMERS
vii. viii. ix. x.
Pressure relief device. Air release plugs. Inspection opening and covers. Bushing with metal parts, arcing horns and gaskets to suit the termination arrangement. Oil temperature indicator with alarm and trip contact. Winding temperature indicator with alarm and trip contact Cover lifting eyes, transformer lifting lugs, jacking pads, towing holes core and winding lifting lugs, supporting structure, foundation bolts etc. Protected type mercury or alcohol in glass thermometer. Bottom and top filter valves with threaded male adopters, bottom sampling valve and drain valve. Bilingual (English & Hindi) Rating and diagram plates. Flanged bi-directional wheels for the transformer.
xi. xii. xiii.
xiv. xv.
xvi. xvii.
xviii. Off load tap changing equipment for transformer. xix. xx. Marshalling box along with necessary fittings.. Earthing terminals.
The fittings listed above are only indicative and any other fittings which are generally required for satisfactory operation of the transformers are deemed to be included. 4.00.00 PERFORMANCE i) Transformers shall be capable of being loaded in accordance with IS : 6600 upto 150%. There shall be no limitation imposed by bushings, tap changer etc. The transformer shall be capable of being operated continuously without danger on any tapping at the rated KVA with voltage variation of +10% corresponding to the voltage of the tapping.
ii) The maximum flux density in any part of the cores and yoke at normal voltage and frequency shall be such that the flux density on any tap position with + 10% voltage variation from voltage corresponding to the tap shall not exceed
POWER TRANSFORMERS
Page 9 of 21
CLAUSE NO.
POWER TRANSFORMERS 1.9 wb/m2. Transformers shall accept, without injurious heating, combined voltage and frequency fluctuations which produce the over fluxing conditions of 120% for 1 minute. The bidder shall indicate 150% over voltage withstand time.
5.00.00
LOSSES AND IMPEDANCE VALUES The bidder shall furnish the maximum guaranteed values of no load and load losses (at 750C) with no plus tolerance in the data requirement sheet and also in relevant Schedule of Bid Proposal Sheets. The offers shall be evaluated on the basis of Loss Capitalisation clause given below.
5.01.00
LOSS CAPITALISATION The capitalisation of losses will be allowed for lower losses offered. The following Capitalisation formula shall be used: Capitalised cost of TRF = Initial cost of TRF + Rs. A x WI + Rs. B x Wc Where : WI = Iron loss in KW & A = 137408 Rupees for iron loss WC = Copper loss in KW & B = 41222 Rupees for copper loss For the purpose of evaluation of transformers , the best of the individual parameters for iron and copper losses for same rating of transformers quoted by any of the bidder in relevant schedule of BPS vol. IB shall be taken as the base and the difference between this and those quoted by the other bidders multiplied by the evaluation factor and the number of transformer included in the scope shall be used to arrive at the adjustment on the basis of per kW differential losses in Rupees indicated in relevant clauses of SCC. This adjustment cost shall be added to Bid price.
5.02.00
Condition for Losses Exceeding Guaranteed Values This shall be as per the conditions specified in relevant clause of Special Conditions of Contract for the contract.
6.00.00
IMPEDANCE VALUES The percentage impedance at 75oC shall be 6.25% for 3150 KVA transformers. The impedance values refer to the principal tapping and are subject to a tolerance of ()10%. The impedance values measured on any other tapping shall not exceed the value measured on the principal tapping by more than ()10%
7.00.00
TESTS AND INSPECTION In process & final testing shall be carried out as per the MQP (Manufacturing Quality Plan) enclosed elsewhere in this document. The following tests shall be carried out in accordance with the details specified in IS:2026 or as specified here
POWER TRANSFORMERS
Page 10 of 21
CLAUSE NO.
POWER TRANSFORMERS Type Tests a) b) c) d) e) f) g) h) Measurement of winding resistance Measurement of voltage ratio and check of voltage vector relationship Measurement of impedance voltage/short-circuit impedance (Principal tapping) and load loss Measurement of no-load loss and current Measurement of insulation resistance Lightning impulse test Temperature rise test Vacuum test: Whereas the tank of the power transformer of 630 and 1600 KVA capacity (excluding tap changing compartment, radiators and coolers) shall be able to withstand 34.7 KN/m2 vacuum gauge pressure (250 mm of Hg), the transformer tank body of 3150 KVA capacity shall be able to withstand a vacuum gauge pressure of 68.0 KN/m2 (500 mm of Hg). The permanent deflection of the flat plate after subjecting the transformer tank of each size to the above vacuum for one hour shall not exceed the following values, and shall not affect the performance of the transformer : Horizontal length of flat plate (mm) Up to and including 750 751 to 1250 1251 to 1750 1751 to 2000 2001 to 2250 2251 to 2500 2501 to 3000 Above 3000 Permanent deflection (mm) 5 6.5 8 9.5 11 12.5 16 19
7.01.00
7.02.00
i) Tank pressure Test The supplier shall offer transformers of identical design & rating which has been type tested & tested for short circuit with stand capability as per IS-2026. The type test & test for short circuit withstand should have been conducted within last five years from a national test house or from similar reputed test house. The bidder shall furnish type test reports for each type rating. If the type tests & test to with stand short circuit test conducted within last five years is incomplete or not conducted within last five years the party shall arrange to carry out such tests at his own cost & risk in the presence of employer/owners representative.
POWER TRANSFORMERS
Page 11 of 21
CLAUSE NO.
POWER TRANSFORMERS Type test reports for similar rating transformer with higher tap range on positive or negative sides or both which includes (+) 2.5% to (-) 10% range shall also be acceptable.
7.03.00
ROUTINE TESTS The following shall constitute the routine tests : a) b) c) d) e) f) Measurement of winding resistance Measurement of voltage ratio and check of voltage vector relationship Measurement of impedance voltage/short-circuit impedance (Principal tapping) and load loss Measurement of no-load loss and current Measurement of insulation resistance Dielectric tests
8.00.0 8.01.0
GAURANTEED TECHNICAL PARTICULARS: GTP of Power Transformers are enclosed herewith in two parts (Part A and Part B). The successful bidder shall supply Power Transformers as per Part A of GTP and additional details which are stipulated in Part B of the GTP shall be filled and submitted for review and approval along with the bid. Make shall be NESCL Corporate Quality Assurance (CQA) approved. Part A of GTP: Sl. No. Description 1. Rated Output)(KVA) 2. Cooling 3. Type 4. No load Voltage ratio(KV) 5. Frequency(Hz) 6. Phase 7. Service 8. Duty 9. Tap 33/11 kV Transformers 3150
ONAN Two winding, oil immersed 33/11
50 Hz Three Outdoor Continuous Off-circuit taps: ranging from (+) 2.5% to (-) 10% in steps of 2.5% each on HV winding.
POWER TRANSFORMERS
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CLAUSE NO.
POWER TRANSFORMERS 10 Overload capacity 11 Maximum Temperature rise a Winding (by resistance method) b Top oil (by thermometer) 12 Impedance at 75 deg. C & permissible tolerance 550C As per IS: 6600 & as specified elsewhere in the specification.
500C The percentage impedance at 75oC shall be 6.25% for 3150 KVA transformers. The impedance values refer to the principal tapping and are subject to a tolerance of ()10%. The impedance values measured on any other tapping shall not exceed the value measured on the principal tapping by more than ()10%. 25 KA on 33 KV side Dyn11 HV Delta 36 LV Star 12
13 Fault level of the system 14 Vector group 15 Windings Winding connection 16 Highest system voltage (KV) 17 One minute power frequency withstand voltage (KV)(rms) 18 Lighting impulse withstand voltage (KV) peak 19 Insulation 20. Neutral
RGGVY WORKS STANDARD TECHNICAL SPECIFICATION (REV.- 03) TECHNICAL SPECIFICATION VOL-II (PART-A)
70
28
170
70
Uniform Solidly Grounded

POWER TRANSFORMERS
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CLAUSE NO.
POWER TRANSFORMERS 21. Phase Bushings a b c Rated voltage (KV) Basic impulse level (KV) peak Minimum creepage distance (mm) Mounting Quantity 22. Neutral Bushing a b Rated voltage (KV) Rated Current (Amp.) Basic impulse level (KV) peak Minimum creepage distance (mm) Mounting Quantity HV 36 170 900 LV 12 70 300
d e
Tank cover or Tank side 3 LV Neutral 12 Equal to phase current 3
70
300 mm
e f
Tank cover or tank side with approval of Owner One No CT required
23. Neutral Busing CT 24. Clearances a Minimum clearance of HV winding to tank in oil (mm) b Minimum clearance of HV winding to earth in oil
RGGVY WORKS STANDARD TECHNICAL SPECIFICATION (REV.- 03) TECHNICAL SPECIFICATION VOL-II (PART-A)
45
45
POWER TRANSFORMERS
Page 14 of 21
CLAUSE NO.
POWER TRANSFORMERS (mm)
c Clearance between neutral to ground in air (mm) d Minimum clearance between phases i in air ii in oil
140
HV350 mm, LV280 mm HV18 mm, LV16 mm
25. Type of oil Conventional single compartment Conservator preservation with Silica Gel Breather 26. Termination Details a HV phases b LV Phase c LV Neutral Direct termination of conductor Direct termination of conductor Copper flats connections
Type test COMPLIED reports (all mentioned in relevant clause)
Part B : Sl. Particulars No. 1. Manufacturer's name and address 2 3. Service & Type Impedance data a) 1) Guaranteed positive sequence impedance between HV & LV at 75 deg. C
POWER TRANSFORMERS
To be filled by the bidder
Page 15 of 21
CLAUSE NO.
POWER TRANSFORMERS Sl. No. i) ii) Particulars Principal tap Maximum tap To be filled by the bidder
iii) Minimum tap b) 4. Zero sequence impedance at principal tap HV winding DC resistance at 75 deg. C in ohms i) Principal tap ii) Maximum tap
iii) Minimum tap 5. 6. LV winding DC resistance Cooling Equipment Details a) b) c) i) ii) Number of radiators and rating as a % of transformer cooling equipment Mounting Radiator details Overall dimensions lxbxh(mm) Type of mounting
iii) Weight with oil (kg) iv) Weight without oil (kg) v) 7. Thickness of radiator tube (mm)
Thermal Data a) b) Temperature rise in top oil over an ambient of 50 deg C Temperature rise in winding by resistance measurement method over an ambient of 50 deg. C Thermal time constant (Hours)
c) 8.
Over excitation withstand time (secs.) for % over excitation of i) ii) 125% 140%
iii) 150%
POWER TRANSFORMERS
Page 16 of 21
CLAUSE NO.
POWER TRANSFORMERS Sl. No. iv) 170% 9. Bushings a) i) ii) High voltage Manufacturer Type Particulars To be filled by the bidder
iii) Rated current (Amps) iv) Total creepage distance (mm) v) b) i) ii) Mounting Low Voltage Manufacturer Type
iii) Rated current (Amps) iv) Total creepage distance (mm) v) c) i) ii) Mounting Neutral (HV) Manufacturer Type
iii) Rated current (Amps) iv) Total creepage distance (mm) v) d) i) ii) Mounting Neutral (LV) Manufacturer Type
iii) Rated current (Amps) iv) Total creepage distance (mm) v) 10. 11. Mounting
Proposed method of transformer transportation (oil filled or N2 filled) Is vacuum filling required, if so state absolute pressure (mm of Hg)
POWER TRANSFORMERS
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CLAUSE NO.
POWER TRANSFORMERS Sl. Particulars No. 12. Total quantity of oil (liters) 13. Tap changing equipment a) b) c) d) 22. Make, Type & model Voltage class & current Number of steps Range To be filled by the bidder
Approximate Dimensions a) b) c) d) e) Tank (lxbxh) (mm) Overall dimensions with radiators (lxbxh) (mm) Height for un-tanking (mm) Shipping dimensions
14.
Dimensions of largest package (lxbxh) (mm) Weight of Transformer Components a) b) c) d) e) f) g) h) i) j) Core (kg.) Windings (kg) Insulation (kg) Tank and fittings (kg) Oil (kg) Untanking weight (heaviest piece) (kg) Total weight (kg) Weight of heaviest pkg. (kg) Total shipping weight (kg)
15. 16.
Parts detached for transport (furnish list) Permissible overloading (% of rating and time in minutes) Conservator a) b) Total volume (Liters) Volume between highest and lowest levels (Liters)
POWER TRANSFORMERS
Page 18 of 21
CLAUSE NO.
POWER TRANSFORMERS Sl. No. 17. Oil a) i) ii) Particulars To be filled by the bidder
Quality of oil Before filling in Before main tank energisation Moisture content (ppm) Max. tan-delta value (at 90 deg. C)
iii) Interfacial tension (N/m) iv) Breakdown strength (kV) b) 18. Core a) b) c) d) e) f) g) i) ii) Type of construction (core / shell) Net core area (mm2) 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 and at 90% voltage (wb/m2) 100% voltage (wb/m2) Quantity including 10% extra (liters)
iii) 110% voltage (wb/m2) 19. Winding a) i) ii) Type of winding HV LV
iii) Tap b) i) ii) c) Current density at rated load HV (A/mm2) LV (A/mm2) Conductor area
POWER TRANSFORMERS
Page 19 of 21
CLAUSE NO.
POWER TRANSFORMERS Sl. No. i) ii) d) i) ii) e) f) i) ii) LV (mm2) Maximum current density under short circuit HV (A/mm2) LV (A/mm2) Magnetizing inrush current (Amps) No load current (Amps) at rated frequency and at 90% voltage 100% voltage Particulars HV (mm2) To be filled by the bidder
iii) 110% voltage g) h) i) ii) i) i) ii) j) 20. Tank a) b) i) ii) Tank coverApproximate thickness of Side (mm) Bottom (mm) Magnetizing current at rated frequency and at rated voltage Leakage reactance HV (ohms) LV (ohms) Resistance HV (ohms) LV (ohms) Air core reactance of HV winding
iii) Cover 21. Vacuum withstand capability of a) b) Main tank Radiators and accessories
POWER TRANSFORMERS
Page 20 of 21
CLAUSE NO.
POWER TRANSFORMERS Sl. Particulars No. 22. Minimum draw bar pull required to move the transformer on level track (kg) 23. Size of filter hose 24 25. 26 Standards Applicable Withstand time for short circuit at terminals (sec.) Efficiency at 75 deg. C at unit power factor i) ii) at full load at 3/4 load To be filled by the bidder
iii) at 1/2 load 27. Loss Data i) ii) 28 a b c No Load Loss(Watts) Full Load Loss(Watts) Neutral Bushing CT for 5 MVA power Transformer CT Ratio VA burden Class of accuracy
POWER TRANSFORMERS
Page 21 of 21
Clause No
BATTERY & BATTERY CHARGER SCOPE This specification covers the requirements and tests for 24 V, 30 V 110 V, 220V partial recombination type Nickel-Cadmium alkaline batteries with chargers, for use in 33/11 KV sub-stations. The batteries covered in this specification are both for indoor and out door use. For out-door application a suitable enclosure shall be provided The shall confirm to IP:54 degree of protection.
1.00.00
2.00.00
APPLICABLE 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. In case of conflict between this specification and those (IS codes, standards etc.) referred to herein, the former shall prevail. Unless otherwise modified in this specification, the Ni-Cd batteries shall comply with latest version of IEC 62259. All work shall be carried out as per the following standards and codes. International Standards IEC: 62259 Indian Standards Description Secondary cells and batteries containing alkaline or other non-acid electrolytes-Nickelcadmium prismatic secondary single cells with partial gas recombination Secondary cells and batteries containing alkaline or other non-acid electrolytes-vented Nickel_Cadmium prismatic rechargeable single cells Rubber & Plastic container alkaline batteries Recommended practice for maintenance, testing & replacement of Ni-Cd storage batteries for generating stations & substations Recommended practice for sizing of Ni-Cd batteries for stationary applications Glass reinforced Polystar sheet moulding compounds. Voltmeter
Sl.No. 1
IEC: 60623
IS: 10918
3 4
IEEE: 1106
5 6 7 3.00.00
IEEE: 1115 IS 13410 IS: 1248
STANDARD RATING The standard voltage ratings of batteries for use at 33/11 KV and 66/11 KV substations shall be 24 volts or 30 volts or 110 volts or 220 volts. The batteries for the above application shall have a rating of 45 Ah (Minimum) in case of 24 V battery system or as per the load requirement of the substation.
CHAPTER-II SECTION-E-10
BATTERY & BATTERY CHARGER
Page 1 of 16
Clause No
BATTERY & BATTERY CHARGER For batteries intended for use with individual or groups of breakers, suitable Ah ratings shall be used depending upon the requirements as specified in the scope of works.
4.00.00
CELL VOLTAGE The nominal voltage of a single cell shall be 1.2 V Nominal Nominal Voltage single Rating cell of voltage battery (V) (V) 24 1.2 30 1.2 110 1.2 220 1.2 Float cell voltage Number of cells (to be finalized) (V) 19 23 87 170 Permissibe D.C. System voltage variation (V) 21.7 to 27 26.2 to 32.7 99.2 to 123.5 193.8 to 241.4 End of discharge cell voltage (Min.) (V) 1.14 1.14 1.14 1.14
(V) 1.4 to1.42 1.4 to1.42 1.4 to 1.42 1.4 to1.42
Note: As the nominal cell voltage is 1.2 V, nominal battery bank voltage may not exactly match nominal DC system voltage. 5.00.00 CONSTRUCTION The cells shall have prismatic, spill-proof and valve-regulated partial recombination type of construction with partial recombination feature. The cells shall be flooded type containing sufficient reserve electrolyte. Battery shall be equipped with nickelplated inter-cell connectors and terminals. The cells shall be housed in high-strength impact resistant & alkali-resistant containers and should be transparent / translucent to facilitate checking of electrolyte level. Container and Lid should be welded and should not cause leakage of electrolyte/gases during operation even in case of normal mechanical/electrical abuses. O-rings of nitrile rubber with EPOXY sealing shall be used to ensure proper sealing of bushings etc. Flip-top vent plugs/ valves with flame arrester feature shall be provided. The regulating valve type design shall be of selfresealing type. Construction of cells shall be to ensure proper air circulation between the cells for heat dissipation/ ventilation (by providing either insulated button separators integral with the outer surface of the cell container or by suitably designing the inter cell connectors). The containers shall be strong enough, so that excessive bulging of container does not occur during service. Cells shall be supplied in filled & charged state or otherwise electrolyte dry form & battery water separately or in liquid form shall be shipped as desired by the owner. Battery shall have provision for water top up to ensure electrolyte level does not fall below recommended level.
Page 2 of 16
Clause No
BATTERY & BATTERY CHARGER ELECTRODES + ve and ve electrodes shall be made by encapsulating/impregnating active material in order to ensure that the battery is able to perform reliably over its life. +ve and ve electrodes shall be separated by micro porous separators. The structure of electrodes shall be elastic enough to absorb mechanical stresses & volume changes during charge/discharge cycles.
6.00.00
7.00.00
ELECTROLYTE The electrolyte shall be prepared from battery grade potassium hydroxide (KOH) confirming to IEC 60993. The cells shall contain sufficient reserve electrolyte for efficient heat dissipation & to reduce water topping up interval. Reserve electrolyte shall not be less than 06 ml/Ah.
8.00.00
CONNECTORS Nickel plated copper intercell connectors shall be used for connecting up adjacent cells and rows. Bolts, nuts and washers shall be nickel-plated steel/stainless steel. All terminals and cell inter-connectors shall be fully insulated or have insulation shrouds.
9.00.00
TERMINALS Separate terminals shall be provided on the end cell for connecting load through DCDB and for connecting charger leads. All terminals shall be of suitably sized nickel-plated steel. Suitable nickel-plated copper lugs shall be provided by the supplier for use of the purchaser for connecting up the load wiring. All connectors and leads shall be suitable for carrying 30-minute discharge current continuously and rated for short circuit duty of 4kA for 01 second.
10.00.00
MANUAL OF INSTRUCTIONS The manufacturer shall supply a copy of the instruction manual for commissioning & initial treatment of the battery and maintenance during service with every battery bank ordered.
11.00.00
RECOMBINATION EFFICIENCY In order to reduce topping-up frequency, recombination of Hydrogen & Oxygen gases evolved during charging/discharging shall be achieved by using safe and reliable technology such as catalytic conversion/valve regulation technique or both. Minimum recombination efficiency shall be 80%. Recombination efficiency test shall be done in accordance with IEC 62259. In case the batteries are operated at high temperatures & are frequently boost charged the water consumption may be higher & topping-up frequency may increase.
Page 3 of 16
Clause No
BATTERY & BATTERY CHARGER BATTERY RACKS Suitable corrosion resistant battery racks and cable supports shall be provided. Metallic racks shall be properly earthed. The bottom tier of stand shall have a ground clearance of 150mm minimum above the floor. Racks shall be made of alkali resistant powder coated steel or stainless steel or FRP to ensure corrosion resistance.
12.00.00
13.00.00
TEMPERATURE RANGE Battery must be capable of continuous operation in temperatures range of -15 oC to +50oC for prolonged periods. No Air-conditioning shall be provided where batteries are to be installed.
14.00.00
ACCESSORIES I) II) III) IV) V) The following accessories (BIS certified) shall be supplied with each set of battery:Clamp-on type digital multi-meter of AC/DC current range having ISI mark. Pair of gloves 10 Slide insulated wrench for opening terminal nuts Plastic/glass syringe Alcohol thermometer Hydrometer for use while filling electrolyte.
15.00.00
CHARGE RATE Fully discharged batteries should be able to get recharged in 7 hours maximum to 90% of capacity with charging current in the range of 0.1 to 0.4C5 rate at 20C. At higher temperatures, the charging time may be more. The trickle charge rate shall be 1-2 mA/Ah.
16.00.00
CELL DESIGNATION The practice as per IS: 10918 (latest version) shall be followed.
17.00.00
POLARITY MARKING The polarity of the terminals shall be marked for identification. Positive terminal may be identified by 'P' or a (+) sign or red colour mark and negative terminal may be identified by 'N' or (-) sign or blue colour mark. Marking shall be permanent and non-deteriorating.
TECHNICAL SPECIFICATION VOL-II (PART-A) CHAPTER-II SECTION-E-10
Page 4 of 16
Clause No
BATTERY & BATTERY CHARGER WARNING MARKING The battery shall be furnished with a warning plate located at conspicuous place specifying the use of 'ALKALINE ELECTROLYTE ONLY' (in block letters) and specifying proper filling level of the electrolyte. Marking shall be permanent and non-deteriorating.
18.00.00
19.00.00
PACKING The batteries shall be securely packed in wooden crates suitable for handling during transit by rail/road and secured to avoid any loss or damage during transit. Carton boxes duly palletized shall also be acceptable.
20.00.00
TESTS Type tests should be as per IS: 10918 Acceptance and routine tests shall be in line with IS: 10918.
Note : In case Type tests are repeated, life cycle test may not be insisted upon Ni-Cd battery of the specific ratings to be ordered, as this test takes a long time (2-3 years). Satisfactory evidence is to be furnished for having made life cycle test on cell of any other Ah capacity of the same design.
Page 5 of 16
Clause No
BATTERY & BATTERY CHARGER Part - B CHARGER FOR Ni-Cd BATTERY (RECOMBINATION TYPE)
1.00.00
SCOPE This specification covers the requirements and tests for Battery charger for partial recombination type Nickel-Cadmium alkaline batteries for use in 33/11 KV substations.
2.00.00
CODES AND 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. In case of conflict between this specification and those (IS codes, standards etc.) referred to herein, the former shall prevail. All work shall be carried out as per the following standards and codes. Sl.No Internatioonal standards 1 2 Indian standards IS:5 IS : 1248 Description Colours for ready mix paints. Specification for Direct acting indicating analogue electrical measuring instruments. Degree of protection provided by enclosures for low voltage switch gear and control gear. Low voltage circuit breaker Specification for low voltage switch gear and control gear. Contactors Low voltage switch-gear and control-gear assembly Static protective relays Control switches Electrical relays for power system protection. Application guide for Electrical relays for AC System Mono-crystalline semi-conductor Rectifier Cells and Stacks. Mono crystalline semi-conductor Rectifier assemblies and equipment.
IEC : 947-1
IS : 13947 Prt-1
4 5 6 7 8 9 10 11 12 13
IEC : 947-2 IEC : 947-3 IEC : 947-4 IEC:439
IS : 13947 Prt.-2 IS : 13947 Prt-3 IS : 13947 Prt-4 IS:8623 IS:8686 IS:6875 IS : 3231 IS : 3842
IEC: 337 IEC:225
IEC 146 IEC 146
IS : 3895 IS : 4540
Page 6 of 16
Clause No
BATTERY & BATTERY CHARGER Sl.No Internatioonal standards 14 Indian standards IS:6619 Description Safety Code for Semi-conductor Rectifier Equipment. Control switches (switching devices for control and auxiliary circuits including contactor relays) for voltages upto 1000 V AC or 1200 V DC. Basic environmental testing procedures for electronic and electrical items. Low voltage fuses for protection of semiconductor devices. Visual indicating lamps Code of practice for phosphating of Iron and Steel. PVC Insulated Cable for working voltages upto and including 1100 V.
15
IS:6875
16
IS : 9000
17
IEC:60269
IS:13703 Prt-4
19 20 21 IEC :227
IS:1901 IS:6005 IS:694 /IS: 1554
Equipment complying with other internationally accepted standards such as IEC, BS, VDE. etc. will also be considered if they ensure performance and constructional features equivalent or superior to standards listed above. In such a case, the Bidder shall clearly indicate the standard(s) adopted, furnish a copy in English of the latest revision of the standards along with copies of all official amendments and revisions in force as on date of opening of bid and shall clearly bring out the salient features for comparison. 3.00.00 EQUIPMENT DESCRIPTION a) The Battery Chargers as well as their automatic regulators shall be of static type. Battery chargers shall be capable of continuous operation at the respective rated load in Float mode, i.e. Float charging the associated Ni-Cd Batteries (partial recombination type) while supplying the D.C. loads. The Batteries shall be Float charged at 1.4 to 1.42 Volts per cell. All chargers shall also be capable of Boost Charging the associated Batteries at 1.53 to 1.7 Volts per cell at the desired rate. The Chargers shall be designed to operate, as mentioned above, up-to an ambient air temperature of 50C. Tapping arrangement in the battery bank shall be provided to limit the over-voltage for supplying load within allowed voltage range under boost charge conditions. The charger should automatically switchover to float charge & to boost charge when the specified limit of voltage is approached. However, necessary timer circuit shall be used to allow a finishing charge before switching over to float mode, as recommended by battery manufacturer in order to ensure that battery gets fully charged.
RGGVY WORKS STANDARD TECHNICAL SPECIFICATION (REV.- 03) TECHNICAL SPECIFICATION VOL-II (PART-A) CHAPTER-II SECTION-E-10
Page 7 of 16
Clause No
BATTERY & BATTERY CHARGER b) Battery Chargers shall automatically select the appropriate mode of operation i.e. Float or Boost. Means shall be provided to avoid current/voltage surges of harmful magnitude/nature, which may arise during changeover. c) Soft start feature shall be provided to build up the voltage to the set value slowly within fifteen seconds. The chargers shall have load limiters, which shall cause, when the voltage control is in automatic mode, a gradual lowering of the output voltage when the DC load current exceeds the load limiter setting of the Charger. The load limiter characteristic shall be such that any sustained overload or short circuit in DC system shall neither damage the Charger nor shall it cause blowing of any of the charger fuses. The Charger shall not trip on overload or external short circuit. After clearance of fault, the Charger voltage shall build up automatically when working in automatic mode. During external short circuit, output of the charger shall be automatically reduced to near zero volt till it is not isolated/disconnected & normal output voltage shall be restrained by charger ckt on isolation with out any harm to source transformer/protection/ regulator ckt d) During Float charging, the Charger output voltage shall remain within 1% of the set value for AC input voltage variation of 230 +10%, -15% frequency variation of 5%, a combined voltage and frequency (absolute sum) variation of 10% and a continuous DC load variation from 5% to full load. Uniform and stepless adjustments of voltage setting shall be provided on the front of the Charger panel covering the entire Float charging output range specified. Stepless adjustment of the load limiter setting shall also be possible from 80% to 100% of the rated output current for Float charging mode. e) During Boost charging, the Battery Chargers shall operate on constant current mode with maximum current limiter setting (When automatic regulator is in service). f) Energising the Charger with fully charged battery connected plus 10% load shall not result in output voltage greater than 110% of the voltage setting. Time taken to stabilise, to within the specified limits in clause (e), shall be less than five seconds. g) Momentary output voltage of the Charger, with the Battery connected shall be within 90% to 110% of the voltage setting during sudden load Change from 80% to 20% of full load or vice-versa. Output voltage shall return to, and remain, within the limits specified in clause (e) in less than 1 second after the above mentioned change. h) The Charger manufacturer may offer an arrangement in which the voltage setting device for Float charging mode is also used as output voltage limit setting device for Boost charging mode, and the load limiter of the float charging mode is also used as Boost charging current setting device.
Page 8 of 16
Clause No
BATTERY & BATTERY CHARGER i) Suitable filter circuits shall be provided in all the Chargers to limit the ripple content (peak to peak) in the output voltage to 3 % irrespective of the DC load, even when they are not connected to a battery. j) The DC System shall be ungrounded and float with respect to the ground potential when healthy. k) Battery shall be isolated in case of short circuit on the load side. l) Battery test circuit shall be provided with suitable resistance for discharging the battery for 30Sec at 5 hr rate. m) All potentiometers shall be electronically locked to contain the various parameters within allowable limits even if the setting position of potentiometers is changed to extreme positions. n) Insulation resistance shall be 5 M Ohm min.
4.00.00
MCB An MCB shall be provided at the incomer. Rectifier-Transformers and Chokes The rectifier transformer and chokes shall be dry and air cooled (AN) type. The rating of the rectifier-transformers and chokes shall correspond to the rating of the associated rectifier assembly. The rectifier-transformers and chokes shall have class-B insulation. Rectifier transformer shall confirm to all type tests as specified in IS 4540/IS 2026. Rectifier Assembly The rectifier assembly shall be full wave bridge type and designed to meet the duty as required by the respective Charger. The rectifier cells shall be provided with their own heat dissipation arrangement with natural air cooling. Heat sinks shall be rated to carry 130% of the load current continuously and the temperature of the heat sink shall not be permitted to exceed 85C absolute duly considering the maximum temperature inside charger panel. The Contractor shall submit calculations to show what maximum junction temperature will be and what the heat sink temperature will be when operating at 130% and 100% load current continuously duly considering the maximum surrounding air temperature for these devices inside the charger panel assuming ambient temperature of 50C outside the panel. Necessary surge protection devices and rectifier type fast acting fuses shall be provided in each arm of the rectifier connections. Design having IGBT or superior technology shall also be acceptable for which full justification & experience shall be required for acceptance. Static silicon controlled
Page 9 of 16
Clause No
BATTERY & BATTERY CHARGER rectifiers and diodes complete with resistor/capacitor network for surge protection shall be provided Instruments Analog or digital D.C. voltmeter, D.C. ammeter and A.C. voltmeter with 96 mm square display shall be provided for all Chargers. The instruments shall be flush mounted type, dust proof and moisture resistant. The instruments shall have easily accessible means for zero adjustments. The instruments shall be of 1.5 accuracy class. Control and Selector Switches Control and selector switches shall be of rotary stayput type of reputed make, confirming to relavant IS with escutcheon plates showing the functions and positions. The switches shall be of sturdy construction and suitable for mounting on panel front. Switches with shrouding of live parts and sealing of contacts against dust ingress shall be preferred. The contact ratings shall be at least the following : i) ii) iii) Fuses Fuses shall be of HRC cartridge fuse link type. Fuses shall be mounted on fuse carriers, which are mounted on fuse bases. Wherever it is not possible to mount fuses on fuse carriers, fuses shall be directly mounted on plug in type bases. In such cases one insulated fuse pulling handle shall be supplied for each charger. Suitable fuse fail detector circuits with alarm contacts shall be provided for all D.C. fuses. Indicating Lamps The indicating lamp shall be of panel mounting, LED type and capable of clear status indication under the normal room illumination. The lamp covers shall be preferably screwed type, unbreakable and moulded from heat resistant material. Blocking Diode Blocking diode with full redundancy shall be provided in the output circuit of each Charger to prevent current flow from the D.C. Battery into the Charger. Annunciation System Visual indications through indicating lamps/LEDs or annunciation facia shall be provided in all Chargers for the following: Make and carry continuously - 10 Amps. Breaking current at 220 V DC - 0.5 Amp. (Inductive) Breaking current at 240 V AC - 5 Amp. At 0.3 p.f.
Page 10 of 16
Clause No
BATTERY & BATTERY CHARGER i. ii. iii. iv. v. vi. vii. viii. ix. x. xi. A.C. supply failure Rectifier fuse failure Surge circuit fuse failure Filter fuse failure Load limiter operated Charger trip Battery on Boost Load-side DC under-voltage & over-voltage alarm Battery side DC over-voltage alarm AC available Battery discharge (Mains available battery discharge) alarm Potential free NO contacts shall be provided for following remote alarms: a) b) Battery on boost Charger trouble (this being a group alarm initiated by any of the faults other than Battery on Boost)
Name Plates and Marking The nameplates shall be made of non-rusting metal/3 ply Lamicoid and shall have black back-ground with white engraved letters and secured by screws. These shall be provided near top edge on the front as well as on rear side of Charger. Nameplates with full and clear inscriptions shall also be provided on and inside the panels for identification of the various equipment. Detailed dimensional drawings, commissioning and operating instructions and Test Certificates of the manufacturer shall be supplied with the equipment. 5.00.00 CONSTRUCTION The indoor Chargers shall be, floor mounted, self-supporting sheet metal enclosed cubicle type. The Contractor shall supply all necessary base frames, anchor bolts and hardware. The Charger shall be fabricated using cold rolled sheet steel not less than 1.6 mm thick. The panel frame shall be fabricated using cold rolled sheet steel of thickness not less than 2.0 mm. Removable un-drilled gland plates of at least 3.0 mm sheet steel and lugs for all cables shall be supplied by the Contractor. The lugs for cables shall be made of electrolytic copper with tin coat. Cable sizes shall be advised to the Contractor at a later date for provision of suitable lugs and gland plates. Ventilation louvers shall be backed with fine brass wire mesh. All doors and covers shall be fitted with nitrile/neoprene/PU rubber gaskets. The Chargers shall have hinged double leaf doors provided on front and/or backside for adequate access to the Charger 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:2147. The construction shall meet the requirements of IS 6619. All equipment mounted in the cabinet shall be provided with individual labels with equipment designation engraved.
Page 11 of 16
Clause No
BATTERY & BATTERY CHARGER In case of outdoor mounting the charger shall be provided with double doors on both front & back. The enclosure shall be provided with a canopy. The layout of Charger components shall be such that their heat losses do not give rise to excessive temperature within the Charger panel. Location of the electronic modules will be such that temperature rise, in no case, will exceed 10C over ambient air temperature outside the Charger. Each Charger panel shall be provided with an illuminating lamp (CFL or tube-light) and one 5 Amp. Socket. Switches and fuses shall be provided separately for each of the above. Locking facilities shall be provided as following: a) For locking Float/Boost selector switch in the float position only. b) The Charger enclosure door shall have provision for padlocks. Padlocking arrangement shall allow ready insertion of the padlock shackle but shall not permit excessive movement of the locked parts with the padlock in position.
6.00.00
Wiring Each Charger shall be furnished completely wired upto power cable lugs and terminal blocks ready for external connection. The power wiring shall be carried out with 1.1 kV grade PVC insulated cables conforming to IS:1554 (Part-I). The control wiring shall be of 1.1kV grade PVC insulated stranded copper conductors of 1.5 sq.mm. minimum, conforming to IS:694. Control wiring terminating at electronic cards shall not be less than 0.75 sq. mm. Control terminal shall be suitable for connecting two wires of 1.5 sq.mm. stranded copper conductors. All terminals shall be numbered for ease of connections and identification. At least 20% spare terminals shall be provided for circuits. Power and control wiring within panels shall be bundled separately. Any terminal or metal work which remains alive at greater than 415 V, when panel door is opened, shall be fully protected by shrouding. An air clearance of at least ten (10) mm shall be maintained throughout all circuits, except low voltage electronic circuits, right upto the terminal lugs. Whenever this clearance is not available, the live parts should be insulated or shrouded.
7.00.00
Painting Pre-treatment & phosphating with 7 tank process shall be provided as per IS: 6005. The phosphate coating shall be class-C as specified in IS: 6005. Electrostatic powder painting with final shade 692 (smoke grey) of IS: 5 shall be provided. The thickness shall not be less than 50 microns.
Page 12 of 16
Clause No
BATTERY & BATTERY CHARGER PACKING & dispatch The equipment shall be dispatched securely packed in wooden crates suitable for handling during transit by rail/road so as to avoid any loss or damage during transit.
8.00.00
9.00.00
TESTS Battery chargers including the components shall confirm to all type tests including heat run test as per relevant Indian standards. Performance test on the chargers as per specification shall also be carried out on each charger. Type Tests Following type tests should have been carried out on each rating and type of Battery Charger for which reports are to be submitted. i. ii. iii. iv. v. vi. vii. viii. ix. Complete physical examination. Temperature rise test at full load (at highest voltage & highest current). Insulation resistance test. High voltage (power frequency) test on power and control circuits except low voltage electronic circuits. Ripple content test at No load Half load Full load Automatic voltage regulator operation test at specified A.C. supply variations at a) No load b) Half load c) Full load Load limiter operation test Input and output surge withstand capability test. Surge Voltage as per ANSIC37.90a shall be applied for period not less than 2 sec. At the following points of the Charger operating at 50 deg. C at full load : i) ii) iii) iv) Across each A.C. input phase Across AC input line to ground. Across D.C. output terminals. Across each D.C. output terminal to ground
x. xi.
xii. Efficiency and power factor measurement.
Page 13 of 16
Clause No
BATTERY & BATTERY CHARGER a) Environmental Tests Steady state performance tests (clause (ix) and (x) ) shall be before and after each of the following tests. i) Soak Test All electronic modules shall be subjected to continuous operation for a minimum period of 72 hours. During last 48 hours, the ambient temperature shall be maintained at 50 deg. C. The 48 hour test period shall be divided into four equal 12 hour segments. The input voltage during each 12 hours shall be nominal voltage for 11 hours followed by 110% of nominal voltage for 30 minutes, followed by 90% of nominal voltage for 30 minutes. The manufacturer shall submit the record of carrying out this test to the owners engineer at the time of inspection. ii) Degree of protection test (IP-42). xiii. Rectifier transformer As per IS 4540. In case the contractor has carried out the type tests within last five years as on the date of bid opening, he may submit the type test reports from NABL accredited laboratory to the owner for waival of conductance of such type tests. These reports should be for the tests conducted on the equipment with identical design to that proposed to be supplied under this contract. The owner reserves the right for conducting any or all of the specified type tests under this contract. Routine Tests Following routine tests shall be carried out on all Rectifier transformers in addition to tests required as per IS-4540. a) Insulation resistance test. b) High voltage (power frequency) test. Following routine tests shall be carried out on all Battery Chargers in addition to tests required as per IS-4540 : a) Complete physical examination. b) Short circuit test at full load and at no load for sustained short circuit of 10 sec (min. shall be carried out). The charger shall not trip, no fuse shall blow and charger current shall be limited to 150% of the rated current. c) Insulation resistance test. d) High voltage (power frequency) test. e) Ripple content test at carried out
Page 14 of 16
Clause No
BATTERY & BATTERY CHARGER i) No load ii) Half load iii) Full load f) Automatic voltage regulator operation test at specified A.C. supply variations at i) No load ii) Half load iii) Full load g) Load limiter operation test h) Checking of proper operation of annunciation system. i) Dynamic response test Overshoot/Undershoot in out put voltage of the charger as a result of sudden change in load from 100% to 20 % and 20% to 100% shall be measured. j) Soak Test (as per cl 7.1.1 xiii(a).i) - shall be carried out on all electrical modules/ panels as routine test. k) The charger shall be checked for gasketing arrangement as per drawing. Following routine tests shall be carried out on annunciation system. a) Burn in test shall be carried out as per below Burn in Test - shall be carried out on all electrical modules as panels with module as routine test. During the test panel/ module shall be subjected to ambient temperature of 50 deg. C for 48 hours in energised condition. The temperature rise inside the cubicle shall not exceed 10 deg. during the temperature rise test.
10.00.00
ACCEPTANCE TESTS: Following acceptance tests and checks shall be carried out by the owner at the manufacturers works: a) Complete physical examination. b) Checking of proper operation of annunciation system. c) Temperature rise test at full load. d) Insulation resistance test. e) Automatic voltage regulator operation.
Page 15 of 16
Clause No
BATTERY & BATTERY CHARGER f) Load limiter operation. g) Dynamic response test. h) Ripple content test i) High voltage power frequency test Overshoot/Undershoot in output voltage of the Charger as a result of sudden change in load from 100% to 20% and 20% to 100% shall be measured with the Batteries connected/disconnected. Output voltage of the Charger connected with Battery shall be within 90 % to 110 % of the voltage setting in above conditions and shall return to, and remain, within the limits specified in clause 3 (d) in less than 2 seconds (as applicable). The Contractor shall furnish for inspection, the type and routine tests certificates for Chokes and transformer whenever required by the Employer.
Page 16 of 16
CLAUSE NO.
33 KV AND 11 KV POST INSULATORS 33 kV AND 11 kV POST INSULATOR Post Insulators are required to provide rigid supports for bus bars part of Isolators, AB Switches and other equipments/conductors in the sub-station. Standard: Except where they conflict with the specific requirement of this specification, the post insulators shall comply with the IS : 2544-1973, IS : 5350 PartII 1969(latest) amendments. Post Insulator unit or an assembly of such units and is intended to rigid support to a live part which is insulated from earth or from another live part. Mechanical Strength: The Post Insulators shall be suitable for the minimum failing loads specified as under: Sl. No. Highest System Voltage Failing Loads (Min.) Bending(N) Torsion(Nm) 1 2 12 kV 36 kV 5000 4500 200 680 Tension (N) 15000 30000 Compression(N) 30000 40000
1.00.00 1.01.00 1.02.00
1.03.00 1.03.01
1.03.02 1.03.03
Puncture Voltage : The voltage at which a the puncture occurs. Creepage Distance : The minimum creepage distance shall be as under : Sl. No. Highest System Voltage Normal and moderately polluted atmosphere (total)
1. 2. 2.00.00
12 kV 36 kV
320 mm 900 mm
ATMOSPHERIC CONDITIONS The material offered shall be suitable for operation under the climatic conditions indicated in Service Condition of Project-Synopsis.
2.02.00 2.02.01 2.02.02
General Requirements The porcelain shall be sound and free defects, thoroughly vitrified and smoothly glazed. Unless otherwise specified the glaze shall be brown in colour. The glaze shall cover all the expose porcelain part of the insulator except those area which serve as support or required to be left un-glazed. Precaution shall be taken during design and manufacture to avoid the following : a) Stress due to expansion and contraction which may lead to deterioration .
TECHNICAL SPECIFICATION VOL-II (PART-A) CHAPTER-II SECTION-E11 POST INSULATORS Page 1 of 5
2.02.03
CLAUSE NO.
33 KV AND 11 KV POST INSULATORS b) c) d) Stress concentration due to direct engagement of the porcelain with the metal fittings. Retention of water in the recesses of metal fitting and Shapes which do not facilitate easy cleaning by normal methods.
2.02.04
Cement used in the construction of the post insulator shall not cause fracture by expansion or loosening by contraction and proper care shall be taken to locate the individual parts correctly during cementing. Further, the cement shall not give rise to chemical reaction with metal fittings and its thickness shall be as uniform as possible. All ferrous metal parts except those of stainless steel, shall be hot dip galvanized and the uniformity of zinc coating shall satisfy the requirements of IS : 2633 1964. The parts shall be galvanized after mechanising. The finished galvanized surface shall be smooth. The threads of the tapped holes in the post insulators metal fittings shall be cut after giving anti-corrosion protection and shall be protected against rest by greasing of other similar means. All other threads shall be cut before giving anti-corrosion protection. The tapped holes shall be suitable for bolts with threads having anti corrosion protection and shall confirm to IS : 4218 (Part-I to VI). The effective length of thread shall not be less than the nominal diameter of the bolt. The post insulator unit shall be assembled in a suitable jig to ensure the correct positioning of the top and bottom metal fitting 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 bottom metal fittings shall be in a vertical plan containing the axis of insulator. CLASSIFICATION The post insulators shall be of type B according to their construction, which is defined here under : A post insulator or a post insulator unit in which the length of the shortest puncture path through solid insulating material is less than half the length of the shortest flash over path through air outside the insulator.
2.02.05
2.02.06
2.02.07
3.00.00
4.00.00 4.01.00
STANDARD INSULATION LEVELS The standard insulator levels of the post insulator or post insulator unit shall be as under :
Highest system voltage
Visible discharge test
Dry one minute power frequency withstand test 35 kV (rms)
Wet one minute power frequency withstand test 35 kV (rms)
Power frequency puncture withstand test 1.3 times
Impulse voltage withstand test
12 kV
9 kV (rms)
75 kV peak
Page 2 of 5
CHAPTER-II SECTION-E11 POST INSULATORS
CLAUSE NO.
33 KV AND 11 KV POST INSULATORS (rms) the actual dry flash over voltage of the unit (kV rms) 27 kV (rms) 75 kV (rms) 75 kV (rms) 1.3 times the actual dry flash over voltage of the unit (kV rms) 170 kV peak
36 kV (rms)
4.03.00 5.00.00 5.01.00 6.00.00 6.01.00
The withstand and flashover voltage are referred to the atmospheric condition. TESTS The insulators shall comply with IS: 2544 for all type, acceptance & routine tests. MARKING Each post insulator shall be legibly and indelibly marked to show the following. a) b) c) Name or trade mark of the manufacturer. Month & year of manufacture. Country of manufacture.
6.01.01 6.02.00 7.00.00
Marking on porcelain shall be printed and shall be applied before firing. Post insulator or post insulator units may also be mark with I.S.I. certification mark. PACKING All post insulators shall be pack in wooden crates suitable for easy but rough handling and acceptable for rail, transport. Where more than one insulator is packed in a create wooden separators shall be fixed between the insulators to keep individual insulator in position without movement within the crate.
Page 3 of 5
CLAUSE NO.
33 KV AND 11 KV POST INSULATORS
GUARANTEED TECHNICAL PARTICULARS: 11kV INSULATOR The following gauranteed technical parameters shall be applicable
Part A Sr. No. Description Applicable standard Indian standard no REC specification no Electrical Characteristics Material Type of Insulators Highest system voltage(KV rms) Nominal system voltage(KV rms) Visible discharge voltage( KV rms) Minimum wet one minute power frequency withstand voltage (kV rms) Power frequency puncture withstand voltage(KV rms) Impulse voltge withstand(kV peak) Mechanical Characteristics Bending (N) Torsion (Nm) Tension (N) Compression (N) Size of insulators creepage distance (min)(mm) ** Color of glaze Tolerance in dimensions, if any 11kV Post Insulator 2544 3/1971 Porcelain Type B 12 11 9 35 1.3 times the actual dry flashover voltage 75 5000 200 15000 30000 380 Brown
1 a b c d e f g h 2 i ii iii iv 3 a b c Part B 1 2
Porcelain diameter(mm) Spacing/height of insulator(mm)
Page 4 of 5
CLAUSE NO.
33 KV AND 11 KV POST INSULATORS
GUARANTEED TECHNICAL PARTICULARS: 33kV INSULATOR The following gauranteed technical parameters shall be applicable
PART A
Sr. No. Description Applicable standard Indian standard no REC specification no Electrical Characteristics Material Type of Insulators Highest system voltage(KV rms) Nominal system voltage(KV rms) Visible discharge voltage( KV rms) Description Minimum wet one minute power frequency withstand voltage (kV rms) Power frequency puncture withstand voltage(KV rms) Impulse voltge withstand(kV peak) Mechanical Characteristics Bending (N) Torsion (Nm) Tension (N) Compression (N) Size of insulators creepage distance (min)(mm) ** Color of glaze Tolerance in dimensions, if any 33kV Post Insulator
2544 13/1979 Porcelain Type B 36 33 27 33kV Post Insulator 75 1.3 times the actual dry flashover voltage 170 4500 680 30000 40000 900 Brown As per IS
1 a b c d e Sr. No. f g h 2 i ii iii iv 3 c 4 5
Part B a b
Porcelain diameter(mm) Spacing/height of insulator(mm)
Page 5 of 5
CLAUSE NO.
CT/PT OPERATED STATIC ENERGY METER SCOPE This specification covers design, engineering, manufacture, inspection, testing at manufacturers works including type testing before dispatch, supply and delivery of three phase 4 wire tri-vector export (import in case of border meters) with Time of the Day register, load profile data record MD register suitable for both unbalanced and balanced load.
1.00.00
2.00.00
APPLICABLE STANDARDS Sl. No. 1. 2. 3. 4. 5. 6. Standards IS : 14697 IEC : 60687 IEC : 62056-21 (Latest Version) IEC : 61000-4-5 (2001-04) IEC : 61358 ANSI/IPC-A-610 Description Specification for AC Static Transformer operated Watt Hour & VAR-Hour meters, classes 0.2 S & 0.5 S AC Static Watt-Hour Meters for Active Energy (classes 0.2 S & 0.5 S) Data exchange for Meter Reading and Direct Local Data Exchange For Electro Magnetic Compatibility Testing and Measurement techniques, Surge immunity test Criteria for selection for tests LIKE Acceptance, Inspection. Workmanship standard for Acceptability of Electronic Assemblies (A standard developed by Institute for Interconnecing and packaging Circuits).
2.01.02
Climatic Conditions i) ii) iii) Temperature : 10oC to 55o C (in shade) Humidity : Max. Altitude above MSL : Upto 95% RH non-condensing 500 meters
3.00.0 3.01.00
Design and Constructional features Location & Mounting The Energy meters shall be supplied suitable for indoor installation. Enclosure shall have IP-51 protection. All the feeder meters to be
CHAPTER-II SECTION-E12 CT/PT OPERATED STATIC ENERGY METER
Page 1 of 14
CLAUSE NO.
CT/PT OPERATED STATIC ENERGY METER suitable for mounting on Simplex type Vertical Panel with rear door, Energy Meter flush mounted and clearly visible, with disconnecting type TBs, fully wired, for placing inside substation control room.
3.02.00
Design Meter shall be designed with application specific integrated circuit (asic) or micro controller; shall have no moving part; electronic components shall be assembled on printed circuit board using surface mounting technology; factory calibration using high accuracy (0.1 class) software based test bench. All components used shall be approved by reputed testing authority at national level or other international recognized testing authority.
3.03.00
Manufacturing Process, Assembly and Testing Meters shall be manufactured using latest and state of the art technology and methods prevalent in electronics industry. All inward flow of major components and sub assembly parts (CT, PT, RTCs/Crystal, LCDs, LEDs, power circuit electronic components etc.) shall have batch and source identification. Multi-layer PCB assembly with PTH (Plated through Hole) using surface mounted component shall have adequate track clearance for power circuits. SMT component shall be assembled using automatic pick-and-place machines with in process 7 stages, Re-flow Soldering oven, for stabilized setting of the components on PCB. For soldered PCBs, cleaning and washing of cards, after wave soldering process is to be carried out as a standard practice. Assembly line of the manufacturing system shall have provision for testing of sub-assembled cards. Manual placing of components and soldering, to be minimized to items, which cannot be handled by automatic machine. Handling of PCB with ICs/C-MOS components, to be restricted to bare minimum and precautions to prevent ESD failure to be provided. Complete assembled and soldered PCB should under go functional testing using computerized Automatic Test Equipment.
Page 2 of 14
CLAUSE NO.
CT/PT OPERATED STATIC ENERGY METER Test points should be provided to check the performance of each block/stage of the meter circuitry. Testing at intermediate and final stage to be carried out with testing instruments, duly calibrated with reference standard, with traceability of source and date.
3.04.00
Displays 7 digits parameter identifier, backlit Liquid Crystal Display (LCD) of minimum 10 mm height, wide viewing angle. Auto display cycling push button required with persistence time of 12 Seconds. Sequence of display of various instantaneous electrical parameters shall be as desired by Owner at the time of order. Normal display shall be Active energy value, on release of push button, at any of the display parameter during scrolling.
3.05.00
Calibration of Meter Meters shall be factory calibrated using high accuracy test bench. Energy Meter shall have test output device, accessible from the front, and be capable of being monitored with suitable testing equipment while in operation at site. Resolution of the device shall enable the starting current test in less than 10 minutes. Accuracy of test bench at works shall be as per the guidelines provided in IS : 12346.
3.06.00
Self-Diagnostic Features The meter shall have self-diagnostic features to check its circuits for any malfunctioning. The bidder shall furnish the details of the selfdiagnostic features.
3.07.00 3.07.01
Construction Meter Case and Cover a) To ensure high reliabililty, long trouble free life, safety against electric shock, spread of fire and effects of excessive temperature, the meter casing and cover shall be made of high quality industrial grade polycarbonate material or better material having adequate strength, which is unbreakable, corrosion resistant & inert to chemicals, flame retardant, immune to ultra violet radiation and meet UV ageing test as per relevant ASTM standards.
Page 3 of 14
CLAUSE NO.
CT/PT OPERATED STATIC ENERGY METER b) The bidder shall indicate hardness, melting temperature and tensile yield strength of the material and necessary test certificate of the same shall be furnished. The meter shall be provided with adequate shielding to withstand external magnetic influence from all directions as per latest amendments of CBIP 88 report. Meter cover shall be continuously ultra sonically welded with meter base from all sides. Suitable locking arrangement shall be provided between the base and cover of the meter.
c)
d)
3.08.00 3.08.01
Sealing Arrangement Two sealing screws shall be provided for proper fixing of the meter cover so that access to the working part shall not be possible without breaking the seal. Necessary provision shall be kept for fixing the utility seal also. Terminal block shall be provided with separate sealing facility by testing group of utility. Terminal Block and Cover The terminal block shall have adequate insulating properties and mechanical strength. The terminal block shall be made from best quality non-hygroscopic, flame retardant polycarbonate material (capable of passing the flammability tests give in IS :11731) with nickel-plated brass studs for connecting terminals. The terminal block base shall be of same material as meter case or any other superior industrial plastic material having sufficient thickness to cover its back and provide enough strength for the purpose of tightening of screws. Clamping screws should be provided inside the terminal cover and should have metallic sleeve moulded within the block to avoid damage during tightening of the screws. The terminals in the terminal block shall be of long socket type suitable for connection of cables with aluminium conductors along with suitable lugs (lugs to be provided by the supplier) having cross sectional area, with adequate length. Double screw arrangement shall be provided to achieve adequate termination. All terminals and connecting screws and washers shall be of tinned / nickel plated brass material. The terminal cover shall be transparent with minimum thickness 2.5 mm and the material shall be same as that of meter case. It shall be of
3.08.02 3.08.03 3.09.00 3.09.01
3.09.02
3.09.03
3.09.04
Page 4 of 14
CLAUSE NO.
CT/PT OPERATED STATIC ENERGY METER extended type and accommodate, in addition to the terminal block, a suitable length of external cable along with its insulation.
3.10.00 3.10.01
Name Plate and Marking: Every meter shall have a nameplate clearly visible and indelible and distinctly marked in accordance with IS : 14697 (latest version). The following information shall appear on a nameplate preferably placed within the meter. 1. 2. 3. Manufacturers name & trade-mark and place of manufacture. Serial number and year of manufacture. Designation of type.
4. Number of phases and number of wires for which the meter is suitable. 5. 6. 7. 8. 9. 10. 11. 12. 4.00.00 4.01.00 Guarantee period. Owners name & meter number. Principal unit in which the meter records. Reference voltage & frequency in Hz. Basic current and rated maximum current. Meter constant (pulse rate of testing signal). Class index. Project Name.
OPERATIONAL REQUIREMENTS Performance under Influence Quantities As per IS 14697. Accuracy for measurement & display of instantaneous quantities shall conform to IS14697.
4.02.00 4.02.01
Additional Technical Features Output Device

i)
ii) iii)
Energy Meter shall have test output, accessible from the front, and be capable of being monitored with suitable testing equipment while in operation at site. Operation indicator must be visible from the front. Test output device shall be provided in the form of LED/LCD.
TECHNICAL SPECIFICATION VOL-II (PART-A) CHAPTER-II SECTION-E12 CT/PT OPERATED STATIC ENERGY METER Page 5 of 14
CLAUSE NO.
CT/PT OPERATED STATIC ENERGY METER
Resolution of the test output device shall be sufficient to enable the starting current test in less than 10 minutes. Nameplate shall indicate the impulse/ Unit with appropriate resolution. 4.02.02 Cumulative Energy Register Meter should have provision for automatic recording of cumulative kWh & MD KW at say 24.00 hours on the last day of the month for each of the past six calendar months and same to be stored in the register/memory. 4.03.00 Temperature Conditions As per Is 14697; Meter to perform satisfactorily under Non-Air Conditioned environment in HT sub-station with Indoor switchgear in some of the locations. 4.04.01 Real Time Internal Clock (RTC) of Energy Meter RTC shall be pre-programmed for 30 Years Day/date without any necessity for correction. Maximum drift shall not exceed +/- 300 Seconds per year. Time & date setting shall only be possible through one of the following: (a) Common Meter Reading Instrument (CMRI) or Meter testing work bench and this shall need password enabling for Consumer meter;
From Base billing system computer thro WAN or Sub-station data logger PC through LAN. 4.04.02 Clock Day/Date Synchronisation Synchronisation of Energy Meter RTC Time/Date shall be possible thro password/Key code enabled command from remote server or sub station PC as per the arrangement. Master Clock reference shall be obtained from Main server or local PC. Synchronisation shall be carried only if the RTC drift is within 10 minutes. Error log to be recorder by the system S/W if the RTC time is out of range.
RGGVY WORKS STANDARD TECHNICAL SPECIFICATION (REV.- 03) TECHNICAL SPECIFICATION VOL-II (PART-A) CHAPTER-II SECTION-E12 CT/PT OPERATED STATIC ENERGY METER Page 6 of 14
CLAUSE NO.
CT/PT OPERATED STATIC ENERGY METER Quantities to be Measured & Displayed As per Appendix G of IS 14697. a) TOD time slot register wise export & Import (when asked) of kWh & kVARh, kVAh energy; Maximum kVA or kW demand with elapsed time. Instantaneous kW, kVA, PHASE WISE kW & kVA, OVERALL pf, MD reset count, frequency, time & date, RTC battery health;
4.05.00
b) c)
In addition, present status of abnormality shall also be possible to be displayed. Tamper details shall be stored in internal memory for retrieval by authorized personnel through either of the following: i) Common Meter Reading Instrument (CMRI) and this shall need password enabling. From Base billing system computer thro WAN or Sub-station data logger PC through LAN.
ii) 4.06.00
Demand Integration Period (DIP) i) Energy Meter shall continuously monitor and calculate the average maximum demand for each demand interval time of 30 minutes and maximum of these in a calendar month shall be stored along with date and time when it occurred; It shall however be possible to change the demand integration period (DIP), from 30 to 15 minutes at site, with proper security; The Maximum demand of past six months shall be stored in the memory with date and time. It shall be also possible to retrieve this data through communication port and MRI. There shall be no resetting button for MDI data and resetting shall be possible, on request by Sub-Station data logger system thro LAN after retrieval of update data or via MRI optical port, with password enabled access, only.
ii)
iii)
iv)
v)
Page 7 of 14
CLAUSE NO.
CT/PT OPERATED STATIC ENERGY METER Time of Day (TOD) Registers 6 or 8 different TOD energy registers as per clause G-8 of IS 14697 are required. Time block settings shall be advised to the supplier at least 4 weeks before commencing delivery. Change of time period for TOD metering shall be with password enabling from CMRI or from base computer for LAN operated meters.
4.07.00
4.08.00
Load Survey Data Registers Storage in Non volatile memory for 40 days, 30 minute demand of any of the flow parameters of kW, kVA, kVAR (or Pf), Average of 3 voltages and phase currents shall be provided.
4.09.00
Communication Facilities & Standards Data architecture and communication protocols shall enable easy multivendor exchange of data without usage of any converting/translating equipment. For this, the data structure adopted within the energy meter shall be on an internationally acceptable method. The data structure/coding details shall be furnished to the Owner. All necessary software required for down loading the information to a user friendly Windows/LINUX based operating system of Base billing computer system, Substation data logger PC system thro CMRI as well as LAN shall be furnished in required number of copies (On CD) without any additional cost to the Owner. Local communication port: a) Meter shall be provided with RS 485 port for periodic data transfer thro LAN to sub-station data logger/Computer; Energy Meter shall operate on industry standard MODBUS protocol and shall be individually addressable RS485 communication port shall be suitable for interfacing multiple Energy Meters. It shall be possible to download stored meter data, on polling basis with the aid of a software schedule by addressing one meter at a time and downloading the stored data into the sub station data logger/Computer. Energy meter shall have a galvanically isolated optical communication port as per IEC 62056-21 or any other internationally accepted port in front of the meter for data transfer to or from a hand held data Collection Device (Common
b)
c)
e)
CLAUSE NO.
CT/PT OPERATED STATIC ENERGY METER Meter Reading Instrument CMRI - conforming to CBIP technical report-111) with proper security and without error. f) one number CMRI Unit at each sub-section is to be supplied under this Project as per the specification stated at (e) above.
4.11.00
Accuracy In case any drift is noticed in the accuracy of the meter, which is beyond the permissible limits, the concerned meter shall be with-drawn from service and Bidder shall supply a new meter without any extra cost as a replacement (with in one month of receipt from owner), during the guarantee period i.e. 2 years from supply.
5.00.00 5.01.00
Inspection, Testing and Dispatch Type Tests i) The meter offered should have successfully passed all type tests described in the IS 14697 Type test certificate shall be submitted along with the offer and the same shall not be more than 36 months old on the date of opening tender. Make & type of major components used in the type-tested meter shall be indicated in the type test certificates.
5.02.00
Acceptance and Routine Tests i) Criteria for selection for such tests requirements shall be as per IS 14697. and performance
5.03.00 5.03.01
Quality Assurance Plan The bidder (manufacturer) shall have a comprehensive quality assurance program at all stages of manufacture for ensuring products giving reliable, trouble free performance. The bidders (manufacturers) quality assurance plan shall be submitted along with bid document, which would be reviewed in detail by the owner in case of award and accepted with modifications, as felt necessary. A sampler manufacturing quality plan document is enclosed in this specification.
5.03.02
The bidders quality assurance programme shall generally cover the following. i) Bidder organization structure for the management and implementation of the proposed quality assurance programme.
CLAUSE NO.
CT/PT OPERATED STATIC ENERGY METER ii) iii) iv) v) Quality System Manual. Design Control System. Documentation Control System. The procedure for purchase of materials, parts, components, source inspection, incoming raw-material inspection, verification of materials purchased etc. System for process controls and fabrication and assembly controls.
vi)
vii) Inspection and test procedure both for manufacture and field activities. viii) Control of calibration and testing of measuring /testing equipments. ix) x) 5.03.03 System for Quality Audits. System for handling storage and delivery.
The Bidder shall accordingly furnish along with the bid i) ii) iii) A comprehensive quality assurance plan which is in practice (for both product & process). A detailed list of bought out items with name of the manufacturer and details about in coming quality control. Quality assurance plan of bidders collaborators in case of foreign collaborators.
5.03.04
Owner reserves the right to carry out quality audit and quality surveillance of the systems and procedure of the bidders quality management & control activities. The bidders shall provide all necessary assistance to enable the owner to carry out such audit & surveillance. MANUFACTURING AND TESTING FACILITIES The following Manufacturing and testing facilities shall be available. The factory shall be completely dust proof. The testing rooms shall be temperature and humidity controlled as per relevant Standards.
TECHNICAL SPECIFICATION VOL-II (PART-A) CHAPTER-II Page SECTION-E12 10 of 14 CT/PT OPERATED STATIC ENERGY METER
6.00.00 6.01.00
CLAUSE NO.
CT/PT OPERATED STATIC ENERGY METER The testing and calibrating equipment should be automatic and all test equipment shall have their valid calibration certificates Power supplies used in testing equipment shall be distortion free with sinusoidal waveforms and maintaining constant voltage current and frequency as per the relevant Standards.
6.02.00
During the manufacturing of the meters following minimum checks shall be carried out. a. b. Meter frame dimension tolerance shall be minimum. The pressure coil shall be made totally encapsulated and care shall be taken to avoid ingress of dust and moisture inside the coil. The assembly of parts shall be done with the help of jigs and fixtures so that human errors are eliminated. The meters shall be batch tested on automatic, computerized test bench and the results shall be printed directly without any human errors. The current coil shall be made with the help of jigs and fixtures. The potential coil shall be made with automatic computerized machine.
c. d.
e. f. 7.00.00 7.01.00
MOUNTING AND FIXING ARRANGEMENT DRAWINGS / DATA SHEET Manufacturer shall ensure following technical points: i) Meter shall be suitable for mounting on Simplex type Vertical panel with rear door; CAT-M4 disconnecting type TBs to be used for Current circuit; Panel wiring to be properly dressed and harnessed; External cables to enter panel from bottom gland plate using double compression glands. External cabling and inter-connection from existing CT/PT to Energy Meter panel shall be shall be in the scope of the contractor/bidder; LAN cabling from Energy Meters to PC/CPU at Sub station shall be in the scope of the contractor/bidder; Energy Meter terminals block shall be adequately sized with regard to maximum conductor dimension, commensurate with current rating of Energy Meter
TECHNICAL SPECIFICATION VOL-II (PART-A) CHAPTER-II Page SECTION-E12 11 of 14 CT/PT OPERATED STATIC ENERGY METER
ii)
iii) iv)
CLAUSE NO.
CT/PT OPERATED STATIC ENERGY METER v) RS 232 to RS 485 when used shall be suitably wounded in side the panel and its cable shall be terminated for external connection One copy of test report, approved data sheet and operating manual shall be despatched with the meter. 4 copies of these documents shall be submitted to owners engineering department for record. Guaranted Technical Parameter The following gauranteed technical parameters shall be applicable.
CHAPTER-II Page SECTION-E12 12 of 14 CT/PT OPERATED STATIC ENERGY METER
CLAUSE NO.

Sr No 1 2 3 4 5 6 Meter shall display in Primary Quantity as per adopted CT ratio Maximum Continuous Current : Frequency : Completely type tested as per Indian Standard IS Minimum starting current : Accuracy class. : Test Output device Operation indicator Power consumption in voltage and current circuit Limits of error at all Power factor of unity/0.5 at multiples of rated currents. Compliance to IS-14697 for Change in error due to a) Variation in frequency: b) Variation in Temperature As per approved SLD of substation where meter to be fitted (2Ib) As per IS 14697 50Hz +/- 5% 14697 0.1% of Ib 0.5 Class LED LED/LCD As per IS-14697 As per IS-14697 Description THREE PHASE METER CT /PT Operated Energy meter Static Three Phase ,CT operated meter for unbalance load current IS-14697:1999 24 Months 63.5 V(Ph-N),110V(Ph-PH) 1A # 0.5 lag-Unity-0.8 lead
Type Standard to which the meter conforms: Guarantee Period from the date of first installation Rated Voltage: Basic Current(Ib): Power factor Range
6 7 8 9 10 11 12 13 14
15 16
As per IS-14697 As per IS-14697 One minute Power frequency withstand Voltage :
17 18 19 20 21 22 23 24 Should be Compliant to EMC & EMI as Basic insulation level: Impulse withstand Voltage Details of meter case: Degree of protection against dust and water : Details of alpha-numeric LCD display i.No. of digits Tamper protection features (List out) TECHNICAL SPECIFICATION VOL-II (PART-A) CHAPTER-II Page SECTION-E12 13 of 14 CT/PT OPERATED STATIC ENERGY METER As per IS-14697 As per IS-14697
CLAUSE NO.
25 26
27 28 29
Tamper immune features (List out) Whether test output provided Limits of error at variaous Power factors of unity/0.5and Loads Meter & Terminal Cover sealing Type Test Certificate
Note; # (Basic Current of 5A may also be required depending on site requirement.the Exact quantity of 5A CT will be communicated during detail Engineering)
CHAPTER-II Page SECTION-E12 14 of 14 CT/PT OPERATED STATIC ENERGY METER
CLAUSE NO.
CIVIL & STRUCTURAL WORKS
1.00.00 1.01.00
GENERAL REQUIREMENTS This chapter includes the technical requirements for 33/11 kV Sub-Station, including control room building and associated design and preparation of all civil & structural drawings and execution of all associated civil works. This Chapter deals mainly with technical specifications for the design, supervision and construction of complete civil & structural works Complete under the scope of this contract. a) The specifications are intended for general description of work, quality and workmanship. The specifications are not however exhaustive to cover minute details and the work shall be executed according to relevant latest Indian Standards/IRC Specifications. In the absence of the above, the work shall be executed according to the best prevailing practices in the trade, recommendations of relevant American or British Standards or to the instructions of Engineer. The IS standards/IRC specifications to be followed are mentioned in the technical specifications attached hereto. They shall be latest edition/version of the same. The Bidder is expected to get himself clarified on any doubts about the specifications etc. before bidding, and the discussions recorded in writing with the Employer in respect of interpretation of any portion of this document. The contractor shall take all necessary precautions to protect all the existing equipments, structures, facilities & buildings etc. from damage. In case any damage occurs due to the activities of the Contractor on account of negligence, ignorance, accidental or any other reason whatsoever, the damage shall be made good by the Contractor at his own cost to the satisfaction of the Engineer. The Contractor shall also take all necessary safety measures, at his own cost, to avoid any harm / injury to his workers and staff from the equipment & facilities of the power station. During the progress of work, the Engineer will exercise supervision of the work to ensure that the technical provisions of the contract are being followed and the work is being executed accurately and properly. However, such supervision shall in no way relieve the Contractor of the responsibility for executing the work in accordance with the specifications. Before submitting the bid, the Bidder shall inspect and examine the site and its surroundings and shall satisfy himself as to the nature of the ground and subsoil, the availability of materials necessary for completion of the work, means of access to site and in general shall himself obtain all necessary information as to risks, contingencies and other circumstances which may influence or affect his offer. No extra claim consequent on any misunderstanding or otherwise shall be allowed.
b)
c)
d)
2.00.00 2.01.00
LAYOUT AND LEVELS The layout and levels of all structures etc. shall be made by the Contractor at his own cost from the general grid of the plot and bench marks given by the Engineer. The Contractor shall give all help in instruments, material and men to the Engineer, at no extra cost, for checking the detailed layout & correctness of the layout and levels. However the Contractor shall be solely responsible for their correctness.
TECHNICAL SPECIFICATION VOL-II (PART-A) SECTION-E-13
RGGVY WORKS STANDARD TECHNICAL
Page 1 of 18
CLAUSE NO.
3.00.00 3.01.00 3.02.00 3.03.00
CODES AND STANDARDS All standards, specifications, acts and code of practice referred to herein shall be the latest editions including all applicable official amendments and revisions. In case of conflict between this specification and those (IS standards, codes etc.) referred to here in, the former shall prevail. Some of the relevant Indian standards, Acts and Codes are referred to here below : a) EXCAVATION AND FILLING
IS : 2720 ( Part II, IV TO VIII, XIV, XXI, XXIII, XXIV, XXVII TO XXIX, XL ) Methods of test for soils determination for water content etc. IS : 9758 b) Guide lines for Dewatering during construction AND HANDLING OF COMMON
PROPERTIES, STORAGE BUILDING MATERIALS
IS : 456 IS : 516 IS : 1199 IS : 2502 IS : 2645 IS : 4326 IS : 5624 IS : 9103 SP : 23 SP : 34 c) SP : 7 (Part VI / Sec.7) IS : 10505
Code of practice for plain and reinforced concrete. Method of test for strength of concrete. Methods of sampling and analysis of concrete. Code of practice for bending and fixing of bars for concrete reinforcement. Specification for Integral cement water proofing compounds. Code of practice for earthquake resistant design and construction of buildings. Specification for foundation bolts. Specification for admixtures for concrete. Handbook of concrete mixes Handbook on concrete reinforcement and detailing.
CAST-IN-SITU CONCRETE AND ALLIED WORKS National Building Code Structural design of prefabrication and systems building. Code of practice for construction of floors and roofs using pre cast reinforced concrete units.
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d) MASONRY AND ALLIED WORKS IS : 1905 IS : 2212 IS : 2250 Code of Practice for Structural Safety of Buildings Masonry walls. Code of Practice for Brickwork. Code of Practice for Preparation and use of Masonry Mortar.
e) FABRICATION AND ERECTION OF STRUCTURAL STEEL WORK IS : 2016 IS : 802(1977) IS : 2062 IS : 800 IS : 9595 IS : 1608 IS:278 IS:2721 f) Specification for plain washers. Part 1:Code of practice for use of Structural Steel in Over Head Transmission Line Towers Specification for Steel for general purpose structural work. Code of practice for use of structural steel in general building construction. Code of procedure of Manual Metal Arc Welding of Mild Steel. Method of Tensile Testing of Steel products other than sheets, strip, wire and tube. GI Barbed wire fence GI chain link fence fabric
PLASTERING AND ALLIED WORKS Code of practice for field slaking of Building lime and preparation of putty. Plaster - of - paris.
IS : 1635 IS : 2333 g)
WATER SUPPLY, DRAINAGE AND SANITATION Specification for concrete pipes. Flushing cisterns for water closets and urinals. Cast iron brackets and supports for wash basins and sinks. Vertically cast iron pressure pipes for water, gas and sewage. Cast iron fittings for pressure pipe for water, gas and sewage.
IS : 458 IS : 774 IS : 775 IS : 1537 IS : 1538

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IS : 1742 IS : 2065 IS : 2326
Code of practice for building drainage. Code of practice for water supply in building. Automatic flushing cisterns for urinals.
IS : 2470 ( Part - I Code of practice for installation of septic tanks. & II ) IS : 2556 ( Part 1 Vitreous sanitary appliances (vitreous china). to 15 ) IS : 3438 IS : 5329 SP : 35 h) Silvered glass mirrors for general purposes. Code of practice for sanitary pipe work above ground for buildings. Hand book on water supply and drainage.
PILING AND FOUNDATION Code of practice for design and construction of simple spread foundations. Code of practice for design and construction of foundations in Soils; General Requirements. Code of practice for designs and construction of Raft foundation. Code of practice for design and construction of machine foundations. Code of practice for determination of Allowable Bearing pressure on Shallow foundation. Shallow foundations. Deep foundations. Code of practice for design and construction of shallow foundations on rocks.
IS : 1080 IS : 1904 IS : 2950 (Part- I) IS : 2974 ( Part-I to V ) IS : 6403 Part I Part II IS : 12070 i) ROADS
IRC : 5 IRC : 14
Standard specifications and Code of practice for road bridges, section - I general Features of Design. Recommended practice of 2cm thick bitumen and tar carpets.
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IRC : 19 IRC : 21 IRC : 37 IRC : 86 IRC : SP : 13 IRC - Publication IS : 73 j) LOADING
Standard specifications and code of practice for water bound macadam. Standard specifications and Code of practice for road bridges, section - III - Cement concrete (plain and reinforced). Guidelines for the Design of flexible pavements. Geometric Design standards for urban roads in plains. Guidelines for the design of small bridges & culverts. Ministry of Surface Transport (Roads Wing), Specifications for road and bridge works. Specification for paving bitumen
IS : 875 ( Pt. I to V ) IS : 1893 IRC : 6 k) SAFETY
Code of practice for design loads other than earthquake) for buildings and structures. Criteria for earthquake resistant design of structures. Standard specifications & code of practice for road bridges, Section - II Loads and stresses.
IS : 3696 (Part I & II) IS : 3764 IS : 5916 IS : 7205 IS : 7969
Safety code for scaffolds and ladders. Safety code for excavation work. Safety code for construction involving use of hot bituminous materials. Safety code for erection on structural steelwork. Safety code for handling and storage of building materials
4.00.00 4.01.00
SUBMISSIONS The following documents shall be submitted by the Bidder for approval of the Employer, prior to commencement of fabrication and erection / construction. This list is not exhaustive but indicative only : i) Detailed Survey of the Area
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ii) iii) iv)
Geo-technical Investigation to decide type of foundation of different structures GA drawing showing Co-ordinates of various Gantry structures and facilities. Drawing showing underground facilities with co-ordinates of all facilities such as Gantry foundation, equipment foundation, R.C.C cable trench, cable ducts, drains, sumps, pits, culverts, other foundations etc. Proposed erection/construction scheme for various structural and civil works envisaged as per design requirement. Foundation design & drawing for Gantry structure & LM. Foundation design &drawing for equipment supports, their control cubicles, bus post supports and bay marshalling kiosks Details of RCC cable and pipe trenches with necessary precast RCC removable covers with lifting facility, sump pits, back-filling, cable tray supports, Design calculation, General arrangement drawings & detailed erection / construction drawings including R/F drawings for substation control room building. Design & drawing of roads and complete drainage system within substation including crossings. Site preparation, soil sterilization / antiweed treatment including gravel filling, but excluding major leveling. Complete fencing along with gate for the substation Structural steel fabrication drawings and Reinforcement bar bending schedules for reference. Electronic soft copy of all the approved drawings.
v) vi) vii) viii)
ix)
x) xi) xii) xiii) iv) 6.00.00 6.01.00 6.01.01
CONTROL ROOM BUILDINGS GENERAL REQUIREMENTS General The scope include the design, engineering and construction including ant termite treatment of Buildings including sanitary, water supply, electrification etc. The building shall be of RCC framed structure of concrete grade M25. The control room building shall be as per Drawing enclosed and shall be Single Storied. An open space of 1 m minimum shall be provided on the periphery of the rows of panel and equipment generally in order to allow easy operator movement and access as well as maintenance.
6.02.00
Design a) The buildings shall be designed : i) To the requirements of the national building code of India, and the standards quoted there in.
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ii)
To adequately suit the requirements of the equipment and apparatus contained in the buildings and in all respects to be compatible with the intended use and occupancy. The building shall have framed super structure. The building shall have minimum one brick thick wall cladding on exterior face. To allow for easy access to equipment and maintenance of the equipment. Wherever required, fire retarding materials for walls, ceilings and doors, which would prevent supporting or spreading of fire. Suitable expansion joints shall be provided in the longitudinal direction wherever necessary with provision of twin columns.
iii) iv)
b)
Individual members of the building frame shall be designed for the worst combination of forces such as bending moment, axial force, shear force, torsion etc. Permissible stresses for different load combinations shall be taken as per relevant is codes. The building lighting shall be designed in accordance with the requirements of relevant section.
c) d) 6.03.00 6.03.01
Design Loads Building structures shall be designed for the most critical combinations of dead loads, super-imposed loads, equipment loads, wind loads, seismic loads, and temperature loads. Dead loads shall include the weight of structures complete with finishes, fixtures and partitions and should be taken as per IS: 1875. The wind loads & seismic forces shall be computed as per data provided in project synopsis. Wind and seismic forces shall not be considered to act simultaneously. Beams shall be designed for incidental point loads of 20 KN to be applied at any point along the beams. The loads shall be subject to purchasers approval. For consideration of loads on structures IS:875, the following minimum superimposed live loads shall, however, be considered for the design. a. b. c. d. e. Roof RCC Floors Floors Stairs, Landings Balconies Toilet Rooms Chequered plate, 1000 kg/m2 500 kg/m2 200 kg/m2 500 kg/m2
6.03.02 6.03.03 6.03.05 6.03.06 6.03.08
150 kg/m2 75 kg/m

2
for accessible roofs for non-accessible roofs
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greeting floor etc. f. 6.04.00 Walkways (general) 300 kg/m2 Submission The following documents are to be submitted for review and approval to the owner prior to commencement of fabrication and erection / construction : 1. 2. Schematic equipment layout Detailed architectural drawings required for execution i.e. Detail floor plans, all elevation, section, stair case detail, toilet detail, finish schedule, colour scheme (both internal and external), door and window details, fixing details for doors and windows, false ceiling etc. Architectural facia and projection, miscellaneous architectural details, coping, flashing, khurras. Water proofing, fillet, surface drain around control room building, rain water down comers, sanitary, plumbing etc. And other details as per requirement. 3. Design intent document giving basis of design shall cover all aspects, parameters, assumption, references, loading faces, loading combination, analysis and design of control room building shall be furnished and got approved before commencement of detailed engineering. Structural analysis, design calculation and drawings for foundations / substructure and superstructure of building, facilities, services etc. Analysis, design calculation and drawings for all underground facilities with coordinates and invert levels like buried pipes, buried cables, trenches, ducts, sewer drains, sumps, manholes, water supply and overhead water tank etc. Copy of all tests / studies / investigation carried out by bidder as per scope. All other designs, calculations, details, drawings or any other submission as indicated elsewhere in this specification and required by owner time to time after award.
4. 5.
6. 7.
6.05.00 6.06.00
Finish Schedule The finishing schedule is given in subsequent clauses. Flooring Flooring in various rooms of control room building shall be as for detailed schedules given in Table -1
6.07.00
Walls Control room buildings shall be of framed superstructure. All walls shall be non-load bearing walls. Min. thickness of external walls shall be 230 mm (one brick) with 1:6 cement sand mortar.
6.08.00
Plastering All internal walls shall have minimum 12mm and 15 mm thick 1:6 cement sand plaster on either side of wall. The ceiling shall have 6mm thick 1:4 cement sand plaster.
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6.09.00
Finishing All external surfaces shall have 18 mm cement plaster in two coats, under layer 12 mm thick cement plaster 1:5 and finished with a top layer 6 mm thick cement plaster 1:6 (DSR 13.19) with water proofing compound. The paint shall be anti-fungal quality of reputed brand suitable for masonry surfaces for high rainfall zone. White cement primer shall be used as per manufacturers recommendation. Internal finish Schedule is given Table - 1 below: TABLE-1 Sl. No. Location Floorin g& Skirting 150 mm high Precast Terrazo tiles Wall Internal Ceiling Doors, Windows, Ventilators
1.
Control Room, Relay Room
Oil bound washable distemper on smooth surface applied with 2 mm thick Plaster of Paris putty Oil bound washable distemper on smooth surface applied with POP putty.
White Wash
1) Standard steel rolled section frames with 5 mm glass for windows 2) Flush door
2.
Substation Incharge, Office, Corridor, staff room Battery room
Precast Terrazo tiles
White Wash
1) Standard steel rolled section frames with 5 mm glass. for windows 2) Flush door
3.
Acid and Alkali Resistan t tiles.
Dado of acid resistant tile 1.2 M high & Paint above 1.2 M to ceiling.
Acid resistant Paint.
1) Standard steel rolled section frames with 5 mm glass. 4 for windows 2) Steel door painted with acid resistant Paint.
4.
Toilet
Ceramic glazed tiles in flooring Terrazo tiles
DADO glazed tile 2.1 White M high for toilet Wash
1) Standard steel rolled ventilators 2) Flush door
5.
Other areas not specified
Oil bound distemper,
White Wash
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6.10.00
Roof Roof of the C.R. Building shall consist of Cast-in-situ RCC slab treated with a water proofing system which shall be an integral cement based treatment conforming to CPWD specification (item no. 25.8 of DSR 1997). The water proofing treatment shall be of following operations: (a) Applying and grouting a slurry coat of neat cement using 2.75 kg/m2 of cement admixed with proprietary water proofing compounds conforming to IS: 2645 over the RCC slab including cleaning the surface before treatment. Laying cement concrete using broken bricks/brick bats 25mm to 100mm size with 50% of cement mortar 1:5 (1 cement : 5 coarse sand) admixed with proprietary water proofing compound conforming to IS: 2645 over 20mm thick layer of cement mortar of min 1:5 (Cement: 5 coarse sand) admixed with proprietary water proofing compound conforming to IS: 2645 to required slope and treating similarly the adjoining walls upto 300 mm height including rounding of junctions of walls and slabs. After two days of proper curing applying a second coat of cement slurry admixed with proprietary water proofing compound conforming to IS: 2645. Finishing the surface with 20mm thick joint less cement mortar of mix 1:4 (1 cement: 4 course sand) admixed with proprietary water proofing compound conforming to IS: 2645 and finally finishing the surface with trowel with neat cement slurry and making of 300 x 300 mm square. The whole terrace so finished shall be flooded with water for a minimum period of two weeks for curing and for final test. All above operations to be done in order and as directed and specified by the Engineer-in-charge. With average thickness of 120 mm and minimum thickness at khurra at 65 mm.
(b)
(c) (d)
(e)
6.11.00 6.12.00
Glazing Minimum thickness of glazing shall be 5 mm. as per IS: 2835 Doors and Windows The details of doors and windows of the control room building shall be as per finish schedule Table-1 and tender drawing with the relevant IS code. Rolling steel shutters and rolling steel grills shall be provided as per layout and requirement of buildings. Paints used in the work shall be of best quality specified in CPWD specification.
6.13.00
Plumbing & Sanitation (i) All plumbing and sanitation shall be executed to comply with the requirements of the appropriate byelaws, rules and regulations of the Local Authority having jurisdiction over such matters. The Contractor shall arrange for all necessary formalities to be met in regard to inspection, testing, obtaining approval and giving notices etc. Syntax or equivalent make PVC Roof water tank of 1000Ltr.capacity for 24 hours storage shall be provided for substations with 11kV indoor switchgear. Galvanized MS pipe of medium class conforming to IS: 1239 shall be used for
(ii) (iii)
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internal & external piping work for potable water supply. (iv) (v) Sand CI pipes with lead joints conforming to IS: 1729 shall be used for sanitary works above ground level. Each toilet shall have the following minimum fittings. (a) WC (Western type) 390 mm high with toilet paper roll holder and all fittings Or WC (Indian Type) Orissa Pattern (580 x 440 mm) with all fittings (both types of WCs shall be provided at alternate locations). Urinal (430 x 260 x 350 mm size) with all fittings. Wash basin (550 x 400 mm) with all fittings. Bathroom mirror (600 x 450 x 6 mm thick) hard board backing CP brass towel rail (600 x 20 mm) with C.P. brass brackets Soap holder and liquid soap dispenser.
(b) (c) (d) (e) (f) (vi) (vii)
All fittings, fastener, grating shall be chromium plated. All sanitary fixtures and fittings shall be of approved quality and type manufactured by well known manufacturers. All items brought to site must bear identification marks of the type of the Manufacturer. Soil, waste and drain pipes, for underground works shall be stoneware for areas not subject to traffic load. Heavy-duty cast iron pipes shall be used otherwise.
(viii)
7.00.00 7.01.00 7.07.00
MISCELLANEOUS GENERAL REQUIREMENTS Bricks having minimum 75kg/cm2 compressive strength shall be used for masonry work Doors and windows on external walls of the buildings (other than areas provided, with insulated metal claddings) shall be provided with RCC sunshade over the openings with 300 mm projection on either side of the openings. Projection of sunshade from the wall shall be minimum 450 mm over window openings and 750 mm over door openings except for main entrance door to the control room where the projection shall be 1500mm. Service ladder shall be provided for access to roof. Angles 45x45x5 mm (minimum) with lugs shall be provided for edge protection all round cut outs/openings in floor slab, edges of drains supporting grating covers, edges of RCC cable/pipe trenches supporting covers, edges of manholes supporting covers, supporting edges of manhole precast cover and any other place where breakage of corners of concrete is expected. Anti termite chemical treatment shall be given to column pits, wall trenches, foundations of buildings, filling below the floors etc. as per IS: 6313 and other relevant Indian Standards. For all civil works covered under this specification, nominal mix by volume batching
7.08.00 7.09.00
7.10.00
7.12.00
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as per CPWD specification is intended. The relationship of grade of concrete and ratio of ingredients shall be as below: Sl. No. 1. 2. 3. Mix M 10 M 15 M 20 Cement 1 1 1 Sand 3 2 1.5 Coarse aggregate of 20 mm down grade as per IS : 383 6 4 3
The material specification, workmanship and acceptance criteria shall be as per relevant clauses of CPWD specification and approved standard Field Quality Plan. 7.13.00 7.14.00 8.00.00 8.01.00 The details given in tender drawings shall be considered along with details available in this section of the specification while deciding various components of the building. Items/components of buildings not explicitly covered in the specification but required for completion of the project shall be deemed to be included in the scope. INTERFACING The proper coordination & execution of all interfacing civil works activities like fixing of conduits in roofs/walls/floors, fixing of foundation bolts, fixing of lighting fixtures, fixing of supports/embedment, provision of cutouts etc. shall be the sole responsibility of the Contractor. He shall plan all such activities in advance and execute in such a manner that interfacing activities do not become bottlenecks and dismantling, breakage etc. is reduced to minimum. WATER SUPPLY (i) (ii) (iii) (iv) Contractor shall make its own arrangement for construction water. The contractor shall carry out all the plumbing/erection works required for supply of water in control room building. The details of tanks, pipes, fittings, fixtures etc for water supply are given elsewhere in the specification under respective sections. A scheme shall be prepared by the contractor indicating the layout and details of water supply which shall be got approved by the Owner before actual start of work including all other incidental items not shown or specified but as may be required for complete performance of the works. For substations with indoor 11kV switchgear bore wells with 4 inch dia PVC pipe and submersible pump of adequate capacity for water supply are in the scope of contractor meeting the day-to-day requirement of the water supply. The depth of the bore well shall be finalized in consulation with site resident manager of employer.
9.00.00
(v)
SECTION-E-13
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(vi)
If the water is supplied by Municipal Corporation then bore well for water supply purposes is not required to be carried out by contractor. Contractor shall also make necessary arrangement /formalities to receive water connection from corporation. Sewerage system shall be provided for control room building. The Contractor shall construct septic tank and soak pit suitable for 5 users if outside of Municipal Corporation zone. Otherwise, all necessary arrangement for the disposal of sewerage to the Municipal Corporations end shall be arranged by the contractor at his own cost for regularizing the disposal activity. The system shall be designed as per relevant IS Codes.
10.00.00
SEWERAGE SYSTEM (i) (ii)
(iii) 11.00.00
DESIGN PARAMETERS FOR SUB-STATION STRUCTURES Gantry structure, which consists of open web towers connected A girders. These shall be made of structural steel conforming to IS: 2062 Grade and duly galvanized conforming to IS: 2629. All joints shall be bolted connections. All bolts shall be 16mm diameter conforming to IS:12427:1988 of property class 5.6 conforming to IS:1367(Part 6):1980. Nuts shall conform to I.S 1363(Part 3):1992 of property class 5 . IS: 802 - 1977 Code of practice for use of structural steel in overhead transmission line towers shall be followed for design of structural supports. Wind pressure of 1320 N/sq mm (for medium zone) up to height of 30 m above existing ground level shall be considered as per IS:802, Part 1(1977) for design of structures. Height & type of towers shall be established based on electrical requirements.
11.01.00
Loading Conditions Towers and girders shall be designed for the following loading conditions : a) b) c) d) e) Transverse load due to wind. Longitudinal load due to unbalanced tension in conductor. Transverse load due to deviation of conductor. Torsion load due to unbalanced vertical and horizontal forces. A construction load of 150 Kg shall be allowed on any member whose horizontal axis is 45 degree or less with the horizontal during erection of structure. Temperature stress. Earthquake forces as per IS:1893.
f) g)
The occurrence of earthquake and maximum wind pressure is unlikely to take place at the same time. The structure shall be designed for either of the two. However, temperature stresses can be ignored, as these towers are freestanding structure in open space.
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Load Combinations and Factor of Safety Simultaneous application of following loads shall be considered for the design of substation structure : a) 1. 2. 3. 4. 5. b) 1. 2. Note: 1) 2) Earthquake forces shall not be combined with wind forces. Direction of wind shall be assumed such as to produce maximum stresses in any member for the combination of wind load with conductor tensions. The wind acting perpendicular and parallel to bus conductor and shield wire shall be considered separately. The conductor tension shall be assumed as acting on only one side of the gantry for the analysis and design of substation gantries. Normal condition Wind load on bus, shield wires, insulator strings, electrical equipment, structural members etc. Unbalanced load due to conductor/wire tension. Dead load of wires/conductors, insulator, electrical equipment and structural members. Load due to angle of deviation of the approach span. Torsion loads due to unbalanced vertical & horizontal forces. Abnormal conditions Short-circuit forces Seismic forces
3) 11.02.00
Factor of Safety The factor of safety for the design of members for substation structures shall be considered as 1.5 .
11.03.00
Minimum Thickness of Members & Galvanizing Thickness All steel work used in construction of gantry structure should be galvanized and minimum section thickness should not be less than 4 mm. Weight of zinc coating shall be at least 0.610 kg/m2 & foundation bolts shall have heavier zinc coating at least 0.80 kg/m2
11.05.00
Design Consideration for Equipment Support The supporting structure for strong bay, LA, PT, VCB, Isolator, CT shall be comprised of lattice structural steel conforming to IS 2062 and shall be designed as per IS: 802.
12.00.00 12.01.00
SUB-STATION SURFACING Entire area of Sub-Station shall be provided with broken stone filling which shall consist of 75mm thick stone metal filling of 40 mm stone aggregate on the top and 75 mm thick filling of 20 mm stone aggregate below extending 1.50 m beyond substation
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fence. Each layer shall be compacted by using half ton roller with 4-5 passes and suitable water sprinkling. Before laying the broken stone fill, the top layer of the soil shall be treated for anti-weed considering the type of weeds found in the vicinity. The antiweed soil sterilization details such as manufacturers name, their specification, test certificate, etc. shall be furnished for Owners approval. Any modification if required in the proposed antiweed treatment chemical shall have to be done by the contractor at no extra cost to the Owner. 13.00.00 13.01.00 SUB-STATION TRENCHES Cable trenches shall be provided for routing of cables from control room to equipments. The cable trench shall be of adequate size. The trenches located within substation shall project at least 300 mm above the finished formation level so that no storm water shall enter into the trench. The bottom of trench shall be provided with a longitudinal slope of 1:500. The downstream end of cable trenches shall be connected through pipe drains to the nearby RCC manholes (to convey water from trenches) of storm water drainage system. The precast covers shall not be more than 300mm in width 65 kg. Lifting hooks shall be provided in the precast covers. Trenches shall be given a slope of 1:50 in the direction perpendicular to the run of the trenches. PVC water stop shall be provided at all expansion joints of all trenches. Angle of size 50x50x6 mm (minimum) with lugs shall be provided in the edges of RCC cable trenches supporting cover, edges of manhole supporting, supporting edges of precast RCC cover and any other place where breakage of corners of concrete is expected. DRAINAGE SYSTEM Open storm water drains shall be provided on both sides of the road and shall be designed to drain the road services as well as all the free and covered areas, etc. Open RCC rectangular section shall be provided for all drains. The thickness of side wall and bottom slab of RCC drains shall be minimum 100 mm or as per design consideration whichever is higher. RCC box/precast RCC pipe culvert shall be provided for road crossing. ROADS AND CULVERTS Roads inside the substation area shall be of (3.75m wide). The base and sub base of the road shall be of water bound macadam. Finished top of road shall be 300 mm above the surrounding ground level. 1. The main approach road including modification of existing road to meet the site conditions, roads for access to equipment and buildings with in substations (including bay extension in existing substations) are in the scope of bidder. Layout of the roads shall be based on General detail & Arrangement drawing for the substation. If extra road is required for functional point of view, which has not been mentioned in the layout drawing, Contractor should provide the same with out extra cost to the owner. Road construction shall be as per IRC standards. Adequate provision shall be made for road drainage. Protection of cut and embankment slopes of roads as per slope stability requirement shall be made.
14.00.00 14.01.00
15.00.00 15.01.00
3. 4.
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5. 16.00.00 16.01.00
All the culverts and its allied structure (required for road/rail, drain trench crossings etc.) shall be designed suitably and should be checked for loading.
TRANSFORMER FOUNDATION The Contractor shall provide a road system integrated with the transformer foundation to enable installation and the replacement of any failed unit. This system shall enable the removal of any failed unit from its foundation to the nearest road. If trench/drain crossings are required then suitable R.C.C. culverts shall be provided in accordance with I.R.C. Code/relevant IS. DESIGN CONSIDERATION FOR FOUNDATION Detail design of foundation shall be as per relevant Indian Standards. The F.O.S. for foundation shall be 10% more than factor of safety for supporting structure i.e. 2.2 for normal condition and 1.65 for abnormal condition Wind Load All structures shall be designed for wind forces in accordance with the IS : 875 (Part 3) and as specified in this document.
17.00.00 17.01.00
17.02.00
17.03.00
Increase in permissible stresses The increase in permissible stress of materials and soil bearing pressure for different load combinations under wind, seismic and temperature loads shall be as per relevant IS Codes.
18.00.00 19.00.00
FENCING GS Barbed wire fencing Entire Sub station shall be provided with GI barbed wire fencing in place of boundary wall. The GS barbed wire shall conform to IS:278. GS barbed wire shall be of Type A or B with size designation 2 or 3 as specified in the IS. For the purpose of fence post ISMC-75 channel shall be used. The gap between consecutive fence posts shall be maximum 2 mtrs. The height of the fence post above ground shall be 2 mtrs & at least 0.5 mtr shall be embedded in concrete of 300x300mm area with a depth of 0.75 mtr. The post shall be painted with two coats of primer & two coats of zinc rich paint. The GS barbed wire shall be placed at a gap of 200 mm horizontally along the entire height of the post & secured tightly with the fence post by suitable arrangement . The bottom most wire shall have a ground clearance of approximately 100mm . Barbed wire shall also be placed along both the diagonal from top of one post to the bottom of another.
19.01.00
GS Chain Link Fence. Chain link fence shall only be provided for 33 kV substations. This shall be provided for fencing out door equipments area of substation .The GS chain link fence fabric shall conform to IS:2721.Standard mesh size not exceeding 63+4mm as per the Table -1 of IS 2721 shall be used.
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Fence post arrangement, size, height , painting etc shall be as specified for barbed wire fencing. The fixing shall be done by use of clamps & bolts 20.00.00 20.01.00 M.S. GATE M.S. Gate of 3.0 M wide x 2.6 M height (2mtr for substation with out door 11kV switchgear) shall be provided. It shall be made in two leaf, with locking arrangements. The gate shall be made with outer frame of 50 NB ( Medium ) M. S. Pipe, vertical & horizontal runners with 40x6 M. S. flat and weld mesh of opening size not exceeding 50 x 25 mm and nominal size of mesh 4 mm dia. Hinges, al-drops and other accessories shall be provided for effective working of the gate. RCC column of size 300X300mm and height equal to the height of gate above FGL shall be provided. The RCC column shall have a depth of one meter below FGL & shall have required RCC footing. 21.00.00 21.01.00 MATERIALS AND GRADE OF CONCRETE Concrete a. b. c. 21.02.00 Minimum grade of structural concrete shall be M20 conforming to IS:456. Blinding concrete below foundations, cable trenches, shall be PCC of minimum grade M-7.5, Blinding concrete under brick foundations shall be minimum 150mm thick in PCC of minimum grade M-10.
Cement Cement shall be ordinary Portland cement conforming to IS:269, Portland slag cement conforming to IS:455, Fly ash based pozzolona cement conforming to IS:1489 (PartI), or Portland pozzolona cement conforming to IS 1489 (PartII). For miscellaneous concrete works, Fly ash based Portland pozzolona cement or Blast slag cement may be used as per the specifications if directed by the Project Manager. Ordinary Portland cement conforming to IS 269 shall be used for all structures requiring grade of concrete M 25 or above. Supply of all types of cement shall be in Bidders scope.
21.03.00
Reinforcement Steel HYSD bars (Fe 415) conforming to IS:1786 shall be used for all structures. Supply of reinforcement steel shall be in bidders scope.
21.04.00
Structural Steel Structural steel shall be of tested quality and shall be of mild steel of Grade A up to 20 mm thickness and of Grade B with normalised steel for thickness above 20 mm and shall conform to IS : 2062. Chequered plates shall conform to IS : 3502 and MS pipes for handrail shall conform to medium grade of IS : 1161. All gratings shall be electroforged type. Minimum thickness of the grating shall be 40mm. The opening size shall not be more than 30mm x 100mm.The minimum thickness of the main bearing bar shall be 3mm. All gratings located inside the building shall be sand blasted and provided with two coats of suitable primer and two
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coats of finish paint (black colour) as per approved painting system. All gratings located outside the building shall be hot double dip galvanised at the rate of 610 gms / Sq.M. Supply of all structural steel shall be in Bidders scope. The Contractor shall keep sufficient stock of cement & steel at site at any point of time when the work is in progress (excluding what has been already incorporated in the works) so that any shortage, disruption / delay in availability of these materials during procurement will not affect the progress of work at site. 22.00.00 22.01.00 GEOTECHNICAL INVESTIGATION & FOUNDATION SYSTEM Successful bidder may carry out soil investigation at all locations where Sub Station are envisaged. Details pertaining to Geo technical investigation & foundation system are specified at Annexure I to this chapter. TESTS FOR MATERIAL / WORKMANSHIP All tests required for various bought out items, materials, quality of workmanship or any other tests as desired by Project Manager and as specified in technical specification shall be carried out by the Contractor at his own cost in the presence of the authorized representative of the Engineer. The Contractor shall submit comprehensive Quality Assurance plan for all materials, equipment, workmanship, services etc. and get it approved from the Employer. However, such check-list shall in no way limit the liability and responsibility of the Contractor in regard to quality of workmanship as detailed out in the specifications. DRAWINGS The successful Bidder shall first submit the structural design calculations along with general arrangement drawings for approval. After the approval of the design calculations by the Owner, detailed construction drawings shall be prepared and submitted for Owners approval along with revised design calculations, if required, within 15 days. Required number of sets of design calculations, drawings and documents shall be submitted by the Contractor. All documents including design calculations shall be prepared in MS office 97 and all drawings shall be drafted using AutoCAD (Release - 2000 or higher version). During every submission one soft copy of the document shall also be submitted. When final approval is obtained from the Employer the Contractor shall submit all the documents in TWO sets of CD ROM (One + One Back - up) together with minimum three sets of distribution prints well documented and page controlled with details of Employers approval marked thereon. Approval of drawings / documents shall not relieve the contractor of the responsibility regarding the adequacy of design and correctness of drawings.
23.00.00 23.01.00
23.02.00
24.00.00 24.01.00
SECTION-E-13
Page 18 of 18
CLAUSE NO.
ANNEXURE-I : GEO-TECHNICAL INVESTIGATION GEOTECHNICAL INVESTIGATION The Contractor shall perform a detailed soil investigation when specified under Scope of Work to arrive at sufficiently accurate, general as well as specific information about the soil profile and the necessary soil parameters of the site in order that the foundation of the various structures can be designed and constructed safely and rationally. A report to the effect will be submitted by the Contractor for Owners specific approval giving details regarding data proposed to be utilised for civil structures design. The Contractor should visit the site to ascertain the soil parameters before submitting the bid. The topography is uneven steeply sloping at few places requiring cutting and filling operations including slope stability and protection measures (if slopes encountered). Any variation in soil data shall not constitute a valid reason for any additional cost & shall not affect the terms & condition of the Contract. Tests must be conducted under all the critical locations i.e. Control Room Building. Tower locations, transformer etc. SCOPE OF WORK This specification covers all the work required for detailed soil investigation and preparation of a detailed report. The work shall include mobilisation of necessary equipment, providing necessary engineering supervision and technical personnel, skilled and unskilled labour etc. as required to carry out field investigation as well as, laboratory investigation, analysis and interpretation of data and results, preparation of detailed Geo-technical report including specific recommendations for the type of foundations and the allowable safe bearing capacity for different sizes of foundations at different founding strata for the various structures of the substation. The Contractor shall make his own arrangement for locating the co-ordinates and various test positions in field as per the information supplied to him and also for determining the reduced level of these locations with respect to the benchmark indicated by the Owner. All the work shall be carried out as per latest edition of the corresponding Indian Standard Codes. Bore Holes(by standard punctuation test) Drilling of bore holes of 150 mm dia. in accordance with the provisions of IS: 1892 at the rate of minimum two number of bore holes to 10 m depth or to refusal which ever occur earlier for the bay extension of existing substation. (By refusal it shall mean that a standard penetration blow count (N) of 100 is recorded for 30 cm penetration). However, for a new substation, minimum three bore-holes shall be done to find out the geological profile of the area. If any unconformity encountered then more bore holes shall be drilled with the approval of Engineer-in-charge for the new projects. However in case deep pile foundations are envisaged the depths have to be regulated as per codel provisions. In cases where rock is encountered, coring in one borehole per bay shall be carried out to 1.5 M in bedrock and continuous core recovery is achieved. Performing Standard Penetration Tests at approximately 1.5 m interval in the borehole starting from 1.5 m below ground level onwards and at every change of stratum. The disturbed samples from the standard penetrometer shall also be collected for necessary tests.
TECHNICAL SPECIFICATION VOL-II (PART A) CHAPTER-II SECTION-14
GEO-TECHNICAL INVESTIGATION
1.00.00 1.01.00
1.02.00
2.00.00 2.01.00
2.01.00
Page 1 of 4
CLAUSE NO.
ANNEXURE-I : GEO-TECHNICAL INVESTIGATION Collecting undisturbed samples of 100/75 mm diameter 450 mm long from the boreholes at intervals of 2.5 m and every change of stratum starting from 1.0 m below ground level onwards in clayey strata. The depth of Water table shall be recorded in each borehole. All samples, both disturbed and undisturbed, shall be identified properly with the borehole number and depth from which they have been taken. The sample shall be sealed at both ends of the sampling tubes with wax immediately after the sampling and shall be packed properly and transported to the Contractors laboratory without any damage or loss. The logging of the boreholes shall be compiled immediately after the boring is completed and a copy of the bolelog shall be handed over to the Engineer-in-charge. Electrical Resistivity Test This test shall be conducted to determine the Electrical resistivity of soil required for designing safe grounding system for the entire station area. The specifications for the equipments and other accessories required for performing electrical resistivity test, the test procedure, and reporting of field observations shall confirm to IS: 3043. The test shall be conducted using Wagners four electrode method as specified in IS: 1892, Appendix-B2. Unless otherwise specified at each test location, the test shall be conducted along two perpendicular lines parallel to the coordinate axis. On each line a minimum of 8 to 10 readings shall be taken by changing the spacing of the electrodes from an initial small value of 0.5 m upto a distance of 10.0 m. Water Sample Representative samples of ground water shall be taken when ground water is first encountered before the addition of water to aid drilling of boreholes. The samples shall be of sufficient quantity for chemical analysis to be carried out and shall be stored in airtight containers. Back Filling of Bore Holes On completion of each hole, the Contractor shall backfill all bore holes as directed by the Owner. The backfill material can be the excavated material and shall be compacted properly. Laboratory Test 1. The laboratory tests shall be carried out progressively during the field work after sufficient number of samples have reached the laboratory in order that the test results of the initial bore holes can be made use of in planning the later stages of the field investigation and quantum of laboratory tests. 2. All samples brought from field, whether disturbed or undisturbed shall be extracted/prepared and examined by competent technical personnel, and the test shall be carried out as per the procedures laid out in the relevant I.S. Codes. The following laboratory tests shall be carried out a) Visual and Engineering Classification b) Liquid limit, plastic limit and shrinkage limit for C- soils. c) Natural moisture content, bulk density and specific gravity. d) Grain size distribution. e) Swell pressure and free swell index determination. f) California bearing ratio.
2.02.00
2.03.00
2.04.00
2.05.00
Page 2 of 4
CLAUSE NO.
ANNEXURE-I : GEO-TECHNICAL INVESTIGATION Consolidated undrained test with pore pressure measurement. Chemical tests on soil and water to determine the carbonates, sulphates, nitrates, chlorides, Ph value, and organic matter and any other chemical harmful to the concrete foundation. i) Rock quality designation (RQD), RMR in case of rock is Encountered. Test Results and Reports The Contractor shall submit the detailed report in two (2) copies wherein information regarding the geological detail of the site, summarised observations and test data, bore logs, and conclusions and recommendations on the type of foundations with supporting calculations for the recommendations. Initially the report shall be submitted by the Contractor in draft form and after the draft report is approved, the final report in two (2) copies shall be submitted. The test data shall bear the signatures of the Investigation Agency, Vendor and also site representative of NESCL. The report shall include but not limited to the following: a) A plan showing the locations of the exploration work i.e. bore holes, dynamic cone penetration tests etc. b) Bore Logs: Bore logs of each bore holes clearly identifying the stratification and the type of soil stratum with depth. The values of Standard Penetration Test (SPT) at the depths where the tests were conducted on the samples collected at various depths shall be clearly shown against that particular stratum. Test results of field and laboratory tests shall be summarised strata wise as well in combined tabular form. All relevant graphs, charts tables, diagrams and photographs, if any, shall be submitted along with report. Sample illustrative reference calculations for settlement, bearing capacity, pile capacity shall be enclosed. Recommendations The report should contain specific recommendations for the type of foundation for the various structures envisaged at site. The Contractor shall acquaint himself about the type of structures and their functions from the Owner. The observations and recommendations shall include but not limited to the following: a) Geological formation of the area, past observations or historical data, if available, for the area and for the structures in the nearby area, fluctuations of water table etc. Slope stability characteristics and landslide history of the area shall be specifically highlighted. Remedial measures to be adopted shall also be given. b) Recommended type of foundations for various structures. If piles are recommended the type, size and capacity of pile and groups of piles shall be given after comparing different types and sizes of piles and pile groups. c) Allowable bearing pressure on the soil at various depths for different sizes of the foundations based on shear strength and settlement characteristics of soil with supporting calculations. Minimum factor of safety for calculating net safe bearing capacity shall be taken as 3.0 (three). Recommendation of liquefaction characteristics of soil shall be provided.
g) h)
2.06.00 2.06.01
2.06.02
2.07.00
Page 3 of 4
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ANNEXURE-I : GEO-TECHNICAL INVESTIGATION d) Recommendations regarding slope of excavations and dewatering schemes, if required. Required protection measures for slope stability for cut & fill slopes of switchyard and approach road with stone pitching/retaining walls shall be clearly spelt out. Calculation shall also be provided for stability adequacy. Comments on the Chemical nature of soil and ground water with due regard to deleterious effects of the same on concrete and steel and recommendations for protective measures. If expansive soil is met with, recommendations on removal or retainment of the same under the structure, road, drains, etc. shall be given. In the latter case detailed specification of any special treatment required including specification or materials to be used, construction method, equipments to be deployed etc. shall be furnished. Illustrative diagram of a symbolic foundation showing details shall be furnished. Recommendations for additional investigations beyond the scope of the present work, if considered such investigation as necessary.
e)
f)
g)
TECHNICAL SPECIFICATION VOL-II (PART A)
CHAPTER-II SECTION-14
Page 4 of 4
CLAUSE NO.
11 KV XLPE CABLE SCOPE This specification covers design, manufacture, testing, transportation and despatch to owners stores of 11 kV Cross Linked Polyethylene (XLPE) insulated and PVC sheathed aluminum cables for use in Distribution System.
1.00.00
2.00.00
APPLICABLE STANDARD The cables shall comply with the latest version of IS:7098 (Pt. II)-Specification for Cross Linked Polyethylene Insulated PVC Sheathed Cables, IS:5831-1984Specification for PVC Insulated and sheath of electric cable and REC Specification No. 63/1993 (Revised 1997).
3.00.00
RATED VOLTAGE AND TEMPERATURE The rated voltage of the cables shall be 6.35 kV/11 kV and the maximum operating voltage shall be 12 kV. Maximum continuous operating temperature (combination of ambient temperature and temperature rise due to load) shall be 900C under normal operation and 250 degree C under short circuit conditions.
4.00.00
TYPE OF CABLES The type of cable shall be single/three-core armoured screened.
5.00.00
STANDARD SIZES OF CABLES The standard size of cable shall be 1CX300 sq mm, 3CX185 sq.mm, 3CX95 sq. mm.
6.00.00 6.01.00 7.00.00 7.01.00
CONTINUOUS CURRENT AND SHORT CIRCUIT RATINGS The values of the continuous current carrying capacities and short circuit rating for 300 sq.mm. and 185 sq.mm. Cable offered shall be as per IS. DETAILS OF CABLES General Construction Conductor screen and insulation screen shall be extruded semi-conductoring compound and shall be applied along with XLPE insulation in a single operation by triple extrution process. The method of curing shall be dry curing / gas curing / steam curing.
7.02.00
Conductor The cable conductors shall be of round, stranded and compacted aluminum of nominal size as stipulated in Table 1 under Clause 5 of IS: 8130. Corresponding wire diameter and number of wires in the conductor shall be as given in IS:8130.
CHAPTER-II SECTION-E15 33 kV XLPE Cable
Page 1 of 2
CLAUSE NO.
11 KV XLPE CABLE
7.03.00
Conductor Screen Conductor screening shall be provided over the conductor by applying by extrusion of semi-conducting compound.
7.04.00
Insulation The insulation shall be of extruded cross linked polyethylene (XLPE) of nominal insulation thickness 3.6 mm and its properties shall conform to IS : 7098 (Pt. II).
7.05.00 7.05.01
Insulation Screen The insulation screen shall consist of two parts; namely, metallic and non-metallic. Non-metallic part shall be applied directly over the insulation of each core and shall consist of extruded semi-conducting compound. The metallic part shall consist of either tape, or braid or concentric serving of wires or a shall be non-magnetic and shall be applied over the non-metallic part. Core-identification & laying up of cores The core identification and laying up of cores shall be as per IS : 7098 (Pt. II). For identification of different cores in three-core cable, use of coloured stripes, red, yellow and blue, or use of numbered strips shall be employed.
7.05.02 7.06.00
7.07.00
Inner Sheath The laid up cores shall be covered with inner sheath made of thermoplastic material applied either by extrusion or wrapping. It shall be ensured that the shape is as circular as possible. Thickness of inner sheath shall conform to IS : 7098 (Pt. II).
7.08.00
Armouring Armouring shall be applied over non-metallic part of insulation screening or the inner sheath as the case may be for single-core cables and over the inner sheath for threecore cables. The method, type, dimensions, joints, conductance etc. of armour shall conform to IS : 7098 (Pt. II).
7.09.00
Outer Sheath The outer sheath shall be applied over the armouring. The minimum thickness and properties of outer sheath shall conform to the requirement of IS : 7098 (Pt. II). the type of PVC compound shall be of STL as per IS : 5831 - 1984.
8.00.00
TESTS The offered cables shall meet complete requirement or type, routine & accceptance tests as per IS : 7098 (Pt. II).
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CLAUSE NO.
11 KV XLPE CABLE
Page 3 of 2
CLAUSE NO.
ACDB & DCDB SCOPE This specification covers design, manufacture, testing before despatch, transportation, supply and delivery to the Owners stores ACDB & DCDB for 33/11 kV Sub Station
1.00.00
2.00.00 2.01.00
CODES AND STANDARDS All equipments shall, generally, comply with the updated issues of : i) ii) iii) iv) IS:8623-Low voltage switchgear & control gear assemblies IS:13947-Low voltage Circuit Breaker Indian Electricity Act. Indian Electricity Rules
3.00.00 3.01.00
CONSRUCTIONAL DETAILS OF SWITCHBOARDS AC Distribution Boards (ACDB), and DC Distribution Boards (DCDB) shall be metal enclosed , indoor type . ACDB shall be mounted on base frame made of 75X75x6 mm ISMC painted black, free standing, floor mounting type & DCDB shall be wall mounted type. The complete structures shall be rigid, self-supporting, free from flaws, twists and bends. All cutouts shall be true in shape and devoid of sharp edges. ACDB & DCDB shall be made out of cold rolled sheet steel of thickness not less than 3mm for weight bearing members such as base frame, front sheet & door frames & 2 mm for sides, door, top & bottom portions. All switchboards shall be of dust-proof and vermin-proof construction and shall be provided with a degree of protection of IP:52 as per IS:13947. However, the busbar chambers having a degree of protection of IP:42 are also acceptable All cutouts shall be provided with synthetic rubber gaskets. Provision of louvers on switchboards would not be preferred. However, louvers backed with metal screen are acceptable on the busbar chambers . ACDB shall be divided into distinct vertical sections (panels), each comprising of the following compartments Sl. No A 1 INCO MER 100A,3Ph+N MCCB 2 B YARD LIGHTING DB 32A MCCB,3Ph+N CONTROL ROOM LIGHTING 32A,MCCB, 3Ph+N AUX AC SUPPLY AUX AC SUPPLY FOR 11kV SWGR, FOR 33kV SWGR,
TECHNICAL SPECIFICATION VOLUME-II (PART-A)
3.02.00
3.03.00
3.04.00
3.05.00
3.08.00
C Maintenance Supply 63A,MCCB, 3Ph+N BATTERY CHARGER 32A, MCCB,3Ph+N SPARE 32A,MCCB,3Ph+N
CHAPTER-II SECTION-E16 ACDB & DCDB Page 1 of 4
CLAUSE NO.
ACDB & DCDB 32A,MCCB,3Ph+N Pump Motor 32A,MCCB,3Ph+N Space heater supply for DCDB 10A,MCCB,3Ph+N 32A,MCCB,3Ph+N Bay Mashalling Box Spare 32A,MCCB,3Ph+N 63A,MCCB, 3Ph+N Spare 10A,MCCB,3Ph+N
4 5
The MCCBs shall have 10kA interrupting capacity & 10kA short time rating for 1 sec. All the MCCBs shall be provided with over current & short circuit protection.
DCDB shall have following feeders 1. Incomer- 32A 2P MCB 2. 33KV C&R panel - 25A, 2P , MCB 3. 11KV SWGR -25A, 2P,MCB 4. Control Room Lighting-10A, 2P, MCB 5. Spare- 10A, 2P,MCB A) BUSBAR COMPARTMENT
A completely enclosed bus bar compartment shall be provided for the horizontal and vertical busbars. Bolted covers shall be provided for access to horizontal and vertical busbars and all joints for repair and maintenance which shall be feasible without disturbing any feeder compartment. Auxiliary and power busbars shall be in separate compartments. B) SWITCHGEAR / FEEDER COMPARTMENT
All equipments associated with an incomer or outgoing feeder shall be housed in a separate compartment of the vertical section. The compartment shall be sheet steel enclosed on all sides. Insulating sheet at rear of the compartment is also acceptable. The front of the compartment shall be provided with the hinged single leaf door with captive screws for positive closure. C) CABLE COMPARTMENT OR CABLE ALLEY
A full-height vertical cable alley of minimum 175 mm width shall be provided for cables. Cable terminations located in cable alley shall be suitably shrouded to prevent accidental contact by falling of tools etc. D) METERING MODULE 1 no metering module shall consist of volt meter with selector switch, ammeter & LED based indicating lamps for l three phase . All out going modules shall have 1 no ammter with selector switch. 3.10.00 Sheet steel barriers shall be provided between two adjacent vertical panels running to the full height of the switchboard, except for the horizontal busbar compartment.
TECHNICAL SPECIFICATION VOLUME-II (PART-A) CHAPTER-II SECTION-E16 ACDB & DCDB Page 2 of 4
CLAUSE NO.
ACDB & DCDB Synthetic rubber gasket shall be provided between the panel sections to avoid ingress of dust into panels. Each shipping section shall have full metal sheets at both ends for transport and storage.
3.11.00
All identical module chassis of same size shall be fully interchangeable without having to carryout any modifications. The internal layout of all modules shall be subject to Employer's approval. The Bidder shall submit dimensional drawings showing complete internal details of busbars and module components, for each type and rating for approval of Employer. Cable entry shall be from bottom. Each switchboard shall be provided with undrilled, removable type gland plate which shall cover the entire cable alley. The gland plate shall preferably be provided in two distinct parts for the easy of terminating addition cables in future. The gland plate shall be provided with gasket to ensure enclosure protection. Brass cable glands shall be provided. The Bidder shall consider layout of panels in a switchboard consisting of various feeder modules. The ACDB shall be fed from the Station transformer by a 3& core Aluminum armoured cable of 100Amps rating to be provided by the bidder. CLEARANCES The minimum clearance in air between phases shall be 25 mm. a live part and an earthed part shall be at least ten (10) mm throughout. Wherever it is not possible to maintain these clearances, insulation shall be provided by sleeving or barriers.
3.13.00
3.16.00
3.18.00
3.19.00
4.00.00 4.01.00
POWER BUSBARS AND INSULATORS ACDB shall be provided with three phase and neutral busbars of aluminium alloy / copper of adequate size. The cross-section of the busbars shall be uniform throughout the length of switchboard and shall be adequately supported and braced All busbars shall be adequately supported by non-hygroscopic, non-combustible, track-resistant and high strength sheet moulded compound or equivalent type polyester fiber glass moulded insulator. All busbars shall be color coded as per IS:375. EARTH BUS AND EARTHING A galvanized steel earth bus shall be provided at the bottom of panel and shall extend throughout the length of each switchboard
4.03.00
4.04.00
4.07.00 5.00.00 5.01.00
CHAPTER-II SECTION-E16 ACDB & DCDB
Page 3 of 4
CLAUSE NO.
ACDB & DCDB Suitable arrangements shall be provided at each end of the horizontal earth bus for bolting to Employer's earthing conductors. The horizontal earth bus shall project out of the switchboard ends and shall have predrilled holes for this connection All hinged doors having potential carrying equipment mounted on it shall be earthed by flexible wire/ braid. SPACE HEATER Space heaters shall be provided in the switchboards for preventing harmful moisture condensation.
5.02.00
5.05.00
13.00.00 13.01.00
14.00.00 14.01.00
INTERNAL WIRING All switchboards shall be supplied completely wired internally upto the terminals, ready to receive external cables. All intercubicle and interpanel wiring and connections between panels of same switchboard including all bus wiring for AC and DC supplies shall be provided by the Bidder. CABLE TERMINATION Cable termination compartment and arrangement for power cables shall be suitable for 1.1 kV grade, stranded aluminium conductor, PVC/XLPE insulated, armoured / unarmoured and PVC sheathed cables. All power cable terminals shall be of stud type and the power cable lugs shall be of tinned copper solderless crimping ring type conforming to IS:8309. All lugs shall be insulated/sleeved. NAME PLATES AND LABELS All feeders shall be provided with prominent, engraved identification plates. The module identification plate shall clearly give the feeder number and feeder designation PAINTING The boards shall be painted with two coats of primer & paint. The colour shall be shade no-691 of IS-5 for external surface & white for internal surface. GASKETS The gaskets, wherever specified, shall be of good quality synthetic rubber with good ageing, compression and oil resistance characteristics suitable for panel applications.
14.02.00
16.00.00 16.01.00
16.02.00
17.00.00 17.01.00
18.00.00
20.00.00 20.01.00
CHAPTER-II SECTION-E16 ACDB & DCDB
Page 4 of 4
CLAUSE NO.
33 kV VACUUM CIRCUIT BREAKERS

SCOPE This specification covers the design, manufacture, assembly, shop testing/inspection before dispatch, packing, forwarding, transportation to site, insurance (during transit, storage and erection), storage, erection, supervision, site testing and commissioning of 36 KV outdoor type vacuum circuit breakers at 33/11 kV substations. The scope of supply shall also include necessary special tools and plants required for erection. The circuit breakers should be complete in all respects with operating mechanisms control cabinet, interlocks, auxiliary switches indicating devices, supporting structures, accessories, etc., described herein and briefly listed in the schedule of requirements. The spares / attachments which are necessary for the smooth functioning of the equipment and specifically are not mentioned here shall be assumed to be included the scope of supply. STANDARDS The circuit breaker shall conform in all respects to the requirements of latest issue of IS/IEC specifications except for modifications specified herein. The list of standards mentioned in this specification and to which the circuit breaker conform is given below: Sl. IS IEC Item
1.00.00 1.01.00
1.02.00 1.03.00
2.00.00 2.01.00 2.02.00
1.
IS-13118
IEC62271-100
High Voltage Breakers
A.C.
Circuit
2.
IS-2099
IEC-137
Bushing for alternating Voltages above 1000 volts Common clauses for high voltages switchgear and control gear standards Specification distances for Creepage
3.
IS : 12729
IEC-694
4.
IEC-815
5.
IS : 3072
Installation and maintenance of switchgear Guide for testing of circuit breakers with respect to out of phase switching IEC-60 High voltage testing technique PVC insulated cables upto and including 1000 volts
CHAPTER-II SECTION-E17 33 KV VACUUM CIRCUIT BREAKER Page 1 of 13
6.
IS : 9135
7. 8. IS : 1554
IEC : 227
CLAUSE NO.

9. IS : 5 Colors for ready mixed paints and enamels IEC : 529 Degree of protection provided enclosure AC Motors Hot Dip Galvanising A.C. Metal Enclosed Switchgear and Controlgear for Rated Voltages Above 1 kV and Up to and Including 52 kV
10.
11. 12. 13
IS : 996 IS : 2629, 2633 IS 3427
IEC : 34 ISO : 1460 IEC 298
3.00.00 3.01.00 3.01.01
SERVICE CONDITONS Auxiliary Power Supply Auxiliary electrical equipment shall be suitable for operation on the following supply system. a) Power Devices (like drive motors) neutral grounded AC supply b) 415/240 Volts, 3 Phase 4 Wire 50 Hz,
DC Alarm, Control and 24V DC ungrounded 2 Wire Protective Devices
3.01.02
The above supply voltage may vary as indicated below and all devices shall be suitable for continuous operation over the entire range of voltages i) AC Supply Voltage Frequency Combined voltage and frequency DC Supply -15% to + 10% OF 36 kV OUTDOOR VACUUM CIRCUIT + +10% to -15% 10%/-15% 5%
ii) 4.00.00 4.00.01
GENERAL REQUIREMENT BREAKERS
The vacuum type circuit breaker, shall have vacuum interrupters, designed to provide a long contact life at all currents up to rated making and breaking current during switching operations. The vacuum interrupters sealed for life shall be encapsulated by porcelain insulators for out door installation requirement. The breakers shall be suitable for out door operation under climatic conditions specified without any protection from sun, rain and dust storm. The vacuum interrupters of each phase shall be housed in a separate porcelain insulator. The three identical poles shall be mounted on a common base frame and the contact system of three poles should be mechanically linked to provide three pole simultaneous opening/closing.
TECHNICAL SPECIFICATION VOL-II (PART-A) CHAPTER-II SECTION-E17 33 KV VACUUM CIRCUIT BREAKER Page 2 of 13
4.00.02
CLAUSE NO.

i) ii) The performance of breakers shall be adequately proven by type tests for the designed rating at internationally reputed independent testing station. All mechanical parts and linkages shall be robust in construction and maintenance free, over at least 10000 switching operations except for lubrication of pins/articulated joints at interval of 5 years or 5000 operations. The circuit breaker shall be supplied complete with all auxiliary equipment, meant necessary for the safe operation, routine and periodic maintenance. The breaker shall be totally restrike free under all duty conditions and shall be capable of performing the duties without opening resistor. The details of any device incorporated to limit or control the rate of rise of restriking voltage across the circuit breaker contacts shall be stated. The complete data for the phase factor, amplitude factor, etc., for rate of rise of re-striking voltage shall be furnished in the tender. The breaker shall be suitable for three phase auto reclosing operation. An operation counter, visible from the ground level even with the mechanism housing closed shall be provided.
iii) iv)
v) vi) 4.01.00 4.01.01
Fixed and Moving Contact The main contacts should have low contact resistance. The contact should be self cleaning type, i.e., the layer of copper oxide should be cleaned during rubbing of contacts. The contact area should be well defined, spring used for contact shall be of gradually rising characteristic i.e., they should be soft. The contacts should not provide contact grip, i.e., electro-magnetic forces should not grip the contacts and oppose the opening process. Separate main contacts and arcing The circuit breaker units shall be suitable for installation on outdoor R.C.C. foundations. Ground clearance of the live parts of the breakers should be as per Indian Electricity Rules1956. Recovery Voltage and Power Factor The circuit breaker shall be capable of interrupting rated power with recovery voltage equal to the rated maximum line to line service voltage at rated frequency and at a power factor equal to or exceeding 0.15.
4.01.03
4.02.00
4.03.00
Automatic Rapid Reclosing 36 kV circuit breaker shall be suitable for 3 pole rapid reclosing. The dead time of the breaker shall be adjustable and the limits of the adjustment shall be stated in the tender.
4.04.00
Out of Phase Switching The circuit breaker shall be capable of satisfactory operation even under conditions of phase opposition that may arise due to faulty synchronization. The maximum power that the breaker can satisfactorily interrupt under Phase Opposition shall be stated in the bid.
4.05.00
Seismic Factor The insulators shall be capable to withstand the seismic acceleration of 0.5 g in horizontal direction and 0.6g in vertical direction.
5.00.00
TEMPERATURE RISE The maximum temperature attained by any part of the equipment when in service at site and under continuous full load conditions and exposed to the direct rays of the sun shall not exceed the permissible limits fixed by IEC. When the standards specify the limits of
CHAPTER-II SECTION-E17 33 KV VACUUM CIRCUIT BREAKER
Page 3 of 13
CLAUSE NO.

temperature rise these shall not be exceeded when corrected for the difference between ambient temperature specified in the approved specification.
6.00.00 6.01.00
INSULATOR SUPPORTS AND HOUSING The puncture strength of bushing shall be greater than the flash over value. The design of bushing shall be such that the complete bushing is a self-contained unit and no audible discharge shall be detected at a voltage upto a working voltage (Phase Voltage) plus 10%. The support insulator shall conform to IEC-137. Minimum clearance between phases, between live parts and grounded objects shall be as per IS-3072-1975 and should conform to Indian Electricity Rules-1956. The minimum creepage distance for severely polluted atmosphere shall be 25 mm/KV the protected creepage distance shall be not less than 50% of total. OPERATING MECHANISM GENERAL REQUIREMENTS The operating mechanism shall be stored energy type in the form of spring charged. The operating mechanism shall be capable to perform the following functions efficiently. i) ii) iii) To provide means where the circuit breaker can be closed rapidly, without hesitation at all currents from zero to rated making current capacity. To hold the circuit breaker in closed position till the tripping signal is received. To allow the circuit breaker to open without delay immediately on receiving tripping signal.
7.00.00 7.01.00
To perform 3 phase auto reclosure duty cycle( For line breakers only). the control & relay panel . The closing spring shall be automatically charged by motor immediately after closing operation. In case of failure of supply to the spring charging motor, the spring shall be chargeable by hand-crank. ` The contact pressure spring and tripping spring shall be charged/compressed during closing operation to ensure the breaker is ready to open. Mechanically ON/OFF indicator, spring charged indicator and operation counter shall be provided on the front of the control cubicle. The tripping spring shall ensure the tripping even in case of failure of any auxiliary spring. a) Tripping/Closing Coils
The circuit breakers shall be provided with two trip coils and one closing coil per breaker. First trip coil shall be utilized for tripping the breaker on main protection fault detection. Second trip coil shall be used to trip the breaker when first trip coil fails to trip the breaker and backup protection comes into operation and shall also be used to trip the breaker on command. The trip coils shall be suitable for preclosing and after closing trip circuit supervision. All the breakers shall have provision for independent electrical operation of trip coils from local as well as remote through local/remote selector switch. The breaker shall be provided with suitable protection device against discrepancies in the operation of individual pole. b) Trip Free and anti pumping Features
The trip free mechanism shall permit the circuit breaker to be tripped by the protective relay even if it is under the process of closing. An anti-pumping device to prevent the circuit breaker from reclosing after an automatic opening shall be provided to avoid the breaker from pumping i.e., anti pumping relay should interrupt the closing coil circuit.
RGGVY-WORKS STANDARD TECHNICAL SPECIFICATION (REV.- 03) TECHNICAL SPECIFICATION VOL-II (PART-A) CHAPTER-II SECTION-E17 33 KV VACUUM CIRCUIT BREAKER Page 4 of 13
CLAUSE NO.

c) Controls
The circuit breaker shall be controlled by a control switch located in the control room. Local/remote selector switch shall be provided for all breakers for selection of Local control/remote control. Provision shall be made for local manual, closing, tripping and spring charging controls. Necessary equipments for local controls shall be housed in the circuit breaker cabinet of weather-proof construction. Each circuit breaker shall have a mechanical open/closed and spring charge indicator Lamps for indicating, close, open and spring charged position of the breaker shall also be provided. Mechanical indicator, to show the `open and `close position of the breaker shall be provided in a position where it will be visible to a man standing on ground with mechanism housing open. An operation counter, visible from the ground even with the mechanism housing closed, shall be provided. Electrical tripping of the breaker shall be performed by shunt trip coils. Closing coil shall operate correctly at all value of supply voltage between 85% and 110% of the rated voltage. Shunt trip coils shall operate correctly under all operating conditions of circuit breaker up to the rated breaking capacity and at all values of supply voltage between 85% and 110% of rated voltage. Bearings which require grease shall be equipped with pressure type fillings. Bearing pins, bolts, nuts and other parts shall be adequately pinned or locked to prevent loosening or changing adjustment with repeated operation of the circuit breaker. It shall be possible to trip the circuit breaker even in the event of failure of power supply. Operating mechanism and all accessories shall be enclosed in control cabinet. A common marshalling box for the three poles of the breaker shall be provided, along with supply of tubing, cables from individual pole operating boxes to the common marshalling box, local. 7.02.00 Spring Operated Mechanism The operating mechanism shall have all the necessary auxiliaries, apparatus for operation and supervision, like motor starter with thermal overload release, one closing coil, two trip coils, push button for local electrical operation, local/remote control selector switch, push button for direct mechanical tripping, auxiliary switches, anti-pumping contactors, operation counter, socket for inspection, lamp and heater with switch. In addition mechanical interlocking system for interlocking with associated isolators shall be provided. Spring charging motor shall be standard single phase universal motor suitable for 220 volts supply. i) ii) Operating voltages for closing/tripping coils shall be 24 Volts DC. Operating voltages for heater elements shall be 240V AC 50 HZ. Other features of the spring operated mechanism shall be as follows. a) The spring operating mechanism shall have adequate energy stored in the operating to close and latch the circuit breaker against the rated making current and also to provide the required energy for tripping mechanism in case the tripping energy is derived from the operating mechanism. The mechanism shall be capable of performing the rated operating duty cycle of O-0.3 Sec-CO-3 Min-CO as per IEC62271-100.
b)
Page 5 of 13
CLAUSE NO.

c) The spring charging motor shall not take more than 30 sec., to fully charge the closing spring made for automatic charging. Charging of spring by the motor should not interfere with the operation of the breakers. The motor shall be adequately rated to carry out a minimum of one duty cycle. Also provision shall be made to protect the motor against overloads. In case of failure of power supply to spring charging motor, the mechanism shall be capable of performing one open-close-open operation. Mechanical interlocks shall be provided in the operating mechanism to prevent discharging of the closing springs when the breaker is already in closed position. Provision shall be made to prevent a closing operation to be carried out with the spring partially charged. Facility shall be provided for manual charging of closing springs.
d) e) f)
g) 7.03.00 Control Cabinet
The switchgear operating mechanism, the control equipment such as switch for local electrical and manual closing and tripping the breakers, various control relays, anti-pumping device, a set of terminal blocks for wiring connections, MCBs for disconnecting the control auxiliary power supplies including relays, etc., shall be enclosed in a cabinet to be mounted on a suitable structure at a convenient working height at the end of the breaker in the outdoor switchyard. a) Enclosure The enclosure shall be made out of cold rolled steel plates not less than 3 mm thick and of light section structural steel. It should be weather proof as well as dust and vermin proof. The enclosure shall have degree of protection IP55 as per IS 13947. The cabinet shall have full width and full length hinged doors mounted on the front that swing fully open. The doors shall be provided with latches to securely hold it with the cabinet. Filtered ventilation, shall be provided along with the rigid supports for control and other equipment. All screws and bolts used for assembling and mounting wire and cable termination, supports, devices and other equipment shall be provided with lock washers or other locking devices. All metal parts shall be clean and free of weld splatter, rust and mill scale prior to application of double coat of zinc chromate primer which should be followed by an under coat to serve as base and binder for the finishing coat. The exterior of the cubicle shall be painted matty grey to shade No.692 of IS-5 or shade No.631 and interior to white shade. The mounting structure shall be galvanized and shall be as per IS-802-II-1978. b) Heaters Suitable space heaters shall be mounted in the cabinet to prevent condensation. Heaters shall be controlled by thermostat. ON/OFF MCB shall be provided. Heaters shall be suitable for 240 V AC supply voltage. c) Lighting One 20 watts fluorescent tube fixture and lamp holder working on 240 V 50 c/s AC supply shall be provided in each switchgear control cubicle section and shall be located to provide adequate interior lighting of the cubicle. A single-pole door operated 20 Amp. T rated lighting switch shall be provided for each cubicle. One duplex 220 Volt convenience outlet shall be provided inside each door or pair of doors inside each cubicle. The lighting and convenient outlet circuits shall be completely wired in conduit and terminated on cubicle terminal blocks.
RGGVY-WORKS STANDARD TECHNICAL SPECIFICATION (REV.- 03) TECHNICAL SPECIFICATION VOL-II (PART-A) CHAPTER-II SECTION-E17 33 KV VACUUM CIRCUIT BREAKER Page 6 of 13
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d) 1. 2. Wiring and Cabling Unless otherwise specified control wire shall be stranded tinned copper switchboard wire with 1.1 kV PVC insulation conforming to the requirements of IS-1554. All the control circuit and secondary wiring shall be wired completely and brought out preferably to a vertical terminal block ready for external connections in the control cabinet. The control wire shall not be of cross-section less than 2.5 mm2 copper. All spare auxiliary contacts of the circuit breaker shall be supplied wired up to terminal block. Each terminal in terminal block shall be suitable for at least 2 x 2.5 mm copper conductor. At least 20 number spare terminals shall be provided over and above the number required. All wiring termination on terminal blocks shall be made through lugs. For current and DC supply circuits disconnecting stud type terminal blocks will be provided. For other control circuits, non-disconnecting snap on type terminal blocks shall be provided. All wires shall be identified with non-metallic sleeve or tube type markers at each termination. Terminal blocks shall be made up of moulded non-inflammable plastic material with blocks and barriers moulded integrally have white marking strips for circuit identification and moulded plastic covers. Grounding
3.
4. 5.
6. 7.
e)
A ground bus of copper bar not less than 6 mm by 25 mm shall be provided along the inside of the front or rear of the each cubicle and equipment rack. The ground bus shall be bolted to the frame of each panel in such a way as to make good electrical contact with each panel or section. Earth terminals at two ends of the cabinet shall be provided for connection of the ground bus to the station earth mat. 8.00.00 ACCESSORIES Each circuit breaker assembly shall be supplied with the following accessories. i) ii) iii) Line and earthing terminals and terminal connectors. Bimetallic terminal connectors. Control housing with: a) One auxiliary switch with adequate number of auxiliary contacts, but not less than 20 nos. (10 NO + 10 NC) for each breaker. b) c) d) e) f) g) Operation counter Position indicator (Close/Open/Spring Charged) Necessary cable glands MCB as required Manual trip device and local test push buttons Terminal blocks and wiring for all control equipment and accessories
CLAUSE NO.

h) i) j) k) l) iv) Adequate number of heaters for continuous operation to prevent moisture condensation in the housing of operating mechanism Selector switch for local/remote control. Internal Illumination fluorescent lamp 5 Amp plug point and socket Motor for spring charging Rating and diagram plate as per IS
9.00.00 9.01.00
SUPPORTING STRUCTURE The circuit breakers shall be supplied complete with hot dip galvanized steel relevant supporting structures, foundation and fixing bolts, etc. The structure shall be made of steel MS angle section conforming to IS 226. The galvanizing shall be as per IS. The mounting of the breaker shall be such as to ensure the safety of the operating staff and should conform to Indian Electricity Rules, 1956. Minimum ground clearance of live part from ground level shall be 3700 mm. The bidder shall submit detailed design calculations and detailed drawings in respect of supporting structures suitable for the equipment offered. The bidder shall specify the loads which shall be transmitted to the equipment foundation under most adverse operating conditions of the breaker. All material for making connections between the circuit breaker and its control shall also be included in the scope of supply. SURFACE FINISH All metal surfaces exposed to atmosphere shall be phosphated as per IS 6005 and there after given two primer coats of zinc chromate and then 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 on 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.
9.02.00
9.03.00 10.00.00 10.01.00
10.02.00 11.00.00 11.01.00
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, shall be hot dip galvanized conforming to latest version of IS:2629 or any other equivalent authoritative standard. CABLE TERMINATION Suitable cable glands for terminating the multicore cable shall be provided at the bottom of the control cabinet.
12.00.00
13.00.00 13.01.00 13.02.00
TERMINAL CONNECTIONS AND EARTH TERMINALS Each circuit breaker connected with incoming and outgoing feeders shall be provided with bolted type bi-directional bimetallic terminal connectors suitable for ACSR conductor Each circuit breaker pole and control cabinet shall be provided with two grounding terminals and clamps for receiving ground connections.
CLAUSE NO.

EARTHING SYSTEM 50x6 GI flat earthing connections shall be included in the scope of supply. The system shall comprise of the leads between the circuit breaker and station mat and the interconnection between phases where necessary. All switchgear enclosures should be bolted metal to metal and should carry the full earth return current. Connection between phases at the earthing points shall be dimensioned for carrying full earth return current. VACUUM INTERRUPTER ASSEMBLY Each pole of the circuit breaker shall be provided with vacuum interrupter, one for each phase, hermetically sealed for life and encapsulated by ceramic insulators. The interrupter shall be provided with steel chromium are chamber. A further shield giving protection to the metal bellows shall also follow the travel of the moving contacts to seal the interrupter against the surroundings atmosphere. It shall have high and consistent dielectric strength of vacuum unaffected by environment and switching operations. Bronzed joints should ensure retention of vacuum for life time. It shall have low and stable contact resistance due to absence of oxidation effects and shall ensure low power loss. The arcing voltage shall be low and minimum contact erosion. DRAWINGS AND INSTRUCTION MANUALS Within 30 days after the award of the contract, the contractor shall supply six sets of drawings which will describe the equipment in details, for the approval of Purchaser. All the drawings and manuals should be in English Language and dimensions and weights shall be in MKS units. Following drawings and documents for each item are to be supplied as part of the contract. a) b) c) d) e) f) g) h) i) j) k) l) General outline drawings, showing dimensions, front and side elevations and plan of the circuit breaker and its local control panel. Outline drawing of support insulators showing dimensions and number of sheds and creepage distance. Assembly and sub-assembly drawings with numbered parts. Sectional views showing the general constructional features, operating mechanism and are extinguishing chamber, etc. Dimension and assembly of important auxiliaries. Detailed drawings of operating mechanism. Test certificates and oscillographs. Detailed drawings of mounting structure. Spare parts and catalogue Wiring diagram showing the local and remote control scheme of breaker. Write up on working of control schematic of breaker. Foundation plan including weights of various components and impact loadings for working foundation design.
14.00.00 14.01.00
15.00.00 15.01.00
15.02.00
16.00.00 16.01.00
16.02.00
16.03.00
Seven copies for each sub-station of the above drawings and instruction manuals covering instructions for installations, operation and maintenance shall be supplied by the contractor(s) without any extra cost.
CLAUSE NO.

TESTS Type Tests Each circuit breaker shall comply with requirements of type tests prescribed in IEC62271-100 ROUTINE TESTS Routine Tests as per IEC-56 shall be carried out on each breaker in presence of purchasers representative at the manufacturers expenses at his works except, where agreed to otherwise. All test reports should be submitted and should be got approved from the Purchaser before despatch of the equipment. SITE TESTS ON CONTROL AND AUXILIARY CIRCUIT The following tests shall be conducted at site before commissioning. 1) 2) 3) 4) Voltage tests on control and auxiliary circuit. Measurements of resistance of the main circuit. Mechanical Operation Tests. Insulation Resistance test
17.00.00 17.01.00 18.00.00 18.01.00
19.00.00 19.01.00
20.00.00 20.01.00 21.00.00
NAME PLATE Equipment should be provided with name plate giving full details of manufacture, capacities and other details as specified in the relevant IS. GAURANTEED TECHNICAL PARAMETERS The following gauranteed technical parameters shall be applicable. PART-A : Base parameters to be ensured while supplying the equipment. Sl. No. i) ii) iii) iv) v) DESCRIPTION Rate Voltage (kV rms) Rated frequency (Hz) System neutral earthing Type of arc quenching medium Rated normal current conditions (Amps) Number of poles Installation Temperature rise Rated short circuit a) Interrupting capacity at 36 kV 25 kA at site VALUES 36 kV 50 Solidly grounded system Vacuum 630 Amps
vi) vii) viii) ix)
3 Outdoor type As per IEC62271-100
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CLAUSE NO.

b) The percentage DC components x) xi) xii) xiii) xiv) Rated short circuit making First pole to clear factor Rated short time current Rated duration of short circuit Total break time for any current upto the rated breaking current with limiting condition of operating and quenching media pressure (ms) Closing time (rms) Mounting As per IEC62271-100 63 kA 1.5 25 kA 1 Second (minimum) < 80 ms
xv) xvi)
<150 ms Hot dip galvanized lattices steel support structured bolted type 400
xvii)
Phase to phase spacing in the switch yard i.e., interpole spacing for breaker (min.) Standard value of rated transient recovery voltage for terminal fault Rated operating a) duty cycle
xviii)
As per IEC62271-100
xix)
O-0.3 Second CO-3 Minutes CO
b) Auto reclosing
Suitable for three phase Auto reclosing duty 170 kVp
xx)
Rated insulation level under heavy pollution condition 1.2/50 micro second lightening Impulse withstand voltage (kV Peak) to earth 1 min. Power Frequency Withstand Voltage kV (rms) to Earth (kV rms) Rated Characteristics for out of Phase breaking a) Out of capacity b) phase breaking
xxi)
70 kV
xxii)
25% of rated breaking capacity
Standard values recovery
of
transient
As per IEC62271-100
CHAPTER-II SECTION-E17 33 KV VACUUM CIRCUIT BREAKER Page 11 of 13
CLAUSE NO.

c) Operating mechanism Spring operated, Anti pumping and Trip free mechanism for Three phase 415 Volts 50 C/S or single phase 50 C/S 240 Volts 3% from normal 50 Hz as per IS : 2026 Part-I 1977 para 4.4 15% 10 NO and 10 NC on each pole Continuous current rating 10 Amps, DC at 110/30 volts DC or 240 V AC 2 (Two) trip coils and 1 close coil 100 kg. Static. The breaker shall be designed to withstand the rated terminal load, wind, load, earthquake load and short circuit forces. xxvi) xxvii) xxviii) xxix) Spring charging motor supply Heater supply Auxiliary DC supply 230V AC 230V AC 24V DC
d)
Power available operating mechanism
e) Permissible frequency
f) Combined variation of frequency and voltage xxiii) Number of auxiliary contacts
xxiv)
Number of coils
xxv)
Rated terminal load
Supply of Aux. Contactor for anti- 24V DC pumping Tripping coil/ Closing coil supply Degree of protection Type test reports (all mentioned in relevant clause) 24V DC with 85%-110% range. IP-55 COMPLIED
xxx) xxxi) xxxii)
PART-B: Following parameters shall be furnished by manufacturer/ bidder. Sl. No. i) ii) DESCRIPTION Type of equipment/ eqpt. Code Rated duration of short circuit (seconds)
VALUES
CLAUSE NO.

iii) iv) v) Min. reclosing time (seconds) Type & material of main contact Material of auxiliary contacts
Page 13 of 13
CLAUSE NO.
STATION TRANSFORMERS SCOPE OF WORK This specification covers design, engineering, manufacture, inspection, testing at manufacturers works including type testing before dispatch, supply and delivery at destination, three phase station transformers of double wound, oil filled, naturally cooled, 50 Hz, outdoor type. APPLICABLE STANDARDS Station transformers shall comply with the latest version of following Standards along with the amendments. i) ii) iii) Indian Standard Specification IS : 1180. Indian Standard Specification IS : 2026. REC Specification 2/1971. (Revised 1997)
1.00.00 1.01.00
2.00.00 2.01.00
3.00.00 3.01.00
RATINGS AND TYPE The kVA ratings and types of station transformer shall be as follows : kVA Ratings 63 No. of Phases Three phase Nominal System No Load Voltage Ratio Voltage (ph-ph) 11 kV 11/0.433 kV
4.00.00
CLIMATIC CONDITIONS Refer Service Conditions of Chapter-Project Synopsis.
5.00.00
WINDING CONNECTIONS & VECTORS The transformer shall have vector notation of Dyn11 type.
6.00.00
TAPS Off-Load Taps shall be provided at 5% in steps of 2.5% on the HT Side.
7.00.00 7.01.00
WINDING Material Super enamel covered copper conductor/DPC copper conductor shall be used.
7.02.00 7.03.00
Electrical Grade Epoxy Dotted insulation paper shall be used for inter-layer insulation of the HV and LV coils. Current density of copper conductor for HV and LV winding shall be not more than 2.5 A/mm2. Conductor used for HV and LV winding shall be from continuous wire without any joint or brazing, as far as possible.
TECHNICAL SPECIFICATION VOL-II,(PART-A) CHAPTER-II SECTION-E18
STATION TRANSFORMERS
7.04.00
Page 1 of 17
CLAUSE NO.
STATION TRANSFORMERS Angle shaped End Rings made from pre-compressed board should preferably be used between the end coils and core. Construction of winding shall be adequately designed to withstand the short circuit test not withstanding the type of conductor being used. CORE The type of Core and Core material shall be as given below: i) ii) The core shall be wound type. The design of magnetic circuit shall be such as to avoid static discharges development of short circuit paths 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. The core shall be constructed from new high grade, non-aging Cold Rolled Grain Oriented (CRGO) silicon steel laminations conforming to grade M4 or better. The bidder shall provide saturation curve of the core material proposed to be used. Core material shall be directly procured either from the manufacturer or through their accredited marketing organization of repute and not through any agent. The complete design of core must ensure permanency of the core losses with continuous working of the transformers. The value of the flux density allowed in the design and grade of lamination used shall be clearly stated in the offer. All parts of the core shall be of robust design, capable of withstanding any shocks to which they may be subjected during handling, lifting, transportation installation and service. Clamping of core and winding assembly with tank should be done by angle iron pieces, welded to tank walls and not to be done with flat iron pieces.
7.05.00 7.07.00 8.00.00 8.01.00
iii) iv)
v)
vi)
vii) Adequate arrangement shall be provided to enable the core and winding to be properly supported. Use of seconds CRGO steel for core construction is strictly prohibited. 8.02.00 8.02.01 8.02.02 8.02.03 Core Clamping Core clamping shall be with top & bottom clamps made of sheet steel, clamped with H.T. steel tie rods or steel belts/tape for proper clamping. M.S. core clamps shall be painted with varnish or oil resistant paint. Provision shall be made in bottom core clamp/plate to arrest movement of active part.
TECHNICAL SPECIFICATION VOL-II,(PART-A)
Page 2 of 17
CLAUSE NO.
STATION TRANSFORMERS PERMISSIBLE FLUX DENSITY & OVERFLUX The flux density at rated voltage and frequency shall not exceed 1.69 tesla. 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 and frequency variation of +5% shall not exceed 1.9 Tesla. The transformer shall be suitable for over fluxing due to combined effect of voltage and frequency. The supplier shall furnish necessary design data in support of this stipulation. The no-load current at Rated Voltage and at 112.5 percent Rated Voltage shall not exceed values as per IS. The core and coil assembly shall be securely held in position to avoid any movement under short-circuit conditions. SYSTEM SHORT CIRCUIT LEVEL The transformer fault level shall be as per IS.
9.00.00 9.01.00
9.02.00 10.00.00
11.00.00 11.01.00 11.01.01
TRANSFORMER TANK Construction The transformer tank shall be made of good quality steel sheet of adequate thickness and shall be suitably stiffened to provide sturdy and robust construction to withstand extreme pressure conditions. The tank shall be capable of withstanding pressure upto (+) 80 Kpa and (-) 70 Kpa (gauge pressure) without any deformation. The tank cover shall have plasticised surface at the top to guard against birdage faults. Alternatively, suitable insulating shrouds shall be provided on the bushing terminals. Pressure Relief Device Pressure relief device shall be provided.
11.01.02
11.02.00
11.03.00
Sealing Gaskets All sealing washers/gaskets shall be made of oil and heat resistant nitrile rubber. Gaskets made of natural rubber or cork sheet are not permissible. Rubberised cork sealing gaskets may be accepted, subject to clearance for quality.
11.04.00 11.04.01 11.04.02
Conservator The transformer shall be provided with conservator. The conservator shall be provided with a drain plug and a filling hole with cover. In addition, the cover of main tank shall be provided with an air release plug to enable trapped air to be released 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.
Page 3 of 17
CLAUSE NO.
STATION TRANSFORMERS 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
0
11.04.03
sump for collection of impurities. The minimum oil level (corresponding to-5 C should be above the sump level. 11.05.00 Each transformer shall be fitted with a transparent type breather in which Silica gel is the dehydrating agent. The breather is so designed that the passage of air through the Silica gel and the external atmosphere is not continuously in contact with silica gel. PAINTING PROCEDURE The paint material and procedure for the station transformer shall be as per details given below: 12.01.00 All paints shall be applied in accordance with the paint manufacturers recommendations. Particular attention shall be paid to the following : a. b. c. d. e. Proper storage to avoid exposure as well as extremes of temperature. Surface preparation prior to painting. Mixing and thinning Application of paints and the recommended limit on time intervals between coats. Shelf life for storage. 1. 2. All paints, when applied in normal full coat, shall be free from runs, sags, wrinkles, patchiness, brush marks or other defects. All primers shall be well marked into the surface, particularly in areas where painting is evident, and the first priming coat shall be applied as soon as possible after cleaning. The paint shall be applied by airless spray according to the manufacturers recommendations. However, wherever airless spray is not possible, conventional spray be used with prior approval of purchaser. The supplier shall, prior to painting protect nameplates, lettering gauges, sight glasses, light fittings and similar such items.
12.00.00
3. 12.02.00
Cleaning and Surface Preparation 1. After all machining, forming and welding has been completed, all steel work surfaces shall be thoroughly cleaned of rust, scale, welding slag or spatter and other contamination prior to any painting. Steel surfaces shall be prepared by Sand / Shot blast cleaning or Chemical cleaning and process including Phosphating to the appropriate quality.
2.
Page 4 of 17
CLAUSE NO.
STATION TRANSFORMERS 3. The Pressure and Volume of the compressed air supply for the blast cleaning shall meet the work requirements and shall be sufficiently free from all water contamination prior to any painting. Chipping, scraping and steel wire brushing using manual or power driven tools cannot remove firmly adherent mill-scale and shall only be used where blast cleaning is impractical.
4.
12.03.00
Protective Coating As soon as all items have been cleaned and within four hours of the subsequent drying, they shall be given suitable anticorrosion protection.
12.04.00
Paint Material Followings are the type of paints that may be suitably used for the items to be painted at shop and supply of matching paint to site: 1. 2. Heat resistant paint (Hot oil proof) for inside surface. For external surfaces one coat of Thermo Setting Paint or 2 coats of Zinc chromate followed by 2 coats of Synthetic Enamel paint. The color of the finishing coats shall be dark admiral gray conforming to No. 632 of IS 5:1961.
12.05.00
Painting Procedure 1. All painting shall be carried out in conformity with both specifications and with the paint manufacturers recommendations. All paints in any one particular system, whether shop or site applied, shall originate from one paint manufacturer. Particular attention shall be paid to the manufacturers instructions on storage, mixing, thinning and pot life. The paint shall only be applied in the manner detailed by the manufacturer e.g. brush, roller, conventional or airless spray and shall be applied under the manufacturers recommended conditions. Minimum and maximum time intervals between coats shall be closely followed. All prepared steel surfaces should be primed before visible re-rusting occurs or within 4 hours whichever is sooner. Chemical treated steel surfaces shall be primed a s soon as the surface is dry and while the surface is warm. Where the quality of film is impaired by excess film thickness (wrinkling, mud cracking or general softness) the supplier shall remove the unsatisfactory paint coatings and apply another. As a general rule, dry film thickness should not exceed the specified minimum dry film thickness by more than 25 %. In all instances, where two or more coats of the same paints are specifies, such coatings may or may not be of contrasting colors. Paint applied to items that are not be painted, shall be removed at suppliers expense, leaving the surface clean, un-stained and undamaged.
2.
3.
4.
5.
Page 5 of 17
CLAUSE NO.
STATION TRANSFORMERS Damages Paint Work 1. Any damage occurring to any part of the painting scheme shall be made good to the same standard of corrosion protection and appearance as that originally employed. Any damaged paint work shall be made good as follows: The damaged area, together with an area extending 25 mm around its boundary, shall be cleaned down to bare metal. a) A priming coat shall immediately applied, followed by a full paint finish equal to that originally applied and extending 50 mm around the perimeter of the originally damaged. The repainted surface shall present a smooth surface. This shall be obtained by carefully chamfering the paint edges before & after priming.
12.06.00
2. 3.
b) 12.07.00
Dry Film Thickness 1. To the maximum extent practicable, the coats shall be applied as a continuous film of uniform thickness and free of pores. Over-spray, skips, runs, sags and drips should be avoided. The different coats may or may not be of same color. Each coat of paint shall allowed to hardened before the next is applied as per manufacturers recommendations. Particular attention must be paid to full film thickness at edges. The requirement for the dry film thickness (DFT) of paint and the material to be used shall be as given below:
2. 3. 4.
Sl. No. 1. a)
Paint type Powder paint Thermo setting powder Liquid Paint Zinc chromite (primer)
Area to be Inside Outside
No. of coats 01 01
Total dry film 20 microns 60 microns
2. a)
Outside
02
45 microns
Page 6 of 17
CLAUSE NO.
STATION TRANSFORMERS b) Synthetic Enamel (Finish Coat) Hot Oil paint Outside 02 35 microns
c) 13.00.00 13.01.00 13.02.00 13.03.00
Inside
01
35 microns
TRANSFORMER OIL New insulating oil of petroleum origin shall be used. The oil shall be of low viscosity type and completely free from additives. Transformer oil shall comply with REC specification : 39/1985 & IS : 335. The requirements have been given in two parts. A) B) For new transformer oil in drums / tankers. For oil after it is filled in the transformer (the values shall be applicable after 3 days from the date of filling).
13.04.00
New Oil The important characteristics of new oil shall be as follows: Characteristics 1. 2. Flash point Pensky Marten (closed), Min. Neutralization value a) Total acidity, Max. b) Inorganic acidity/alkalinity 3. 4. Corrosive Sulphur Electric Strength (breakdown voltage) Min. a) New unfiltered oil b) New oil after filtration 5. 6. Dielectric dissipation factor (tan delta) at 900 C (Max.) Specific resistance (resistivity) a) At 900 C (Min.) b) At 270 C (Min.) 30x1012 ohm-cm 500x1012 ohm-cm
Requirement 1400 C
0.03 mg KOH/g Nil Non - Corrosive
30 kV (ms) 50 kV (ms) 0.005
Page 7 of 17
CLAUSE NO.
STATION TRANSFORMERS 7. Oxidation stabililty a) Neutralization value after oxidation (Max.) b) Total sludge after oxidation (Max.) 8. Ageing Characteristics a) Specific resistance (resistivity) i) ii) at 270 C at 900 C 2.5x10 12 ohm-cm (Min.) 0.2x10 12 ohm-cm (Min.) 0.20 Max. 0.05 Max. 0.4mg KOH/g 0.10% by weight
b) Dielectric dissipation factor (tan delta) at 900C c) Total acidity in mg KOH/g d) Total sludge 13.05.00 Characteristics of oil in the Transformer
The important characteristics of the transformer oil after it is filled in the transformer (after 3 days of filling) shall be as follows: Characteristics 1. 2. 3. 4. 5. 6. 7. 13.06.00 Tests All tests to verify the characteristics as incorporated in this specification shall be carried out in accordance with IS:335-1983 or its latest version. 14.00.00 14.01.00 TERMINAL ARRANGEMEMT The transformer shall be fitted on high voltage and low voltage sides with outdoor type bushings of appropriate voltage and current ratings. The three phase
Specification 30 kV Min. 0.01 Max. 10x1012 1400C (Min.) 0.03 N/m (Min.) 0.05 mg KOH/g (Max.) 35 (Max.)
Electric strength (Breakdown voltage) Dielection dissipation factor (tan deltla) at 900C Specific delta resistance (resistivity) at 270 C (Ohm-cm) Flash point, P.M (Closed) Interfacial tension at 270 C Neutralization value (total acidity) Water content, PPM
Page 8 of 17
CLAUSE NO.
STATION TRANSFORMERS transformers shall have three HV bushings and four LV bushings. LV Neutral Terminal of bushing shall be connected to earth externally. All bushings shall conform to IS : 1347 and 2099. The bushings shall not have arcing horns.
14.02.00
The high voltage bushings shall conform to IS:2099:1986. The low voltage bushings shall conform to IS-7421:1974. Alternatively the low voltage side may be made suitable for adoption of PVC cable of suitable size. The terminal arrangements shall be such that it shall be possible to replace the bushings (external) without opening the cover and also without affecting the sealing of the transformer. HV Bushing The bushing shall be of porcelain. The dimensions of the outer bushing shall conform to IS 3347 (part 3/Sec 1) : 1972..The internal bushing shall be of either porcelain or tough insulating material, HGS-REC (II) like epoxy and shall have embedded stem. For typical arrangement, Appendix-II of REC specification No. 2/1971 (R-1997) can be referred.
14.03.00
14.04.00
14.05.00
LV Bushing The LV bushing shall be of two parts external porcelain part & internal made of epoxy. For details, Appendix-II of REC Specification No. 2/1971 (R-1997) can be referred.
14.06.00
Bushing Terminals Both HV and LV bushing stems shall be made of aluminum alloy conforming to the requirement of IS:3347. The bushing terminals shall be of clamp type to directly receive aluminium conductors (of cables) without requiring use of lugs. The terminals shall be directly screwed on to the stem to ensure effective sealing of the bushings
14.07.00
The design of internal bushings shall be such as to provide adequate creepage distance in accordance with 7.1 of IS 2099 : 1986 and minimum clearance as given below: HV side Internal External Phase to phase Phase to earth 127 mm 76 mm 255 mm 140 mm LV side Internal External 45 mm 20 mm 75 mm 40 mm
14.08.00
All sealing washers/ gaskets shall be made of oil and heat-resistant nitrile rubber.
Page 9 of 17
CLAUSE NO.
STATION TRANSFORMERS SURGE ARRESTER FOR DTs Applicable Standards The surge arrestors shall comply IS:3070 Part-III latest amendment and REC Specification No. 10/1976.
15.00.00 15.01.00
15.02.00
Electric Requirements i) ii) iii) iv) Nominal system voltage Highest system voltage Frequency Fault level 11 kV 12 kV 50 Hz 250 MVA
15.03.00 15.03.01
Atmospheric Conditions The atmosphere at places is laden with dust in suspension during the dry months and subject to fog in cold months. The temperature variation between the daily minimum and maximum is large. Heavy lightning is usual in the area during the month of May to November. The area is also subjected to heavy monsoon rains 80% to 90% of the annual precipitation during the months of June to October. Design Requirements The Technical requirements have been detailed out below : Sl. No. Particulars 1. 2. 3. 4. 5. 6. 7. 8. Nominal system voltage Type of Arrestor Applicable standard Rated Arrestor voltage kV rms Maximum continuous operating voltage kV rms Nominal discharge current rating (8/20 micro sec) kA Minimum discharge capability (kA/kV) Long duration discharge class Requirements 11 kV Metal Oxide IEC-99/4 IS:3070 Part-III latest amendment 9 7.2 5.0 As per long duration discharge class 2 of IEC 99/4 2
15.04.00 15.04.01
Page 10 of 17
CLAUSE NO.
STATION TRANSFORMERS 9. Maximum residual voltage at nominal discharge current of 8/20 micro sec. wave, kV peak Maximum steep current impulse residual voltage at nominal discharge current, kV Peak
32
10.
38
11. 12. 13.
Maximum switching impulse residual voltage at 500 Amp. (Peak) NA Minimum prospective symmetrical current (kA) Impulse high current short duration discharge of 4/10 micro sec. Wave (kAP) Max. radio interference voltage at 1000 Hz (micro volts) Overall temporary over voltage withstand capacity (KV rms) 1.0 Sec. 10.0 Sec. 100.0 Sec. Impulse withstand voltage (KVP) Current impulse withstand level Pressure relief device Disconnecting device Min. creepage distance of porcelain housing (mm) Top & Bottom metal cap Terminal arrangement 10 9.5 75 18 impulse of long duration current 75 Amp. Peak for 1000 micro-secs. N.A. As per required specification IS:3070 (Part-II)-1985 300 Hot Dip Galvanized Built in clamping type can be adjusted for Horizontal & Vertical Power off to suit conductor save squirrel to carbon 15
65 -
14. 15. a) b) c) 16. 17. 18. 19. 20. 21. 22.
Page 11 of 17
CLAUSE NO.
STATION TRANSFORMERS 23. Earthing Terminal The base of L.A. shall be provided with two separate terminal / distinctly marked for connection to earth
15.04.02
Residual voltage at nominal discharge current of 8/20 micro sec. wave is specified above, however, it is preferred still lower residual voltage to ensure better protection. Each and every individual unit of surge arrestor shall be hermetically sealed and fully protected against ingress of moisture for which suitable rubber gaskets with effective sealing system should be used. The hermetic seal shall be effective for ensure life time service of arresters and under the service conditions specified. The agency shall furnish sectional view showing details of sealing employed. Manufacturers should device a suitable routine production testing to verify the efficiency of sealing. All the units of arresters of same rating shall be interchangeable type without adversely affecting the performance. Application of LA The 11 kV arrestor provided on Station Transformer shall protect the equipment system against lightning surges. These shall be connected in series with the ground lead and should not affect the sealing system of the arrestor. The earthing connection of the transformer and associated Surge arrestor shall be provided as per procedure, described for D.T sub-station in this specification. Drawings The Bidder shall furnish two sets of following drawings for owners approval before commencing the erection of Station Transformer. General outline drawings of the complete equipment with technical parameters, Drawings showing clearance from ground and other live objects and between adjustment poles of surge arresters required at various heights of surge arrestors. 1. 2. Drawings showing details of mounting structure and of surge arresters. Drawing showing details of line and ground terminals and connection.
15.04.03
15.04.04
15.05.00 15.05.01
15.06.00 15.06.01
16.00.00 16.01.00
FITTINGS The following standard fittings shall be provided a) An extended pipe for filling of oil at the top with welded cover. The pipe shall be suitably threaded over a sufficient length so that it may be possible to provide a refilling connection after removing the welded cover. 11 kV Lightning Arresters: High surge capacity 9 kV, 5 kA lightning arrester conforming to relevant Indian Standard Specification shall be mounted on each phase of the transformer, clamped securely to the tank, to protect the
b)
Page 12 of 17
CLAUSE NO.
STATION TRANSFORMERS transformer and associated line equipment from the occasional high voltage surges resulting from lightning or switching operations. The earthing terminal of the lightning arresters shall be connected solidly to the transformer tank earthing terminal. d) e) f) Two earthing terminals Two lifting lugs (on Tank body) Rating and terminal marking plate(s).
16.02.00
The following standard fittings shall be provided for three phase station transformers only. a) Oil level gauge indicating three positions of oil marked as follows: b) c) Minimum (-50C) 300C Maximum (980C)
Plain breathing device comprising an inverted U-pipe with wire gauze at the open end or Silica gel breather, as required by the purchaser. Drain-cum-Sampling valve (Steel) of the type shown in Fig. 1 welded to the tank. The special tool for operating this value shall be supplied with the transformer. Thermometer pocket
d) 17.00.00 17.01.00
MOUNTING ARRANGEMENT The under-base of all transformers shall be provided with two 75x40mm channels 460mm long with holes (at a centre-to-centre distance of 415mm) to make them suitable for fixing on a platform or plinth. For mounting dimensions, Fig 3 of REC Specification 2 / 1971 can be referred. RATING AND TERMINAL MARKING PLATE The transformer shall be provided with non-detachable rating marking plate(s) of weather proof material, fitted in a visible position and showing the complete information given in Clause No. 15.2 of IS : 2026 (PartI)1977.
18.00.00
19.00.00
LIMITS OF TEMPERATURE RISE The temperature rise shall not exceed the limits of 550C (measured by resistance) for transformer windings and 450C (measured by thermometer) in top oil above the ambient temperature of 500C, when tested in accordance with IS : 2026 (Part-2).
20.00.00
The percentage impedance at 750C shall be 4.5% subject to tolerance as per 2026.
IS:
Page 13 of 17
CLAUSE NO.
STATION TRANSFORMERS LOSSES & IMPEDANCE VALUES The bidder shall furnish the maximum guaranteed values of no load 0 and load losses (at 75 C) with no plus tolerance in the data requirement sheet and also in relevant Schedule of Bid Proposal Sheets
21.00.00
21.01.00
CAPITALISATION OF LOSSES This clause shall be same as Losses & Impedance Values clause of 1/3 phase distribution transformer specified elsewhere in this specification.
22.00.00 22.01.00
TESTS ACCEPTANCE TEST Routine & acceptance test shall be done as per IS: 1180
22.02.00 23.02.01
Type Test The supplier shall offer transformers of identical design & rating which has been type tested & tested for short circuit with stand capability as per relevant IS. The type test & test for short circuit withstand should have been conducted within last five years from a national test house or from similar reputed test house. The bidder shall furnish type test reports for each type rating. If the type tests & test to with stand short circuit test conducted within last five years is incomplete or not conducted within last five years the party shall arrange to carry out such tests at his own cost & risk in the presence of employer/owners representative. Even if such tests have been conducted within last five years employer/owner reserves the right to repeat such tests for which the cost shall be borne by employer/owner. INSPECTION All routine tests and inspection shall be made at the place of manufacture unless otherwise especially agreed upon by the manufacturer and purchaser at the time of purchase. The manufacturer shall provide the inspector, representing the purchaser, all the data, drawings and calculations without approved to satisfy him that material is being used in accordance with the specification and relevant standards. The purchaser has the right to have any tests carried out at his own cost, by an independent agency, whenever there is a dispute regarding the quality of supply. GENERAL TECHNICAL PARTICULARS: GTP of Station Transformers are enclosed herewith in two parts (Part A and Part B). The successful bidder shall supply Station Transformers as per Part A of GTP and additional details which are stipulated in Part B of the GTP shall be filled and submitted for review and approval along with the bid. Make shall be NESCL Corporate Quality Assurance (CQA) approved.
23.02.02 23.00.00 23.01.00
23.02.00 24.00.00
Page 14 of 17
CLAUSE NO.
Part A: Sl.No.. Description 1 2 3 Continuous max. rating as per this specification. Nominal Voltage ratio of transformer Method of Connection HV / LV Max.HotSpotTemp.Deg.C.(Ambientairtemp.onwhi ch above is based) Deg.C. a)Max. Observable Oil temp. Deg.C.(ambient air temp. on which above is based) Deg.C. b) Max. Winding Temperature at an ambient temp. of % Impedance voltage at normal ratio between HV & LV windings Type of transformers, shell type/core type wound core
63 KVA(3-ph) 63 KVA 11/0.433 kV Delta/Star 115.90C over maximum ambient of 500C
5 6 7
450C 550C 4.5% +/- 10% Tol SHELL TYPE Wound Core 75kV/Type M4 or better stack core. peak NA As per IS:335 YES
8 9 10 11 12 13 14 15
Impulse test voltage level HV Windings LV Windings Characteristics of transformer oil Whether transformer will be transported with oil? Name of the manufacturer and place manufacturer Fixed losses at normal voltage ratio (watts) at 750C(Max.) Load losses at normal voltage (watts) at 750C(Max.) ratio
Total losses at normal voltage ratio (watts) at 750C(Max.) Efficiency at normal voltage i) Unity Power Factor a) At 50% Load b) At 75% Load c) At full Load ii) 0.8 Power Factor a) At 50% Load b) At 75% Load c) At full Load
16
Page 15 of 17
CLAUSE NO.
STATION TRANSFORMERS Sl.No.. Description Regulation as percentage of normal voltage. 17 A) At unity power factor% b) At 0.8 Power factor lagging% Type of Insulation used in 18 a) HV Windings b) LV Windings Type of Insulation used in a) Core bolts 19 b) Core bolt washers c) End plates d) Core lamination 20 Total content of oil in liters 21 Type of transformers tank I) Approx. overall dimensions 23 a) Height mm b) Breadth mm c) Width mm ii) Tank dimensions a) Diameter mm b) Height mm Weight of insulated conductor a) HV (min.) kg. 24 b) LV (min.) kg. 25 Weight of core (min.) kg. Weight of complete transformer arranged for 26 transport kg. a) With oil b) Without oil 27 Tank cover sealing 28 Gasket material Painting 29 i)External ii) Internal 30 Core window height (App.) Watts 31 Center to center distance of the core 32 No. of L.V. Turns (App.) 33 No. of H V turns (App.) Wt. Of the LV winding for Transformer 34 (App/job) kg. Wt. Of the HV winding for Transformer 35 (App/job) kg. 36 No. of LV Coils/phase 37 No. of HV coils. phase 63 KVA(3-ph)
Page 16 of 17
CLAUSE NO.
STATION TRANSFORMERS Sl.No.. Description 38 Height of LV Windings 39 Height of HV Windings 40 ID/OD of LV Winding 41 ID/OD of HV Winding(app.) 42 Size of the duct in LV winding 43 Size of the duct in HV winding Size of the duct between 43 LV 44 HV winding to LV clearance 45 HV winding to tank clearance 46 Calculated impendence 47 HV to earth creepage distance 63 KVA(3-ph) mm mm mm mm mm mm mm mm mm % mm HV Z&
Page 17 of 17
CLAUSE NO.
GENERAL CONSTRUCTIONAL PRACTICES (33 KV, 11kV& LT LINES)
1.00.00 1.01.00
ROUTE SURVEY Successful bidder shall carry out detailed survey and prepare the detailed route of 33 KV, 11KV & LT lines, location of Distribution Transformer on topographical sheets / mouja maps available from government agencies. The bidder shall make his own arrangements for obtaining the topographical maps/mouzas maps from the concerned agencies. The final route map for 33 KV, 11KV & LT lines, shall be prepared and submitted by the bidder, showing the proposed pole position, ground clearance, conductor sag and various crossings i.e. railway lines, communication lines, EHT lines, rivers, road and stream crossings on the map to a scale of 1:25000. All LT lines along with pole locations are to be marked on village / mouza maps / patwari maps to a scale 1:5000. Pole Spotting (a) Span
1.02.00
Maximum span of HT & LT Lines with proposed conductors shall be as per REC construction standards or as specified in the table below.
Sl. No Line type 33KV line, bare conductors , Triangular configuration Support (Height in mtrs/KG class) PCC(9/300) PCC(9/400) 11KVline bare conductors , Triangular configuration PCC(8/140) PCC(8/200) 11KVline, ABC 3 PCC(8/200) 3 Phase LT line with bare conductors PCC(8/140) PCC(8/200) 1 Phase LT line with bare conductors PCC(8/140) PCC(8/200) LT 3 PH ABC 6 PCC(8/200) LT 1 PH ABC 7 PCC(8/200) RGGVY WORKS STANDARD TECHNICAL SPECIFICATION (REV.- 03) TECHNICAL SPECIFICATION VOL-II (PART-B) CHAPTER-II SECTION-E0
GENERAL CONSTRUCTIONAL PRACTICES(33,11KV&LT LINES)
REC Standard No. or span in mtrs.
As per REC construction standard M-2,M-11
As per REC construction standard A-8,A34
PCC(8/140) 40 mtrs.
As per REC construction standard B-8 & B36
As per REC construction standard B-11 & B37
PCC(8/140) 50mtrs
PCC(8/140) 60mtrs
Page 1 of 18
CLAUSE NO.
The following types of pole configurations shall be used at respective locations given below. after finalization of survey & pole spotting a) b) SP (Single Pole support) DP (Double Pole support) i) 0o - 10o deviation. i) 10o - 60o deviation ii) For sectionalizing 33kV & 11kVline at an interval of 1.6 kM iii) For sectionalizing 11kV lines with AB cable at an interval of 500mtrs c) (b) FP (Four Pole support) Road Crossing At all major road crossings, the poles shall be fitted with strain type insulators but the ground clearance at the roads under maximum temperature and in still air shall be such that even with conductor broken in adjacent span, ground clearance of the conductor from the road surfaces shall not be less than 6.1 meters. (c) Railway Crossings At the time of route survey, the railway crossings shall be finalized as per the regulation laid down by the Railway Authorities. The following are the important features of the prevailing regulations (revised in 1987): i) ii) (d) The crossing shall be at right angle to the railway track. Railway crossing shall be by the use of underground cable of appropriate size. (i) 60o - 90o deviation
Power Line Crossings Where the proposed lines require to cross over another line of the same voltage or lower voltage, provisions to prevent the possibility of its coming into contact with other overhead lines shall be made in accordance with the Indian Electricity Rules, 1956 as amended from time to time. All the works related to the above proposal shall be deemed to be included in the scope of the Contractor. Where existing lines of higher voltages are to be crossed under another line, the bidder shall take up suitable re-routing so as to obtain necessary sectional clearances, other wise crossing through 11 kV cable/AB cable shall be proposed.
Page 2 of 18
CLAUSE NO.
(e)
Telecommunication Line Crossings i) The angle of crossing shall be as near to 90 degree as possible. However, deviation to the extent of 30 degree may be permitted under exceptionally difficult situations. When the angle of crossing has to be below 60 degree, the matter will be referred to the authority in-charge of the telecommunication system. On a request from the Contractor, the permission of the telecommunication authority may be obtained by the Purchaser. Also, in the crossing span, power line support will be as near the telecommunication line as possible, to obtain increased vertical clearance between the wires. HT line shall be routed with requisite suppression with parallel telecom line to avoid inductance during faults.
ii)
iii) (f)
Details Enroute All topographical details, permanent features, such as trees, telecommunication lines, building etc. 5.5 meter on either side of the alignment shall be detailed on the route plan.
(g)
Clearance from Ground, Building, Trees etc. Clearance from ground, buildings, trees and telephone lines shall be provided in conformity with the Indian Electricity Rules, 1956 as amended upto date. The bidder shall select the height of the poles such that all electrical clearances are maintained. RCC/rail poles shall be used for all road & drain crossings, if required. In case of exceptional terrain, rail pole may be used with the approval of owner.
(h)
The minimum planting depth of poles shall be governed by IS : 1678. However, if due to the ground conditions, e.g. water logged area etc. depth of planting of poles shall be suitably increased the bidder will supply the poles of suitable height in order to maintain the required clearances, the vendor will submit the details of the same on case to case basis. Guarding mesh shall be used in all electric line / telecom line / road / drain / canal crossing and at all points as per statutory requirements. The bidder shall provide & install anti climbing devices and danger plates on all poles and DT stations.
(i)
Design Parameters a) b) c) Factor of safety 2.0 in normal condition for 33 kV & 2.5 for 11 kV line & LT line for PCC supports. Wind Pressure on Pole & conductor As per IS 802 Wind load on cross-arms, insulators guy-wire etc. shall be considered.
TECHNICAL SPECIFICATION VOL-II (PART-B) CHAPTER-II SECTION-E0
Page 3 of 18
CLAUSE NO.
d) e)
Wind load on full projected area of conductors and pole is to be considered for design. Ground clearance shall be minimum 5.2m for 33 kV line & 4.6 m for 11 kV line & LT line for bare conductor at locations other than along and across road crossings. Ground clearance shall be minimum 4m for 11 kV ABC line & LT ABC line. All other clearance shall be as per IE.Rules. The live metal clearance shall be as per IS: 5613 and shall be min.330 mm for 33 kV line.
f) g) h) 2.02.00 2.00.00 2.01.00
Pole accessories like danger plates, phase plates, anti climbing device, shall be provided. POLES Excavation of pole pit Excavation cost for pits shall be included by the contractor in the bid for following type of soils inclusive of dewatering of pits and shoring and shuttering wherever necessary. i) All type of soils and soil conditions but excluding hard rock
For the purpose of pole planting, normally pit size shall be 600x500x1500 (mm). In case bidder employs Earth augers, the Pit size can be considered 0.7 meter dia with 1.5 meter depth. ii) Hard rock
For hard rock locations, 1 meter deep hole of diameter 20% in excess of the longest dimension of the bottom most portion of pole shall be excavated. The pole shall be grouted in the pit with 1:2:4 nominal concrete mix at the time of pole erection.For hard rock, the excavation cost per location shall remain same for all type of foundations. Controlled blasting shall be permitted only in case of hard or rocky soil. The contractor shall be responsible for any damage or accidents arising out of the process of blasting. Blasting shall not be permitted if the area around location is inhabited. In such case, the contractor shall have to follow other methods like drilling etc. 2.01.01 PCC footing and compaction of soil The planting depth of pole shall be 1500 mm in the ground except in wet soil and black cotton soil where depth shall be increased by 0.2 mtr. to 0.3 mtr. with reduced wind span.
Page 4 of 18
CLAUSE NO.
Following arrangement shall be adopted for proper erection of PCC type poles and compaction of the soil around the base / foot of the poles, under this package. 1. 2. All the PCC poles shall be provided with a RCC block base having dimensions and constitutions as per REC Construction Standard K-1. The poles shall then be lifted to the pit with the help of wooden supports. The pole shall then be kept in the vertical position with the help of 25 mm (min.) manila ropes, which will act as the temporary anchor. The verticality of the pole shall be checked by spirit level in both longitudinal & transverse directions. The temporary anchor shall be removed only when poles set properly in the foundation after compaction the soil. Entire void space above the block is to be filled with Jhama (Burnt Brick) and excavated earth. Concreting of foundation upto a height of 1.8 mtrs. From the bottom of the pit with a circular cross-section of radius 0.25 mtrs. (Volume of 0.3 cu.mtr. per pole) in the ratio of 1:2:4 shall be done at the following locations: i) ii) iii) iv) v) vi) For all 33KV poles At all the tapping points and dead end poles. At all the points where DT is to be installed. At all the points as per REC construction dwg. No. A-10 (for the diversion angle of 10-60 degree) Within a maximum distance of 1 km from the last Jhama filled pole structure. Both side poles at all the crossing for road, nallaha railway crossings etc.
3. 4.
vii) For all Rail poles, double pole and four pole structures. 5. In case the route of 33/11 kV lines encounters marshy low laying area, special type of foundations shall be used. In such a case, difference in excavation quantity, concreting & reinforcement between special foundation and normal foundation shall be paid extra as per Delhi Schedule of Rate (DSR) applicable on the date of bid opening. No other payment incidental to special foundation locations shall be made to the contractor.
2.02.00 2.02.01 2.02.02
Earthing of Poles In 33/11 kV & LT line, each pole shall be earthed with spike type earthing as per REC Construction Standard J-2 All DP & Four pole structures & the poles on both sides of railway, Telecommunication, road, drain & river crossing shall be earthed by pipe earthing as
Page 5 of 18
CLAUSE NO.
per enclosed REC Construction Standard J-2. 2.02.03 In rocky areas where digging of earth pits up to 1500mm is not possible spike earthing in horizontal configuration buried at a depth of not less than 800mm may be used In rocky areas where individual earthing of poles is not possible, an overhead GI earth wire shall be run as per REC construction standard drawing- A5. This earth wire shall be earthed at three different points in one Km using pipe earthing as per REC construction standard J2. The dimension of over head GI earth wire shall not be less than 6mm dia. & 4mm dia respectively for 33KV &11KV lines EXTENSION POLE PCC pole with pole extension arrangement up to two meters shall be used at low ground level locations for maintaining ground clearance and for road/ line crossings for HT & LT lines. Extension of poles shall be by use of ISLC 100(100x50x6mm) rolled galvanized channel up to three meters. An overlap of one meter shall be maintained with the pole. Wherever such extended poles will be used the span on both sides of the extension pole shall be suitably reduced to take care of loading on the pole. PROVIDING OF GUYS/STRUT POLES TO SUPPORTS The arrangement for guys shall be as per REC Construction standard G1 for PCC poles. Strut poles/flying guys wherever required shall be installed on various pole locations as per REC construction standards .For selection of guying locations REC guidelines & construction practices & IS :5613 shall be followed. The stay rod should be placed in a position so that the angle of rod with the vertical face of the pit is 300/450 as the case may be. In this work anchor type guy sets are to be used. These guys shall be provided at (i) Angle locations (ii) Dead end locations (iii) T-off points (iv) Steep gradient locations. (v) Double Pole, & four poles (vi) Wind stays along tangent locations at 40% of pole locations (vii) For double pole structure (DP), four stays along the line, two in each direction and two stays along the bisection of the angle of deviation (or more) as
RGGVY WORKS STANDARD TECHNICAL SPECIFICATION (REV.- 03) TECHNICAL SPECIFICATION VOL-II (PART-B) CHAPTER-II SECTION-E0
2.02.04
2.03.00 2.03.01
2.03.02
2.030.03 3.00.00 3.01.00
3.02.00
Page 6 of 18
CLAUSE NO.
required depending on the angle of deviation are to be provided. Hot dip galvanized stay sets are to be used. 3.03.00 3.04.00 3.05.00 G.I. stay wires of size 7/3.15 mm (10 SWG) with GI turn buckle rod of 16 mm dia & 16 mm dia GI stay stay rods, shall be used for 11KV & LT line. G.I. stay wires of size 7/4 mm with GI turn buckle rod of 20 mm dia & 20 mm dia GI stay rods shall be used for 33 KV line. Precast RCC anchor plate as per REC construction standard K1 shall be used for the purpose of anchoring the guy rod with a bolt arrangement at one end and other end is given shape of 40mm dia circle to bind one end of the stay wire. The size of the stay pit shall be 500mmx500mmx1600mm with concrete mix of 1:2:4 having volume in stay pit of 800x500x500=0.2 cubic mtr for embedding RCC stay plate assembly and the balance pit to be filled with earth duly rammed. In case of firm soil, concreting is not required. The turn buckle shall be mounted at the pole end of the stay and guy wire so fixed that the turn buckle is half way in the working position, thus giving the maximum movement for tightening or loosening. If the guy wire proves to be hazardous, it should be protected with suitable asbestos pipe filled with concrete of about 2 m length above the ground level, painted with white and black strips so that, it may be visible at night. CROSS ARMS Cross Arms for 33 KV and 11 KV Overhead Power Lines shall be made out of 100x50x6 mm and 75 x 40 x6 mm M.S. channel. Cross Arms made out of M.S. angle shall not be used. Cross arms shall conform to specification given under the head miscellaneous items in this specifications. For 33 KV line, cross arms a MS strip of 100x50x5 mm shall be welded for providing additional mechanical strength at the seat of the pin insulator Fixing of Cross Arms After the erection of supports and providing guys, the cross-arms are to be mounted on the support with necessary clamps, bolts and nuts. The practice of fixing the cross arms before the pole erection can also be followed. In case, the cross-arm shall be mounted after the pole is erected, the lineman should climb the pole with necessary tools. The cross-arm shall then tied to a hand line and pulled up by the ground man through a pulley, till the cross-arm reaches the line man. The ground man should station himself on one side, so that if any material drops from the top of the pole, it may not strike him. All the materials should be lifted or lowered through the hand line, and should not be dropped.
3.06.00
3.06.00 3.07.00
3.08.00
4.00.00 4.01.00
4.01.01
4.02.00
Page 7 of 18
CLAUSE NO.
5.00.00 5.01.00 5.01.01
INSTALLATION OF LINE MATERIALS Insulator and Bindings Porcelain or composite insulators as per specification given elsewhere in this volume shall be used. Prior to fixing, all insulators shall be cleaned in a manner that will not spoil, injure or scratch surface of the insulator, but in no case shall any oil be used for that purpose. Pin insulators shall be used on all poles in straight line and disc or shackle insulators on angle and dead end poles.
5.01.02
Strain insulators shall be used at line sectionalizing locations, dead end locations, major crossings and locations where the angle of deviation of line is more than 100. For 11KV lines Tong & Clevis type strain insulator with fittings shall be used & for 33KV lines Ball & Socket type strain insulators with fittings shall be used. The pins for insulators shall be fixed in the holes provided in the cross-arms and the pole top brackets. The insulators shall be mounted in their places over the pins and tightened. In the case of strain or angle supports, where strain fittings are provided for this purpose, one strap of the strain fittings is placed over the cross-arm before placing the bolt in the hole of cross-arms. The nut of the straps shall be so tightened that the strap can move freely in horizontal direction. For LT lines, with bare conductor, shackle insulator shall be used. These shall be as per REC construction standard drawing Nos. B-2 (Protective Guard Type), and B-6 for 3 Ph-4 wire lines. For single phase lines, the same shall be as per REC construction standard No. B-15. Helical Fittings Helically formed fittings conforming to REC standard No-25 shall be used for 11KV & LT lines.
5.01.03
5.01.04
5.01.05
5.02.00 5.02.01
Handling of Conductor and Earth wire Running Out of the Conductors: The contractor shall be entirely responsible for any damage to the pole or conductors during stringing. Care shall be taken that the conductors do not touch and rub against the ground or objects, which could scratch or damage the strands. The sequence of running out shall be from the top to down i.e. the top conductor shall be run out first, followed in succession by the side conductors. Unbalanced loads on poles shall be avoided as far as possible. When lines being erected run parallel to existing energized power lines, the Contractor shall take adequate safety precautions to protect personnel from the potentially dangerous condition.
5.02.02
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5.03.00
Monitoring of Conductors during Stringing The conductor shall be continuously observed for loose or broken strands or any other damage during the running out operations. Repair to conductors, if necessary, shall be carried out with repair sleeves. Repairing of the conductor surface shall be carried out only in case of minor damage, scuff marks, etc. The final conductor surface shall be clean, smooth and free from projections, sharp points, cuts, abrasions, etc. The Contractor shall be entirely responsible for any damage to the poles during stringing.
5.04.00 5.04.01
Crossings All crossings shall be at right angles. Derricks or other equivalent methods ensuring that normal services need not be interrupted nor damage caused to property shall be used during stringing operations where roads, channels, telecommunication lines, power lines and railway lines have to be crossed. The contractor shall coordinate with state electricity board for obtaining work permit and shut down of the concerned line. However. shut down shall be obtained when working at crossings of overhead power lines. The Contractor shall be entirely responsible for the proper handling of the conductor, earthwire and accessories in the field. Guarding shall be provided at all crossings. The Guardings shall consists of GI guard cross arm of length 2.5 mtrs made out of 75 x 40 x 6 mm channel & shall be hot dipped galvanized generally conforming to IS:2633/72. The clamps shall also be hot dipped galvanized generally conforming to IS:2633/72. Guardings shall be erected with ground & line clearances as per the I.E. rules. The guarding shall be provided with GI wire 8 SWG for 11KV & LT line & 4 SWG for 33KV line. Binding wire & suitable I bolt & nut bolts for cross arm to cross arm. Guard wire shall be separately earthed at both ends. Protective guarding for 33KV, 11 kV & LT lines crossing the roads / canals or any other lines shall be as per REC construction standards M6, A1& B1 respectively. 11kV railway line crossing shall be constructed by using two runs of XLPE insulated armoured UG cable of 3Cx185sq. mm. aluminium conductor. For the purpose DP structure with PCC poles shall be erected at both ends of railway crossing. The incoming DP structure shall have 400 Amp AB switch arrangement. The cable shall be routed through GI pipe & clamped to the pole. The bidder should include the cost of all structural material, channel, clamps, connectors, hardware & accessories like anticlimbing device, danger board, earthling arrangement, insulators, AB switch & support structures for AB switch, etc except PCC poles. The cost of cable shall include the cable cost along with the cost for termination kits. Arrangement for river crossing along the existing bridge, on galvanized MS Angle support, clamping, cleating and fixed support, shall be adopted. The arrangement drawing shall be prepared and got approved from the Owner/Consultant before actual execution of work. Fixing of Angle support on the bridge shall be adopted with proper safety precautions and approval of the local authority. In case of multiple Cables, separate tier support is to be provided on the entire length of the bridge. Any masonry
5.04.02
5.04.03
5.04.04
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or PCC work required after fixing of the support clamp/Angle shall be covered in scope of work. Any welded part of angler to the steel reinforcement of the bridge shall be painted with three coats of Anti-corrosive Zinc paint. DP structure with PCC poles shall be erected at both ends of river crossing. The incoming DP structure shall have AB switch arrangement the cable shall be clamped to the pole through GI pipe. The bidder should include the cost of DP structure with PCC pole along with all structural material, channel, clamps, connectors, hardware & accessories like anticlimbing device, danger board, earthling arrangement, insulators. AB switch & support structures for AB switch etc. The cost of cable shall include the cable cost long with the cost for termination and jointing Kits. 5.05.00 Anti-climbing Devices Anti Climbing Devices shall be provided with G.I. Barbed wire, they shall be provided and installed by the Contractor for all poles. The barbed wire shall conform to IS:278 (Grade A1). The barbed wires shall be given chromating dip as per procedure laid down in IS:1340. 5.06.00 Painting Materials All the metal parts except G.I. parts are to be painted with one coat of red oxide and one coat of aluminium paint to the satisfaction of the Engineer-in-Charge. 6.00.00 6.00.01 STRINGING OF CONDUCTOR The works include spreading of conductors or HT/LT AB Cables without any damage and stringing with proper tension without any kinks/damage including binding of conductor at pin points, jumpering at cut points etc. The ground & line clearances at road crossings along roads, L.T. crossings & other crossings shall be as per the relevant I.E. rules. While transporting conductors drums to site, precautions are to be taken so that the conductor does not get damaged. The drum shall be mounted on cable drum support. The direction of rotation of the drum shall be according to the mark in the drum so that the conductor could be drawn. While drawing the conductor, it shall not rub causing damage. The conductor shall be passed over poles on wooden or aluminium snatch block (pulley) mounted on the poles for this purpose. The conductor shall be pulled through come-along clamps to stringing the conductor between the tension locations. Conductor splices shall not crack or otherwise be susceptible to damage in the stringing operation. The Contractor shall use only such equipment / methods during conductor stringing which ensures complete compliance in this regard. All the joints including mid span joints on the conductor and earth-wire shall be of the compression type, in accordance with the recommendations of the manufacturer, for which all necessary tools and equipment like compressors, dies, etc., shall be obtained by the Contractor. Each part of the joint shall be cleaned by wire brush till it is free of rust or dirt, etc., and be properly greased with anti-corrosive compound,
6.00.02
6.00.03 6.00.04
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before the final compression is carried out with the compressors. After completing the jointing, tensioning operation shall be commenced. 6.00.05 All the joints or splices shall be made at least 15 meters away from the pole. No joints or splices shall be made in spans crossing over main roads, railways and small river spans. Not more than one joint per sub-conductor per span shall be allowed. The compression type fittings shall be of the self centering type. After compressing the joint, the aluminium sleeve shall have all corners rounded; burrs and sharp edges removed and smoothened. During stringing of conductor to avoid any damage to the joint, the contractor shall use a suitable protector for mid span compression joints in case they are to be passed over pulley blocks / aerial rollers. The pulley groove size shall be such that the joint along with protection can be passed over it smoothly. Permitted Extra Consumption of Contractor Supplied Materials The quantities of conductor, insulator, earth-wire, hardware fittings, conductor & earth-wire accessories indicated in BPS are tentative and actual quantity will depend upon final survey (check survey). Payment for contractor supplied line materials shall be made for the quantities incorporated in the works plus permitted extra quantities as mentioned below Contractor shall make every effort to minimise the breakage, losses and wastage of the line material during erection. However the Contractor shall be permitted the extra consumption upto the limit as specified in the table below and shall be permitted to dispose of the scrap, if any, at their end. Note: Sl. No. 1 3 4 Item Conductor HT & LT ABC Cable Cable(Power & service wire) % of Permitted Consumption 1 1 1 Extra
6.00.06
6.00.07
In case of conductor the permitted extra consumption limit of 1% is inclusive of sag, jumpering, damages, losses & wastage. The Contractor shall not be required to return to the Purchaser empty conductor/earthwire left over drums and shall dispose of the same at his cost 6.01.00 6.01.01 Tensioning and Sagging Operations The tensioning and sagging shall be done in accordance with the stringing charts or sag tables provided in REC standard. The initial stringing chart shall be used for the conductor and final stringing chart for the earth-wire. The conductors shall be pulled up to the desired sag and left in running blocks for at least one hour after which the sag shall be rechecked and adjusted, if necessary, before transferring the
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conductors from the running blocks to the suspension clamps. The conductor shall be clamped within 36 hours of sagging in. 6.01.02 The sag will be checked in the first and the last section span for sections up to eight spans and in one additional intermediate span for sections with more than eight spans. The sag shall also be checked when the conductors have been drawn up and transferred from running blocks to the insulator clamps. At sharp vertical angles, conductor and earth-wire sags and tensions shall be checked for equality on both sides of the angle and running block. The suspension insulator assemblies will normally assume verticality when the conductor is clamped. Tensioning and sagging operations shall be carried out in calm weather when rapid changes in temperature are not likely to occur. Clipping in Clipping of the conductors into position shall be done in accordance with the manufacturers recommendations. Jumpers at section and angle towers shall be formed to parabolic shape to ensure maximum clearance requirements. Fasteners in all fittings and accessories shall be secured in position. The security clip shall be properly opened and sprung into position. 6.03.00 Fixing of Conductors and Earthwire Accessories Conductor and earth-wire accessories supplied by the Contractor shall be installed by Contractor as per the design requirements and manufacturers instruction within 24 hours of the conductor / earth-wire clamping. While installing the conductor and earth-wire accessories, proper care shall be taken to ensure that the surfaces are clean and smooth and that no damage occurs to any part of the accessories or of the conductors. 6.04.00 Replacement If any replacements are to be effected after stringing and tensioning or during maintenance e.g. replacement of cross arms, the conductor shall be suitably tied to the pole at tension points or transferred to suitable roller pulleys at suspension points. 7.00.00 7.01.00 7.01.01 TAPPING ARRANGEMENT FROM EXISTING 11KV LINE Single pole tapping arrangement Tapping of existing 11kV line shall be taken by providing a horizontal cross arm below the existing V cross arm of the pole & mounting disc insulators on it. The tapping conductors shall be guided by providing pin insulators as required. If the existing pole is found weak or unsuitable for tapping a new pole may be erected for the purpose. A new two pole structure shall be erected within 10-15 meters of this tapping pole & the new line will emerge from this two pole structure with disc insulators. The Taping pole to the double pole conductor tension should be such that it avoids looseness & sag to the extent possible & it should avoid extra tension on the tapping
6.01.03
6.02.00
7.01.02
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pole. However if the new line length emanating from the taping pole is less than 300 mtrs this double pole structure shall not be used. 7.02.00 Double pole tapping arrangement As an alternative to single pole tapping arrangement double pole tapping arrangement may also be adopted depending on the convience of locating the double pole. 8.00.00 RECONDUCTORING OF EXISTING 11kV LINES The Standard Technical Specification & General Constructional Practices for various equipments / material as given in Part-B, Chapter-II shall be applicable for Reconductoring work. 8.01.00 Survey shall be carried out by the contractor for the existing line which shall be reconductored. Damaged poles & pole accessories like V cross arms, insulators, stay sets, hardware, anti climbing devices, earthing arrangements etc shall be replaced. Re-conductoring of 11 kV line shall be done with appropriate conductor, as per the requirement given in the Bid Proposal Sheet (BPS). In addition, all the defective/damaged poles, cross arms, hardware fittings, disc/pin insulators, stay set, earthing and other materials required to be replaced during Re-conductoring shall be in the scope of the bidder. Erection of new poles & failure containment structures (normally DP/ four pole structure) as per the requirements shall be done keeping in view use of new conductor size & span. Such failure containment structures are generally required at the following points and are in the scope of contractors work. i) ii) iii) iv) At the tapping points or at the first structure immediately after tapping. At points where a DT is installed/to be installed. At angle points i.e. with diversion angle of 10-60 degree. At the distance of 1.6 km from the last DP.
8.02.00
8.03.00
8.04.00
Four Pole structures shall be used as per REC construction Dwg. No. A-10 (for the diversion angle of 60-90 degree). 8.05.00 The dismantled conductor are to be rewound in the wooden drums (which are to be a arranged by the contractor at his own cost) with proper care and returned to the store of owner as per the direction of the Engineer-in-charge with transit insurance and proper accounting details. Similarly, any rail pole, which is dismantled but not to be reused in line shall also be returned to the store of owner as per the direction of the
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Engineer-in-charge with transit insurance and proper accounting details in duly filled prescribed format. The insurance for dismantled conductor and rail poles shall be arranged by the contractor in consultation/approval of the Employer for which insurable values shall be intimated by the Employer and the insurance premium shall be borne by the contractor. All other materials, like PCC poles, cross-arms and other structural materials, insulators, GI wire, earthing set, stay set etc., which are dismantled but not to be reused in the line, shall be disposed off by the contractor. The bidder shall appropriately consider this aspect while pricing their bid and no adjustment in price, whatsoever, shall be done during execution of the contract. 8.06.00 Aligning/re-erection of tilted/bent poles wherever found in the route of line along with strengthening of its foundation is in the scope of the bidder. Before undertaking the Re-conductoring work in the given line, the bidder shall make assessment of type and quantity of the existing conductor in consultation/presence of owners representative. While Re-conductoring of 11 kV line, disconnection/connection of existing Distribution Transformer shall be in the scope of the contractor/bidder. The supply and erection of line material for achieving the DT disconnection and connection shall be in the scope of the contractor. Empty conductor drums, available after laying of conductor, shall be disposed of by the contractor at his cost. These drums may be used for rewinding of Conductor removed from the line at the later stage of Re-conductoring work. Any other work not mentioned above exclusively but required for accomplishing desired work will be in the scope of the bidder/contractor. For all above activities shut down will be provided for the line by owner. Restoring the disturbance/damage caused by above activities to the existing infrastructure e.g. road, water/sewerage pipes, telecommunication lines etc. will be in the scope of the bidder/contractor. While repairing & replacing the equipment, if any equipment gets damaged due to negligent handling of the contractor the same shall be replaced by the contractor, at his cost, to the owner/employers satisfaction. Survey of existing lines Survey shall be carried out by the contractor of existing lines.The details/requirement of HT and LT lines shall be provided to successful bidder during detailed engineering. Approximate requirement is enclosed in the bid document. These overhead lines shall be mainly routed over private property, public utility areas. Hence, the contractor should carry out site work with due care and attention to avoid any type of inconvenience to land owner or public. In the course of surveying by the contractor, any conspicuous variation in route length of the line shall be brought to the notice of
RGGVY WORKS STANDARD TECHNICAL SPECIFICATION (REV.- 03) TECHNICAL SPECIFICATION VOL-II (PART-B) CHAPTER-II SECTION-E0
8.07.00
8.08.00
8.09.00
8.10.00
8.11.00
8.12.00
8.13.00
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Engineer in charge. The Employer, if considers this variation unavoidable, shall make necessary alteration in line route which shall be carried out accordingly and revised route map shall be submitted for owners approval by the contractor. 8.14.00 Span Since the work shall be done on the existing line, the existing span shall be maintained. However, if any new pole is required to be erected along the route of existing line, the span should be as near as possible to the basic design span indicated elsewhere in the specification depending on the conductor size, pole & wind pressure zone. 8.15.00 8.15.01 Type of Conductor & Conductor Configuration AAAC/ACSR of nominal cross section of sq. mm. 50 shall generally be used for reconductoring of 11 kV line. Specific type of conductor to be used shall be as specified in the Bid Proposal Sheet. The 11 kV feeder reconductoring shall be a 3 phase 3 wire systems. Conductor configuration shall be as be as per existing configuration before reconductoring. L.T. LINE ARRANGEMENT LT lines shall be constructed with AAAC/ ACSR (nominal cross sectional area of 30 sq. mm.) ,AAC( nominal cross sectional area of 25 sq. mm.) or Aerial Bunched Cable type Conductor (ABC) with Messenger wire for Support at each of the Pole as per the final line route to be decided based on survey & as per REC construction standard. The PCC poles, to be used for this purpose shall be of 8.0 mtrs height. Pole footing arrangement shall be identical to the other similar poles described in this specification. For LT lines with ABC , instead of Cross arms and insulator, these poles shall have eye hook & insulated Suspension & dead end clamp arrangement for anchoring of bearer wire associated with ABC line. These shall be generally as per the REC Construction Standard: E-34 & E-35 but with insulation. For tapping of ABC line to ABC line piercing connectors as per technical specification described else where shall be used. The loose end of the ABC cable shall be capped & sealed with PVC cap & silicone based adhesive or any other weather proof adhesive. For tapping of existing bare conductor line to ABC line connectors as per REC standard E-36(With cover) shall be used Locations, where single or 3 phase 4 wire LT lines have to cross important through fare (Main Road, HT line etc.), the line shall be on poles with horizontal configuration. These shall be as per REC construction standard drawing No. B-1 (guard wire with cross lacing) and clearances as per IE Rule. Suitable extension arrangement shall be provided to maintain the clearances and sags with guarding arrangement.
8.15.02 9.00.00 9.01.00
9.02.00
9.03.00 9.04.00 9.05.00 9.06.00
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10.00.00 10.00.01
COMPOSITE NEW LINES Where ever composite lines are envisaged the same shall have the following configurations using 8 mtr poles. 1) 2) 11KV three phase line with triangular formation of bare conductor & LT line with ABC. 11KV three phase line with ABC & LT line with ABC
10.00.02 11.00.00 11.01.00
Where 11KV line with bare conductor & LT line with bare conductor to be used as composite lines, 9 mtr poles shall be used . FINAL CHECKING, TESTING AND COMMISSIONING After completion of the works, final checking of the line shall be carried out by the Contractor to ensure that all foundation works, pole erection and stringing have been done strictly according to the specifications and as approved by the Owner. All the works shall be thoroughly inspected in order to ensure that: i) ii) iii) iv) v) vi) Sufficient backfilled earth covers each foundation pit and is adequately compacted. All poles are used strictly according to final approved drawing and are free of any defect or damage whatsoever. The stringing of the conductors has been done as per the desired clearances. All conductor accessories are properly installed. All other requirements for completion of works such as fixing of danger plate and anti-climbing device have been fulfilled. The insulation of the line as a whole is tested by the Contractor through provision of his own equipment, labour, etc., to the satisfaction of the Purchaser.
vii) All poles are properly grounded. viii) The line is tested satisfactorily for commissioning purpose. 12.00.0 SIGN BOARD A sign board as shown below shall be erected at a suitable location, preferably near the office of Sarpanch/gram panchayat /or any other prominent location of the village indicating the village has been electrified under RGGVY. Such boards shall be installed in all the Un-electrified villages where the works have been completed or about to complete.
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12.03.01
SPECIFICATION OF THE BOARD
Components 1 2 3 4 Iron sheet Size of Iron sheet Iron angle Painting on board
Desired specification MS 16Gauge(1.6..) 4ftX3ft 50X50X5 mm Two coats of enmel over one coat of red oxide Coulered printing by screen printing method or equivalent 4ft
Printing on board
Height of board from ground Length of angle to be insertedinside ground
1.5ft with 1 ft hole pass
The language shall be Devnagari & English for Hindi speaking states ; vernacular & English for other states.
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PCC POLES SCOPE This specification covers design, manufacture, testing before despatch, packing, transportation and delivery of Pre stressed Cement Conctrete (PCC) poles suitable for use in overhead power lines.
1.00.00
2.00.00
APPLICABLE STANDARDS The poles shall comply with the latest issues of following standards: a) b) c) d) e) REC Specification No. 15/1979 PCC Poles for 11kV LT Line RCC Specification No. 24/1983 PCC Poles for 33kV Line IS: 1678, Specification for prestressed concrete poles for overhead power, traction and telecommunication lines. IS: 2905, Methods of test for concrete poles for over-head power and telecommunication lines. IS: 7321, Code of practice for selection, handling and erection of concrete poles for over-head power and telecommunication lines.
3.00.00 3.01.00
MATERIALS CEMENT The cement used in the manufacture of prestressed concrete poles shall be of any one type given below. (i) 43 grade Ordinary Portland Cement (OPC) conforming to IS :8112. (ii) 53 grade OPC conforming to IS:12269. (iii) Rapid hardening Portland cement conforming to IS : 8041 E .
3.02.00
AGGREGATES Aggregates used for the manufacture of pre-stressed concrete poles shall conform to IS: 383 (specification for coarse and fine aggregates from natural sources for concrete). The nominal maximum size of aggregate shall in no case exceed 12 mm.
3.03.00
WATER Water should be free from chlorides, sulphates, other salts and organic matter. Potable water will be generally suitable.
CHAPTER-II SECTION-E1 PCC POLES
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PCC POLES ADMIXTURES Admixtures conforming to IS:9103, free from any type of chlorides & and salts may be used with prior approval of the owner.
3.04.00
3.05.00
PRESTRESSING STEEL The pre-stressing steel wires, including those used as un-tensioned wires, shall conform to any one of the following standards. (i) IS:1785 (Part-I) (Specification for plain hard-drawn steel wire for prestressed concrete. PartI cold drawn stress relieved wire), IS:1785 (PartII) (Specification for plain hard-drawn steel wire), IS:6003 (Specification for indented wire for pre-stressed concrete).
(ii) (iii) 4.00.00
CONCRETE MIX The concrete mix shall be designed to the requirements laid down for controlled concrete (also called design mix concrete) in IS : 1343 (code of practice for prestressed concrete) and IS: 456 (code of practice for plain and reinforced concrete), subject to the following special conditions; a) b) c) d) Minimum compressive strength of cube at 28 days should be at least 400 kg/cm2. The concrete strength at transfer should be at least 200 kg/cm2. The mix should contain at least 380 kg. of cement per cubic meter of concrete. The mix should contain as low water content as is consistent with adequate workability. If it becomes necessary to add water to increase the workability, the cement content also should be raised in such a way that the original value of water cement ratio is maintained.
5.00.00 5.01.00
DESIGN REQUIREMENTS The poles shall be designed for the following requirements: a) The planting depth of poles shall be as per IS:1678 and a depth marker shall be provided at adistance of planting depth from the bottom of the pole for verification of erected pole, at site. For poles between 7.5mtr to 9mtr the palnting depth shall be 1.5 meters. The working load on the poles should correspond to those that are likely to come on the pole during their service life.
b)
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PCC POLES c) d) e) f) g) h) i) The factor of safety for poles upto 8 mtrs shall not be less than 2.5 & that for 9mtr shall not be less than 2. The F.O.S. against first crack load shall be 1.0. At average permanent load, permissible tensile stress in concrete shall be 30 kg. /cm2. At the design value of first crack load, the modules of rupture shall not exceed 53.0 kg/cm2 for M-40 concrete. The ultimate moment capacity in the longitudinal direction should be at least one fourth of that in the transverse direction. The maximum compressive stress in concrete at the time of transfer of prestress should not exceed 0.8 times the cube strength. The concrete strength at transfer shall not be less than half the 28 days strength ensured in the design, i.e. 400 x 0.5 = 200 kg. /cm2.
5.02.00
Dimensions and Reinforcements The cross-sectional dimensions and the details of prestressing wire should conform to the particulars given in ANNEXURE-1. However any change in external dimension as per the practices being followed in state Utilities may be acceptable subject to meeting all other requirements specified in this specification. The provisions of holes for fixing cross-arms and other fixtures should conform to the REC specification 15/1979 for 11kV & LT line No24/1983 for 33kV line.
6.00.00 6.01.00
MANUFACTURE All pre-stressing wires and reinforcements shall be accurately fixed as shown in the drawings and maintained in position during manufacture. The un-tensioned reinforcement, as indicated in the drawings, should be held in position by the use of stirrups, which should go round all the wires. All wires shall be accurately stretched with uniform pre-stress in each wire. Each wire or group of wires shall be anchored positively during casting. Care shall be taken to see that the anchorages do not yield before the concrete attains the necessary strength. COVER The cover of concrete measured from the outside of the pre-stressing tendon shall be normally 20 mm.
6.02.00
6.03.00
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PCC POLES WELDING AND LAPPING OF STEEL The high tensile steel wire shall be continuous over the entire length of the tendon. Welding shall not be allowed in any case. However, jointing or coupling may be permitted provided the strength of the joint or coupling is not less than the strength of each individual wire.
6.04.00
6.05.00
COMPACTING Concrete shall be compacted by spinning, vibrating, shocking or other suitable mechanical means. Hand compaction shall not be permitted.
6.06.00 6.06.01
CURING The concrete shall be covered with a layer of sacking, canvas, Hessian or similar absorbent material and kept constantly wet up to the time when the strength of concrete is at least equal to the minimum strength of concrete at transfer of prestress. Thereafter, the pole may be removed from the mould and watered at intervals to prevent surface cracking of the unit; the interval should depend on the atmospheric humidity and temperature. The presstressing wires shall be detensioned only after the concrete has attained the specified strength at transfer (i.e. 210 kg/cm2). The cubes cast for the purpose of determining the strength at transfer should be cured, as far as possible, under conditions similar to those under which the poles are cured. The transfer stage shall be determined based on the daily tests carried out on concrete cubes till the specified strength indicated above is reached. Thereafter the test on concrete shall be carried out as detailed in IS: 1343 (code of practice for prestressed concrete). The manufacturer shall supply when required by the purchaser or his representative, result of compressive test conducted in accordance with IS: 456 (code of practice for plain and reinforced concrete) on concrete cubes made from the concrete used for the poles. If the purchaser so desires, the manufacturer shall supply cubes for test purposes and such cubes shall be tested in accordance with IS: 456 (code of practice for plain and reinforced concrete). The detensioning shall be done by slowly releasing the wires, without imparting shock or sudden load to the poles. The rate of detensioning may be controlled by any suitable means either mechanical (screw type) or hydraulic. The poles shall not be detensioned or released by cutting the prestressing wires using flames or bar croppers while the wires are still under tension. LIFTING EYE-HOOKS OR HOLES Separate eye-hooks shall be provided for handling and transport, one each at a distance of 0.15 times the overall length from either end of the pole. Eye-hooks, if provided, should be properly anchored and should be on the face that has the shorter
6.06.02
6.06.03
6.07.00
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PCC POLES dimension of the cross-section. Holes, if provided for lifting purposes, should be perpendicular to the broad face of the pole.
6.08.00 6.08.01
Stacking & Transportation Stacking should be done in such a manner that the broad side of the pole is vertical. Each tier in the stack should be supported on timber sleepers located at 0.15 times the overall length, measured from the end. The timber supports in the stack should be aligned in a vertical line. Poles should be transported with their broad faces placed vertically and in such a manner that shocks are avoided. Supports should be so arranged that they are located approx. at a distance equal to 0.15 times the overall length from the ends. The erections of the pole should be carried out in such a way that the erection loads are applied so as to cause moment with respect to the major axis. i.e. the rope used for hoisting the pole should be parallel to the broader face of the pole. EARTHING Earthing shall be provided by having a length of a 8 SWG GI wire embedded in concrete during manufacture and the ends of the wires left projecting from the pole to a length of 150 mm. at 250 mm. from top and 300 mm below ground level. The earth wire shall not be allowed to come in contact with the prestressing wires.
6.08.02
6.09.00
7.00.00 7.01.00 7.01.01
TESTS Transverse Strength Test Poles made from ordinary Portland cement shall be tested only on the completion of 28 days and poles made from rapid-hardening cement only on the completion of 14 days, after the day of manufacture. The pole may be tested in either horizontal or vertical position. If tested in horizontal position, provisions shall be made to compensate for the overhanging weight of the pole, for this purpose the over-hanging portion of the pole may be supported on a movable trolley or similar device. The pole shall be rigidly supported at the butt end for a distance equal to the agreed depth of planting i.e. 1.5 M. Load shall be applied at a point 600 mm from the top of the pole and shall be steadily and gradually increased to design value of the transverse load at first crack. The deflection at this load shall be measured. A prestressed concrete pole shall be deemed not to have passed the test if visible cracks appear at a stage prior to the application of the design transverse load for the first crack.. The load shall then be reduced to zero and increased gradually to a load equal to the first crack load plus 10% of the minimum ultimate transverse load, and held up for 2 minutes. This procedure shall be repeated until the load reaches the value of 80% of
TECHNICAL SPECIFICATION VOL-II (PART-B) CHAPTER-II SECTION-E1 PCC POLES Page 5 of 8
7.01.02
7.01.03
7.01.04
CLAUSE NO.
PCC POLES the minimum ultimate transverse load and thereafter increased by 5 % of the minimum ultimate transverse load until failure occurs. Each time the load is applied, it shall be held for 2 minutes. The load applied to prestressed concrete pole at the point of failure shall be measured to the nearest five Kg.
7.02.00 7.02.01
Measurement of Cover After completion of the transverse strength test, the sample pole shall be taken and checked for cover. The cover of the pole shall be measured at 3 points, one within 1.8 meters from the butt end of the pole, the second within 0.6 meter from the top and the third at an intermediate point and the mean value compared with the specified value. The mean value of the measured cover should not differ by more than 1 mm from the specified cover. The individual values should not differ by more than 3 mm from specified value. If these requirements are not met, the workmanship with reference to aligning of the end plates and prestressing wires and assembly of moulds should be improved and inspection at pre-production stage tightened suitably. SAMPLING AND INSPECTION Scale of Sampling Lot: In any batch, all poles of the same class and same dimensions shall be grouped together to constitute a lot. Sub-lot: If the number of poles in a lot exceeds 500, the lot shall be divided into a suitable number of sub lots such that the number of poles in any sub-lot shall not exceed 500. The acceptance or otherwise of sub-lot shall be determined on the basis of performance of samples selected from it. The number of poles to be selected from a lot or a sublot shall depend upon its size and shall be in accordance with Col. 1 and 2 of the following table: SAMPLE SIZE AND CRITERION FOR CONFORMITY Size of lot or sub-lot Dimensional Requirement Sample Permissible No. size of defective samples (2 ) (3 ) 10 1 15 1 20 2
7.02.02
7.02.03
8.00.00 8.01.00 8.01.01
8.01.02
8.01.03
No. of poles for transverse strength test (4 ) 2 3 4

CHAPTER-II SECTION-E1 PCC POLES Page 6 of 8
(1 ) Upto 100 101 to 200 201 to 300

CLAUSE NO.
PCC POLES 301 to 500 30 3 5
8.01.04
These poles shall be selected at random. In order to ensure randomness, all the poles in the lot or the sub-lot may be arranged in a serial order and starting from any random pole, every nth pole may be included in the sample, being the integral part of N/n where N is the size of the lot or the sub-lot and n is the sample size. Number of Tests All the poles as selected shall be tested for overall length, cross-section and uprightness. The tolerance shall be 15 mm on overall length, 3 mm on cross sectional dimensions and 0.5 % on uprightness. The number of poles to be tested for transverse strength test shall be accordance with col. 4 of the above table. These poles may be selected from those already tested as per sampling procedure given in scale of sampling. Criteria for Conformity A lot of sub-lot shall be considered as conforming to this specification if the conditions are satisfied. The number of poles which does not satisfy the requirements of overall length, cross-section and uprightness shall not exceed the corresponding number given in Col. 3 of Table (Sample Size & criterion for conformity) if the number of such poles exceeds the corresponding number, all poles in the lot or sublot shall be tested for these requirements, and those not satisfying the requirements shall be rejected. All the poles tested for transverse strength test shall satisfy the requirements of the test. If one or more poles fail, twice the number of poles originally tested shall be selected from those already selected and subjected to the test. If there is no failure among these poles, the lot or the sub-lot shall be considered to have satisfied the requirement of this test. MARKING The pole shall be clearly and indelibly indented / with the following particulars during manufacture so has to be easily read after erection in position. a) b) c) d) e) Project Name : RGGVY/NESCL Month and year of manufacture Transverse strength of pole in kg. Makers serial no. and mark. Depth marker at 1.5 mtrs, from bottom to verify planting depth.
TECHNICAL SPECIFICATION VOL-II (PART-B) CHAPTER-II SECTION-E1 PCC POLES Page 7 of 8
8.02.00 8.02.01
8.02.02
8.03.00 8.03.01
8.03.02
9.00.00 9.01.00
CLAUSE NO.
LOAD IN KG
LENG TH OF POLE 8 290 270 315 355 365 395 405 225 100 20 0 225 100 20 0 185 100 16 0 185 100 16 0 115 105 12 2 4.45 105 100 10 2 4.50 145 90 12 2 3.95 40 N/mm2 40 N/mm2 40 N/mm2 40 N/mm2 40 N/mm2 40 N/mm2 40 N/mm2 2.5 2.5 2.5 2 2 2 2
140
BOT TOM DEP TH 275
TOP DEPT H IN mm 105
BREAD NO. OF TH IN TENSIO mm NED WIRES 90 8
NO. OF UNTEN SIONE D 2
LENGTH OF EACH UNTENSIO NED WIRE 4.7
MINIMU M CUBE STRENGT H ( 28 40 N/mm2
FACTO R OF SAFET Y 2.5
200
140
200
300
PCC POLES
ANNEXURE-I DESIGNS FOR PRESTRESSED CONCRETE POLES
DIAMETER OF PRESTRESSING WIRES = 4 mm WITH A MINIMUM ULTIMATE TENSILE STRENGTH OF 175 Kg/mm sq.
TECHNICAL SPECIFICATION VOL-II (PART-B) NOTE : 1.
9.5
300
400
9.5
400
CHAPTER-II SECTION-E1 PCC POLES Untensioned wires of the given length should be placed at the bottom end of the pole.
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CLAUSE NO.
AAAC, AAC & ACSR CONDUCTORS SCOPE This specification covers design, manufacture, testing before dispatch, supply and delivery of All Aluminium (AA), Aluminum Conductors Steel Reinforced (ACSR) All Aluminum Alloy (AAA) Conductors.
1.00.00
2.00.00
APPLICABLE STANDARD The Conductor shall strictly comply with the following Indian Standard Specification relevant to the conductor.
i) ii) iii) 3.00.00
IS : 398- Aluminium Coductors for Over head Transmission Purposes (Part-I):Aluminium Stranded Conductors IS :398- Aluminium Coductors for Over head Transmission Purposes (Part-II): Aluminium Conductors Galvanised steel reinforced IS :398- Aluminium Coductors for Over head Transmission Purposes(PartSpecification for Aluminium Alloy (Aluminium, Magnesium ,Silicon Type)
MATERIAL The conductors shall be of best quality and workmanship. The steel reinforced aluminum conductors shall be manufactured of hard drawn EC grade aluminum wires and high tensile galvanized steel wires of the sizes and with mechanical and electrical properties as specified in the Standard. The coating on the galvanized steel wires may be applied by the hot process or electrolytic process in accordance with IS : 4826-1968 (specifications for galvanized coating on round steel wires). AAA Conductor shall however be constructed of heat-treated aluminum magnesium silicon alloy wire. The wires shall be smooth and free from all imperfections such as spills and splits and rolling and wire drawing defects etc. resulting in reduction in cross-sectional area over the entire length. PHYSICAL PROPERTIES Physical properties shall conform to the relevant IS specifications. The wires of Aluminum Alloy Conductor shall be of heat treated aluminum, magnesium, silicon alloy having composition appropriate to the technical and electrical properties as specified in Table-I of IS : 398 (Pt-IV)/1994.
5.00.00
6.00.00
JOINTS IN WIRES a) Joints in strands shall be as permited by relevant IS.

AA , AAAC & ACSR CONDUCTORS
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CLAUSE NO.
AAAC, AAC & ACSR CONDUCTORS STRANDING The wires used in the manufacture of a stranded conductor before stranding satisfy all requirement of IS : 398 (Part- I, II & IV). The lay ratio of the layer shall be within the limit given In all construction, the successive layers shall have opposite directions of lay. The outer most layer being right handed. The wires in each layer shall be evenly and closely stranded.
7.00.00
9.00.00
PACKING AND MARKING The conductor shall be wound in non-returnable reels or drums conforming to IS : 1778-1961 (Specifications for reels and drums for bare wire) or the latest version thereof. The drums shall be marked with the following details :a) b) c) d) e) f) g) h) i) Manufacturers Name Trade mark, if any Drum No. & Identification Number Size of Conductor Number & lengths of pieces of Conductor on each Drum Gross Mass of the Packing Net Mass of Conductor ISI or relevant International Standard specification mark, if any. Project Name: RGGVY.
10.00.00
PACKING CONDITION The reels/drums shall be of such constructions as to assure delivery of conductors free from displacement and damage and should be able to withstand all stresses due to handling and the stringing operation so that the conductor surface is not dented, scratched or damaged in any way during manufacture, transport and erection. The conductor shall be properly lagged on the Drums. The conductor drum should be suitable for wheel mounting. Before reeling, cardboard or other suitable material shall be secured to the drum and inside flanges
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CLAUSE NO.
AAAC, AAC & ACSR CONDUCTORS of the drums. After reeling the conductor, the exposed surface should be wrapped with suitable soft material e.g. polythene sheet etc. across the flanges to protect the conductor from dirt, grit and damage during transportation and handling and also prevent ingress of rain water during storage/transport. All wooden components shall be manufactured out of seasoned wood of good quality free from defect that may materially weaken the component parts of the Drums. Preservative treatment for anti-termite/anti-fungus shall be applied to the entire drum with preservatives of a quality which is not harmful to the conductor.
11.00.00
STANDARD LENGTH AND GROSS WEIGHT OF CONDUCTOR The gross weight of each package shall not exceed to the following limits subject to a tolerance of +10%. Longer length shall be acceptable but short lengths of not less than 50% of the standard lengths, as indicated below, shall be acceptable to the max. extent of 10 % of the quantity ordered for each size. Conductor Size(Nominal area) in sq. mm. 20 to 35 50 80 100 Weight Length
1100 kg 1500 kg 1600 kg 2000 kg
2 km 1.7 km 1.3 km 1.1 km
12.00.00
TESTS All tests shall be carried out as per relevant IS
13.00.00
CHECKING AND VERIFICATION OF LENGTH OF CONDUCTORS The supplier/manufacturer of conductor should arrange for the inspection by the representative of the owner specially authorized for this purpose. At least 5% of the total number of Drums of conductors taken at random should be checked to ascertain the lengths of conductor adopting either of the following two methods :a) The drum along with the conductor should be weighed and six empty drums along with protective laggings & studs etc. normally used for winding the conductor should also be weighed. Net weight of the conductor should be calculated by subtracting the average weight of the six empty drums from
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CLAUSE NO.
AAAC, AAC & ACSR CONDUCTORS the gross weight of the conductor and drums. Having known the weight of the conductor, the length of the conductor can be computed. b) Arrangements should be made available in the works of the manufacturer for transferring the conductor from one reel to another at the same time measuring the length of the conductor so transferred by means of a metre. Percentage shortage if any in the length thus obtained and as declared by the agency in the packing list shall be applied to all the drums.
14.00.00
CHECK MEASUREMENT Where length of conductor is verified by weighment basis the determining factor will be length/weight ratio of the sample drums verified at the firms premises of the lot of which the drum under measurement at the consignees end forms a part. Wherever at the end of the consignee, length measurement machines are available, conductors shall be accepted by verification of lengths only and where the length measurement machines are not available, conductor shall be accepted on weighment basis. In case, where the recorded weight on the drum tallies with the measured weight at consignee end, then the conductor length shall be accepted as recorded on the drum. In other cases, the determining factor will be weight/length ratio of the sample(s) inspected at the firms premises of the lot of which the drum under measurement at the consignees end, forms a part. The factors of weight/length ratio shall however be made available to the consignee in the dispatch instructions itself. If such factors are not available due to some reasons, actual measurement of diameter shall be made and weight/length ratio shall be obtained for the purpose of computing length.
15.00.0
Guaranteed Technical parameters (GTP) The following gauranteed technical parameters shall be applicable\ PART-A SL.No Description 1 Type 2 Applicable standard i 3 i 4 i Indian Standard no. Chemical Composition of Raw Materials Grade of Aluminium ingots Aluminium Strands after stranding Diameter (mm) a)Nominal
Particulars AA Gnat 25 sq. mm 7/2.21mm IS 398 Part -1/1996 ;IS 5484;IS 4026 IS:398 Part I Grade-2 (99.6 % Al)
2.21
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CLAUSE NO.
AAAC, AAC & ACSR CONDUCTORS b)Maximum c)Minimum Minimum Breaking load of strand (kN) Minimum Breaking load of strand (kN) Maximum Resistance of 1km length ( Ohm) AAAC Stranded Conductor Minimum Breaking Load of Conductor (kN) Lay ratio of conductor D.C. resistance of conductor at 20 deg. C (Ohm/Km) Standard length of conductor (Meter) Tolerance on Standard length of conductor 2.24 2.18 0.65(After Stranding) 0.68(Before Stranding) 7.503
ii iii iv 5 i ii iii iv
4.52 10(Min) to 14(Max) 1.096 2000
v 6 7 i ii iii
Longer length than standard length shall be acceptable Direction of lay for outside layer Right Hand Conductor Drum As per IS:1778 Flange Diameter(mm) 1195 Barrel Diameter(mm) 600 Traverse(mm) 710 Type test reports (all mentioned in COMPLIED relevant clause)
Make shall be NESCL Corporate Quality Assurance(CQA) Approved SL.No 1 2 i 3 4 i Type Applicable standard Indian Standard no. Chemical Composition of Raw Materials Aluminium Strands after stranding Diameter (mm) a)Nominal b)Maximum c)Minimum Minimum Breaking load of strand (kN) Minimum Breaking load of strand (kN)
Description
Particulars AAA Weasel 34sq. mm 7/2.50mm IS 398 Part -4/1996 & 9997/1991 IS:9997
ii iii
2.5 2.53 2.47 1.44(After Stranding) 1.52(Before Stranding)

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CLAUSE NO.
AAAC, AAC & ACSR CONDUCTORS iv 5 i ii iii iv Maximum Resistance of 1km length ( Ohm) AAAC Stranded Conductor Minimum Breaking Load of Conductor (kN) Lay ratio of conductor D.C. resistance of conductor at 20 deg. C (Ohm/Km) Standard length of conductor (Meter) 6.845 10.11 10(Min) to 14(Max)
v 6 7 i ii iii
0.99 2000 Longer length than standard length shall be acceptable Tolerance on Standard length of conductor Direction of lay for outside layer Right Hand Conductor Drum As per IS:1778 Flange Diameter(mm) 1195 Barrel Diameter(mm) 600 Traverse(mm) 710 Type test reports (all mentioned in relevant COMPLIED clause)
Make shall be NESCL Corporate Quality Assurance(CQA) Approved SL.No 1 2 i 3 4 i Description Type Applicable Standard Indian Standard No. Chemical Composition of Raw Materials Aluminium Strands after stranding Diameter (mm) a)Nominal b)Maximum c)Minimum Minimum Breaking load of strand (kN) Minimum Breaking load of strand (kN) Maximum Resistance of 1km length ( Ohm) AAAC Stranded Conductor Minimum Breaking Load of Conductor (kN) Lay ratio of conductor D.C. resistance of conductor at 20 deg. C (Ohm/Km) Standard length of conductor (Meter)
Particulars AAA Rabbit 55sq.mm7/3.15mm IS 398 Part -4/1996 & 9997/1991 IS:9997
ii iii iv 5 i ii
3.15 3.18 3.12 2.29(After Stranding) 2.41(Before Stranding) 4.29 16.03 10(Min) to 14(Max)
iii iv
0.621 1700
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CLAUSE NO.
AAAC, AAC & ACSR CONDUCTORS Longer length than standard length shall Tolerance on Standard length of conductor be acceptable Direction of lay for outside layer Right Hand Conductor Drum As per IS:1778 Flange Diameter(mm) 1195 Barrel Diameter(mm) 600 Traverse(mm) 710 Type test reports (all mentioned in relevant COMPLIED clause)
v 6 7 i ii iii
Make shall be NESCL Corporate Quality Assurance(CQA) Approved SL.No 1 2 i 3 4 i Type Applicable standard Indian Standard no. Chemical Composition of Raw Materials Aluminium Strands after stranding Diameter (mm) a)Nominal b)Maximum c)Minimum Minimum Breaking load of strand (kN) Minimum Breaking load of strand (kN) Maximum Resistance of 1km length ( Ohm) AAAC Stranded Conductor Minimum Breaking Load of Conductor (kN) Lay ratio of conductor D.C. resistance of conductor at 20 deg. C (Ohm/Km) Standard length of conductor (Meter) Description Particulars AAA Dog 100sq.mm7/4.26mm IS 398 Part -4/1996 & 9997/1991 IS:9997
ii iii iv 5 i ii iii iv
4.26 4.3 4.22 4.18(After Stranding) 4.40(Before Stranding) 2.345 29.26 10(Min) to 14(Max) 0.339 1100 Longer length than standard length shall be acceptable Right Hand As per IS:1778 1195 600 710
v 6 7 i ii iii
Tolerance on Standard length of conductor Direction of lay for outside layer Conductor Drum Flange Diameter(mm) Barrel Diameter(mm) Traverse(mm)
CLAUSE NO.
AAAC, AAC & ACSR CONDUCTORS Type test reports (all mentioned in relevant COMPLIED clause) Make shall be NESCL Corporate Quality Assurance(CQA) Approved SL.No 1 2 Description Type Applicable standard Particulars ACSR Panther 200sq.mm(30/7/3.00) IS 398 Part 2/1996,4026/1987 & 4826/1979;IS 5484 IS:4026 (Grade 2 ) IS:398 Part-2/1996
i 3 4 5 i
ii iii iv 6 i
Indian Standard no. Chemical Composition of EC Grade Aluminium Chemical Composition of Steel Aluminium Strands Diameter (mm) a)Nominal b)Maximum c)Minimum Minimum Breaking load of strand (kN) Minimum Breaking load of strand (kN) Maximum Resistance of 1km length ( Ohm) Steel Strands Diameter (mm) a)Nominal b)Maximum c)Minimum Minimum Breaking load of strand (kN) Minimum Breaking load of strand (kN) Type of Galvanising Mass of zinc coating and number of dips ACSR Stranded Conductor Maximum Resistance of 1km length ( Ohm) Minimum Breaking Load of Conductor (kN)
3 3.03 2.97 1.11(After Stranding) 1.17(Before Stranding) 4.079
ii iii 7 8 i ii
3 3.06 2.94 8.83(After Stranding) 9.29(Before Stranding) Heavily Coated Hard IS:4826 0.139 89.67 As per IS 398-P-II i.e. Steel core=13 to 28,Al-Outer most layer=10 to 14,AlLayer immediately beneath outer most layer=10 to 16 1000
iii iv
Lay ratio Standard length of conductor (Meter)

CLAUSE NO.
AAAC, AAC & ACSR CONDUCTORS Longer length than standard length shall Tolerance on Standard length of conductor be acceptable Direction of lay for outside layer Right Hand Conductor Drum As per IS:1778 Flange Diameter(mm) 1370 Barrel Diameter(mm) 600 Traverse(mm) 710 Type test reports (all mentioned in relevant COMPLIED clause)
v 9 10 i ii iii
Make shall be NESCL Corporate Quality Assurance(CQA) Approved SL.No Description Particulars ACSR Dog 100sq.mm(Al-6/4.72 Steel-7/1.57) IS 398 Part 2/1996,4026/1987 & 4826/1979;IS 5484 IS:4026 (Grade 2 ) IS:398 Part-2/1996
1 2
Type Applicable standard
i 3 4 5 i
ii iii iv 6 i
Indian Standard no. Chemical Composition of EC Grade Aluminium Chemical Composition of Steel Aluminium Strands Diameter (mm) a)Nominal b)Maximum c)Minimum Minimum Breaking load of strand (kN) Minimum Breaking load of strand (kN) Maximum Resistance of 1km length ( Ohm) Steel Strands Diameter (mm) a)Nominal b)Maximum c)Minimum Minimum Breaking load of strand (kN) Minimum Breaking load of strand (kN) Type of Galvanising Mass of zinc coating and number of dips ACSR Stranded Conductor Maximum Resistance of 1km length ( Ohm)
4.72 4.77 4.67 2.64(After Stranding) 2.78(Before Stranding) 1.65
ii iii 7 8 i
1.57 1.6 1.54 2.57(After Stranding) 2.7(Before Stranding) Heavily Coated Hard IS:4826 0.2792
CLAUSE NO.
AAAC, AAC & ACSR CONDUCTORS ii Minimum Breaking Load of Conductor (kN) 32.41 As per IS 398-P-II i.e. Steel core=13 to 28,Al-Outer most layer=10 to 14 1100 Longer length than standard length shall be acceptable Right Hand As per IS:1778 1195 600 710
iii iv
Lay ratio Standard length of conductor (Meter)
v 9 10 i ii iii
Tolerance on Standard length of conductor Direction of lay for outside layer Conductor Drum Flange Diameter(mm) Barrel Diameter(mm) Traverse(mm)
Make shall be NESCL Corporate Quality Assurance(CQA) Approved Type Tests to be performed on:S.No AAAC(IS:398 PIV) Breaking Load test of Indivisual Al Alloy Wire before stranding 1 Elongation test of Indivisual Al Alloy Wire 2 before stranding Resistance test of Indivisual Al Alloy Wire 3 before stranding ACSR(IS:398 P II) Breaking Load test on indivisual Al & Galvanised Steel wires before stranding Ductulity Test on galvanised Steel Wires Resistance test on Al Wires before stranding Wrapping Tests on indivisual wires of Al & Steel Measurement of dia. Of Al and Steel wires Galvanising Test Measurement of Lay Ratio/Direction of Lay Surface Condition Test on Conductor AAC(IS:398 PI) Measurement of diameter of aluminium wire Breaking load test of individual aluminium Wrapping test of aluminium wire Resistance test of aluminium wire Measurement of lay ratio
4 5 6 7 8
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AAAC, AAC & ACSR CONDUCTORS Test for Ultimate Breaking Load on stranded conductor Stress-Strain Test on conductor
9 10
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CLAUSE NO.
HT AND LT INSULATOR FITTINGS SCOPE This specification covers design, manufacture, testing before dispatch, packing, and delivery of Porcelain insulator & insulator fittings (Pin & Strain type only) for use in 33kV, 11kV, & LT lines including guy strain insulators. Post insulator shall conform to specification given in Part-A: 33/11kV substation of this Volume.
1.00.00
2.00.00
STANDARD The insulators shall comply with the latest version of following standards. IS: 1445 IS: 7935 IS: 731 IS: 2486 Porcelain insulators for overhead power lines with a nominal voltage upto & including 1000V Insulator fittings for overhead power lines with a nominal voltage upto & including 1000V Specification for porcelain insulators for overhead power lines with a nominal voltage greater than 1000V (Pt I) - Metal fittings for insulators for overhead power lines with nominal voltage greater than 1000V Pt-1, General requirement & tests. (Pt 2) - Insulator fittings for overhead Power lines with nominal voltage grater than 1000V Part 2 Dimensional requirements - Specification for porcelain guy strain insulators. -Guide for the selection of insulation in respect of polluted condition
IS: 2486 IS: 5300 IS:13134
REC SPECIFICATION NO. 3/1971 4/1972 13/1979 21/1981 3.00.00 11kV Porcelain insulators & Fittings Porcelain insulators & fittings for 415/240V O/H Power lines. Porcelain insulators & fittings for 33kV O/H Power lines. Guy strain insulator
ATMOSPHERIC CONDITIONS The material offered shall be suitable for operating under the climatic conditions indicated in General Terms and Conditions of this tender specification.
4.00.00 4.00.01
GENERAL REQUIREMENTS The porcelain shall be sound, free from defects, thoroughly vitrified and smoothly glazed. The glaze shall be brown in colour & cover all the porcelain parts of the Insulator except those areas, which serve as supports during firing or are left unglazed for the purpose of assembly.
TECHNICAL SPECIFICATION VOL-II (Part-B) CHAPTER-II SECTION-E3
HT & LT INSULATORS INSULATOR FITTINGS
Page 1 of 12
CLAUSE NO.
HT AND LT INSULATOR FITTINGS SPECIFIC REQUIREMENTS FOR INSULATORS The insulators shall conform to the following specific conditions of respective IS given in the table below. Minimum mechanic al failing load in KN Minimum Creepage distance in mm Normal & Heavily moderately polluted polluted atmosph atmosphere ere
5.00.00
Insulator
Designation
Pin
Type- 1 & 2 of IS:1445 Type-1 IS:1445 of of
3.5 11.5 16 5 Dimensions shall be as per IS:1445
LT Shackle
Type-2 IS:1445 Pin 11KV Strain* Pin 33KV Strain** Strain Guy*** Type- C 1445 Type-A of IS 1445
Type-B of IS:731 45 10 Type-B of IS:731 70 44 88
240
320
720
900
41 57
of IS
*11KV strain insulators shall be tong & clevis type. **33KV strain insulators shall be ball & socket type only ***One A type guy insulator shall be used for LT line; One C type guy insulator shall be used for 11KV line & two C type of guy insulator shall be used for 33kV line. 6.00.00 TESTS The insulators shall comply with the following tests as per Indian Standards.
TECHNICAL SPECIFICATION VOL-II (Part-B)
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CLAUSE NO.
HT AND LT INSULATOR FITTINGS Type Tests The following constitute the type tests: 1. 2. 3. 4. 5. 6. 6. 7. 8. 9. 10. 11. 12. Visual Examination Verification of dimensions Visible discharge tests Impulse withstand voltage tests (applicable for all insulators except Guy Strain Insulator) Wet Power frequency withstand voltage test Dry power frequency withstand voltage test (only for Guy Strain Insulator) Temperature cycle test Mechanical failing load test (for pin insulators only) Puncture test (applicable for all insulators except LT & Guy Strain Insulator) Porosity test Galvanising test (for 11 kV disc insulators) Electro-Mechanical failing load Test (for Strain Insulators only) Thermal Mechanical Performance Test (for Strain Insulators only)
6.01.00
Type test certificates from recognized Lab for the tests carried out on prototype of same specifications shall be enclosed with the tender. 6.02.00 Routine Tests The following shall be carried out as routine tests: 1. 2. 3. 4. 6.03.00 Visual examination Electrical routine tests (only for 11 kV insulators) Mechanical routine tests (only for 11 kV insulators) Hydraulic Internal Pressure Test on Shells (For Disc Insulators) .
Acceptance Tests The samples after withstood the routine tests shall be subjected to the following acceptance tests in order indicated below: 1. 2. 3. 4. 5. 6. Verification of dimensions Temperature cycle test Electromechanical failing load test Puncture test (except LT and Guy Strain insulators) Porosity test Galvanising test (only for Disc insulators)
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CLAUSE NO.
HT AND LT INSULATOR FITTINGS Tolerance in insulator dimensions shall be as per the relevant Indian Standards.
7.00.00
MARKING Each insulator shall be legibly and indelibly marked to shows the following:Name and trade mark of manufacturer Month and Year of manufacture Minimum failing load in KN Country of manufacture.
Marking on porcelain shall be printed/engraved and shall be applied before firing. 8.00.00 8.00.01 PACKING All insulators shall be packed in wooden crates suitable for easy but rough handling and acceptable for rail and road transport. Where more than one insulator is packed in a crate, wooden separators shall be fixed between the insulators to keep individual insulators in position without movement with in the crate. GTP for insulator GTP for 33KV insulator The following gauranteed technical parameters shall be applicable. PART-A Sr. Description No. 33kV Pin Insulator 33kV Ball & socket type Disc Insulator 731 731 13/1979 & REC Technical Specification for composite insulator
9.00.00 9.01.00
Applicable standard Indian standard no
1 a b c d e
f g
REC specification no Electrical Characteristics Material Type of Insulators Highest system voltage(KV rms) Nominal system voltage(KV rms) Visible discharge voltage( KV rms) Minimum wet one minute power frequency withstand voltage (kV rms) Power frequency puncture withstand
Porcelain / Composite Type B Type B 36 36 33 33 27 27 75 1.3 times the actual

75 180
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CLAUSE NO.
HT AND LT INSULATOR FITTINGS voltage(KV rms) h 2 a b c 3 a b c i ii 4 5 Impulse voltge withstand(kV peak) Mechanical Characteristics Electromechanical failing load(kN) Ball and socket size(mm) Applicable standard for special characteristics Size of insulators Porcelain diameter(mm) Spacing/height of insulator(mm) creepage distance (min)(mm) Normal & Moderately Polluted Heavily polluted Color of glaze Tolerance in dimensions, if any Type test reports (all mentioned in relevant clause) dry flashover voltage 170 70 16 IS 3188-1980 255 145 720 900 Brown As per IS COMPLIED
170 10 NA NA 320 280 720 900 Brown As per IS COMPLIED
Make shall be NESCL Corporate Quality Assurance (CQA) approved. 9.02.0 GTP for 11KV insulator The following gauranteed technical parameters shall be applicable.
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CLAUSE NO.
HT AND LT INSULATOR FITTINGS
Sr No.
Description
1 2
Indian standard no REC specification no
11kV Ball & 11kV socket type Pin Disc Insulator Insulator 731 731 3/1971 & REC Technical Specification for composite insulator Porcelain / Composite Type B Type B 12 12 11 11 9 9 35 35
3 a b c d e f
Electrical Characteristics Material Type of Insulators Highest system voltage(KV rms) Nominal system voltage(KV rms) Visible discharge voltage( KV rms) Minimum wet one minute power frequency withstand voltage (kV rms)
h 4 g Mechanical Characteristics a Electromechanical failing load(kN)
Power frequency puncture withstand voltage(KV rms) Impulse voltge withstand(kV peak)
1.3 times the actual dry 105 flashover 75 voltage 75 45 16 IS 3188-1980 255 145 240 Brown AS per IS COMPLIED 5 NA NA 125 132 240 Brown AS per IS COMPLIED
Ball and socket size(mm) b c Applicable standard for special characteristics 5 Size of insulators a Porcelain diameter(mm) b Spacing/height of insulator(mm) c creepage distance (min)(mm) 6 Color of glaze 7 Tolerance in dimensions, if any Type test reports (all mentioned in relevant clause)
Make shall be NESCL Corporate Quality Assurance (CQA) approved. 9.03.00 GTP for LT insulator The following gauranteed technical parameters shall be applicable.
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CLAUSE NO.
HT AND LT INSULATOR FITTINGS
PART-A S.no Description Pin insulator Shackle insulator Type-1 1445 4/1973 Porcelain 1000 1100 23 Shackle insulator Type-2 1445 4/1973 Porcelain 1000 1100 23
1 a b 2 a b c
e f 3 1 2 3 a b 4 5
Applicable standard Indian standard no REC specification no Electrical characteristics Material Nominal System Voltage (rms V) Highest System Voltage (rms V) Dry one minute power freuency withstand voltage (rms kV) Wet one minute power freuency withstand voltage (rms kV) Power frequency puncture withstand voltage (rms kV) Mechanical Characteristics Minimum failing load ( KN) Color of glaze Size of insulators Diameter of Insulator (mm) Height of Insulator (mm) Tolerance in dimensions, if any IS designation Type test reports (all mentioned in relevant clause)
1445 4/1973 Porcelain 1000 1100 23
10 60 3.5 Brown 65(base) 100 As per IS
10 60 11.5 Brown 90(TOP) 75 As per IS
10 60 13 Brown 115(TOP) 100 As per IS
Type 1 & 2 Type-1 type-2 COMPLIED COMPLIED
Make shall be NESCL Corporate Quality Assurance (CQA) approved. 9.04.00 GTP for guy insulator The following gauranteed technical parameters shall be applicable.
PART-A
RGGVY WORKS STANDARD TECHNICAL SPECIFICATION (REV.- 03) TECHNICAL SPECIFICATION VOL-II (Part-B) CHAPTER-II SECTION-E3
Page 7 of 12
CLAUSE NO.
HT AND LT INSULATOR FITTINGS HT Guy Insulator 5300 21/1981 Porcelain 33 36 27 13 1.3 x actual dry FOV 57 88 Brown 85mm 140mm As per ISS Type C COMPLIED LT Guy Insulator 5300 21/1982 Porcelain 0.43 0.6 18 8 1.3 x actual dry FOV 41 44 Brown 65 90 As per ISS Type A COMPLIED
S.no 1 a b 2 a b c d e f 2 a b 3 4 a b 5 6
Description Applicable standard Indian standard no REC specification no Electrical characteristics Material Nominal System Voltage(KV rms) Highest System Voltage(KV rms) Dry one minute power freuency withstand voltage(KV rms) Wet one minute power freuency withstand voltage(KV rms) Power frequency puncture withstand voltage Mechanical Characteristics Minimum creepage distance(mm minimum) Minimum failing load(kN) Color of glaze Size of insulators Diameter of Insulator Height of Insulator Tolerance in dimensions, if any IS designation Type test reports (all mentioned in relevant clause)
INSULATOR FITTINGS 10.00.00 SCOPE The specification covers design, manufacture, testing before dispatch, packing transportation and delivery of 1 2. 3. GS Pins for pin insulators Helically formed pin insulator ties Fittings for disc/strain insulators
11.00.00
APPLICABLE STANDARDS
Page 8 of 12
CLAUSE NO.
HT AND LT INSULATOR FITTINGS Pins shall comply with the requirements of of IS : 2486 (Pt.-I), IS : 2486 (Part-II & III). Helically formed fittings shall comply with IS : 12048. Fittings for strain insulators shall comply with the requirements of IS : 2486 Pt.-I to IV and REC Specification No. 3/1971 (Revised 1993), 4/1972 (Revised 1979)
12.00.00 12.01.00 12.01.01 12.01.02
GENERAL REQUIREMENTS Pin for Pin Insulator The pins shall be single piece obtained by the process of forging All ferrous pins & nuts shall be galvanized by the hot dip process. Other fittings i.e. flat washers and spring washers may be electro - galvanized as per Clause 5.2.3 of IS:2486 (Part-I), and should satisfy the tests as per IS:1573 of 1986 and subsequent amendments (if any). The threads of nuts and taped holes when cut after galvanizing shall be well oiled or greased. 11 kV Pins shall be of small Steel head type Fig. No. 5, S-165P as per IS : 2486 (Part-II) having stalk length of 165 mm and shank length of 150 mm with minimum failing load of 5 KN. The thimble for 11 KV Pin Insulator should be suitable for use with Galvanized Steel Pins conforming to reference S-165 of IS 2486 (Part II) with shank length 150mm which is provided with a small steelhead LT Pins for Pin Insulator shall have a stalk length of 135 mm, shank length of 125 mm and minimum failing load of 2 kN. Pin Insulator Ties Helically formed insulator ties shall be suitable for specified conductor size. Helically formed ties used for holding the conductor on the pin insulator shall be made of aluminium alloy or aluminized steel or aluminium-clad steel wire and shall conform to the requirement of IS:12048. Elastomer pad for insulator shall be used with the ties to avoid abrasion of the conductor coming into direct contact with the insulator. Helically formed dead-end grip having a prefabricated loop to fit into the grooved contour of the thimble on one end for application over the conductor at the other end. The formed fitting shall conform to the requirement of IS:12048. Fittings for Strain Insulators The Fittings shall consist of the following components.
12.01.03
12.01.04
12.01.05 12.02.00 12.02.01
12.02.03 11.02.03
12.02.04
12.03.01
Cross arm strap & tension clamp & other fittings shall conform to IS: 2486 (Part-II).
Page 9 of 12
CLAUSE NO.
HT AND LT INSULATOR FITTINGS Shackle Insulator Fittings Strap type fittings shall consist of the following: a) b) c) d) A pair GI bolts hexagonal head and nuts 2 Nos. GI bolts with hexagonal and nuts 2 Nos. spring washers Helically formed conductor dead-end fittings made of aluminum alloy or aluminum-clad steel conforming to the requirement of REC Spec. No 25/1983.
12.04.00 12.04.01
12.04.02
Alternatively, U clamp shall be required. These shall consist of: a) b) c) d) GI U-clamp 1 No. GI bolt and nut 1 No. spring washer Helically formed distribution side tie made of aluminum alloy or aluminumclad steel conforming to the requirements of REC Spec. No. 25/1983
U clamp fittings are intended only for use on tangent locations or for service lines where load is small; the strap fittings are meant for angle and dead-end locations. 13.00.00 13.01.00 TESTS Tests for GS Pins The type test certificate giving the results of samples tested for the tests, as per Clause 4.3.1 of IS:2486 (Part-I) / 1974 shall compulsorily be enclosed by the Bidder along with their supply in support of evidence of compliance of the specifications and guaranteed particulars. 13.02.00 Type Tests 1. 2. 3. 4. 5. 13.03.00 Freedom from defects Verification of dimensions Galvanizing test (both uniformity of Zinc coating and Wt. of Zinc Coating) Mechanical Tests Chemical composition tests
Routine Tests Routine tests shall be conducted as per requirement of Clause 4.3.3 of IS: 2486 (Part-I)
13.04.00
Acceptance Tests :
Page 10 of 12
CLAUSE NO.
HT AND LT INSULATOR FITTINGS The dimensional requirement of 11 kV GS pins offered for pre-despatch inspection shall be checked and verified as per IS: 2486 (Part-II) and the following tests shall be carried out and witnessed by the Inspecting Officer during inspection of the material as per requirement of the IS:2486 (Part-I).
13.04.01 13.04.02 13.04.03 13.04.04 13.05.00
Checking of threads on heads : The dimensions of the threads on the heads of pins shall be checked and verified by means of gauges (Ref. IS: 2486 (Part-II). Galvanizing Test: The uniformity of zinc coating and Wt. of zinc coating for pins and nuts shall be verified as per requirements of IS : 2633. Mechanical Test : This test shall be conducted in accordance with the Clause 4.6 of IS:2486 (Part-I). Visual Examination Test : All the pins shall be checked visually for its good workmanship and finishing. The helically formed fittings for Strain insulators & ties for pin insulators shall be subjected to tests as per IS:12048. The other hardware fittings shall be tested as per IS: 2486 (Part-I). Method of Galvanizing As per IS 2633 (Hot Dip for 11 KV Galvanizing GS Pins and Nuts) Sl.No. Tests i. ii. Dip Test For GS Pins 4 dips of 1 minute each For GI Nuts 4 dips of 1 minute each
14.00.00
Mass of zinc coating 300 gms/m2 (Minimum) 300 gms/m2 (Min)
The mass of zinc coating on pins shall be as per Clause-4 of IS:4759 and in case of Nuts shall be as per Clause No.4 of IS:1367 (Part-XIII). The above tests shall invariably be conducted during all routine inspection of material. (S.No. I, II & III). 15.00.00 MARKING Each and every material shall be legibly and indelibly engraved / embossed with NAME OR TRADE MARK of the manufacturer should be. 16.00.00 16.01.00 PACKING For packing of GI pins, strain clamps and related hardware, double gunny bags or wooden cases shall be used. The heads and threaded portions of pins and the fittings shall be properly protected against damage. The gross weight of the packing shall not exceed 50 Kg. Helically formed fittings shall be packed in card-board/wooden boxes. Fittings for different sizes of conductors shall be packed in different boxes and shall be complete witht their minor accessories
16.02.00
Page 11 of 12
CLAUSE NO.
HT AND LT INSULATOR FITTINGS fitted in place and colour codes on tags/fittings shall be marked to identify suitability for different sizes of conductors as per IS : 12048.
Page 12 of 12
CLAUSE NO.
11 kV XLPE CABLES SCOPE This specification covers design, manufacture, testing, transportation and despatch to owners stores of 11 kV Cross Linked Polyethylene (XLPE) insulated and PVC sheathed aluminum cables for use in Distribution System.
1.00.00
2.00.00
APPLICABLE STANDARD The cables shall comply with the latest version of IS:7098 (Pt. II)-Specification for Cross Linked Polyethylene Insulated PVC Sheathed Cables, IS:5831-1984Specification for PVC Insulated and sheath of electric cable and REC Specification No. 63/1993 (Revised 1997).
3.00.00
RATED VOLTAGE AND TEMPERATURE The rated voltage of the cables shall be 6.35 kV/11 kV and the maximum operating voltage shall be 12 kV. Maximum continuous operating temperature (combination of ambient temperature and temperature rise due to load) shall be 900C under normal operation and 250 degree C under short circuit conditions.
4.00.00
TYPE OF CABLES The type of cable shall be three-core armoured screened.
5.00.00
STANDARD SIZES OF CABLES The standard size of cable shall be 3x95 sq.mm.
6.00.00 6.00.01
DETAILS OF CABLES General Construction Conductor screen and insulation screen shall be extruded semi-conductoring compound and shall be applied along with XLPE insulation in a single operation by triple extrusion process. The method of curing shall be dry curing / gas curing / steam curing.
6.01.00
Conductor The cable conductors shall be of round, stranded and compacted aluminum of nominal size as stipulated in Table 1 under Clause 5 of IS: 8130. Corresponding wire diameter and number of wires in the conductor shall be as given in IS : 8130.
7.02.00
Conductor Screen Conductor screening shall be provided over the conductor by applying by extrusion of semi-conducting compound.
CHAPTER-II SECTION-E4 11 kV XLPE Cables
Page 1 of 4
CLAUSE NO.
11 kV XLPE CABLES Insulation The insulation shall be of extruded cross linked polyethylene (XLPE) of nominal insulation thickness 3.6 mm and its properties shall conform to IS : 7098 (Pt. II).
6.03.00
6.04.00 6.04.01
Insulation Screen The insulation screen shall consist of two parts; namely, metallic and non-metallic. Non-metallic part shall be applied directly over the insulation of each core and shall consist of extruded semi-conducting compound. The metallic part shall consist of either tape, or braid or concentric serving of wires or a shall be non-magnetic and shall be applied over the non-metallic part. Core-identification & laying up of cores The core identification and laying up of cores shall be as per IS : 7098 (Pt. II). For identification of different cores in three-core cable, use of coloured stripes, red, yellow and blue, or use of numbered strips shall be employed.
6.04.02 6.05.00
6.06.00
Inner Sheath The laid up cores shall be covered with inner sheath made of thermoplastic material applied either by extrusion or wrapping. It shall be ensured that the shape is as circular as possible. Thickness of inner sheath shall conform to IS : 7098 (Pt. II).
6.07.00
Armouring Armouring shall be applied over non-metallic part of insulation screening or the inner sheath as the case may be for single-core cables and over the inner sheath for threecore cables. The method, type, dimensions, joints, conductance etc. of armour shall conform to IS : 7098 (Pt. II).
6.08.00
Outer Sheath The outer sheath shall be applied over the armouring. The minimum thickness and properties of outer sheath shall conform to the requirement of IS : 7098 (Pt. II). The type of PVC compound shall be of STL as per IS : 5831 - 1984.
7.00.00
TESTS The following tests shall be carried out on the cables as per IS : 7098 (Pt. II).
7.01.00
Type Tests a) Tests on conductor i) ii) iii) Tensile test Wrapping test Resistance test
TECHNICAL SPECIFICATION VOL-II (PART-B) CHAPTER-II SECTION-E4 11 kV XLPE Cables Page 2 of 4
CLAUSE NO.
11 kV XLPE CABLES b) c) d) Tests for armouring wires/strips Tests for thickness of insulation and sheath Physical tests for insulation i) ii) iii) iv) v) e) Tensile strength and elongation at break Ageing in air oven Hot test Shrinkage test Water absorption
Physical Tests for outer sheath i) ii) iii) iv) v) Tensile strength and elongation at break Ageing in air oven Shrinkage test Hot deformation Bleeding and blooming test
f) g) h)
Partial discharge test Bending Test Dielectric power factor test : i) ii) As a function of voltage As a function of temperature
i) j) k) l) m) 7.02.00
Insulation resistance test (volume resistivity) Heating cycle test Impulse withstand test High voltage test Flammability test
Acceptance Tests a) b) c) d) e) f) g) h) Tensile test Wrapping test Conductor resistance test Test for thickness of insulation and sheath Hot set test for insulation Tensile strength and elongation at break test for insulation and sheath Partial discharge test High voltage test
TECHNICAL SPECIFICATION VOL-II (PART-B) CHAPTER-II SECTION-E4 11 kV XLPE Cables Page 3 of 4
CLAUSE NO.
11 kV XLPE CABLES i) Insulation resistance (volume resistivity) test
7.03.00
Routine Tests a) b) c) Conductor resistance test Partial discharge test High voltage test
8.00.00 8.01.00
PACKING AND MARKING Packing The cables shall be supplied in wooden drums conforming to IS:10418. The standard length of cable in each drum shall be 0.5 KM ( ) 5%.
8.02.00
Marking The cable drum shall carry the information as per requirement of IS : 7098 (Pt. II) including the project name i.e. RGGVY work by NTPC Electric Supply Co. Ltd., Noida shall be printed.
8.03.00
The manufacturers name or trade-mark, the voltage grade, year of manufacture etc. may be printed or embossed on the cable as stipulated in IS : 7098 (Pt. II). INSPECTION All the tests and inspection shall be made at the place of manufacture. The manufacturers shall afford the inspector representing the purchaser all reasonable facilities without charge, to satisfy him that material is being furnished in accordance with the Specification. The purchaser has the right to have tests carried out at his own cost by an independent agency whenever there is a dispute regarding the quality of supply.
9.00.00
CHAPTER-II SECTION-E4 11 kV XLPE Cables
Page 4 of 4
CLAUSE NO.
LT AERIAL BUNCHED CABLES
1.00.00
SCOPE This specification covers design, manufacture, testing before despatch, transportation, supply and delivery to the Owners stores of cross linked polyethylene (XLPE) insulated aluminum conductor Aerial Bunched Cable twisted over a central bare aluminum alloy messenger wire for use as overhead distribution feeders.
2.00.00
RATED VOLTAGE The rated voltage of the cables shall be 1100 volts.
3.00.00
APPLICABLE STANDARDS The LT ABC shall comply to latest version of the following Standards as amended from time to time: IS:14255 : Specification for Aerial bunched cables for working voltages upto and including 1100 V. IS:10810-1984 : Methods of Test for Cables. IS:8130-1984 : Conductors for Insulated Cables. IS:398 (Part-IV)-1979 : Aluminium Alloy Conductors. REC Specification No. : 32/1984.
4.00.00
GENERAL The insulated phase conductors (with additional street lighting conductor, if provided) shall be twisted around the bare aluminum alloy messenger wire, which shall take all the mechanical stress. The messenger wire shall also serve as the earthcum-neutral wire.
5.00.00
PHASE CONDUCTORS The phase conductors and street lighting conductors shall be insulated with black weather-resistant, suitable for 1100 V insulation. The insulated conductors shall generally conform to the Indian Standards quoted above. The phase conductors shall be provided with one, two and three 'ridges' for quick identification.
6.00.00
MESSENGER (NEUTRAL CONDUCTOR) The bare messenger wire shall be made of aluminum alloy generally conforming to IS:398 (Part-IV)-1979 composed of 7 strands and shall be suitably compacted to have smooth round surface to avoid damage to the insulation of the phase conductors
RGGVY WORKS
STANDARD TECHNICAL
CHAPTER-II SECTION-E5 LT AERIAL BUNCHED CABLES
Page 1 of 4
CLAUSE NO.
LT AERIAL BUNCHED CABLES twisted around the messenger. There shall be no joints in any wire of the stranded messenger conductor except those made in the base rod or wires before final drawing.
7.00.00 7.01.00
XLPE INSULATION Application of Insulation The insulation shall be so applied that it fits closely on the conductor and it shall be possible to remove it without damaging the conductor. The co lour of insulation shall be black. TESTS FOR PHASE/STREET LIGHT CONDUCTORS
9.01.00 9.03.00 9.03.01
All tests shall be carried out as per IS-14255-1995 TEST FOR MESSENGER All tests shall be carried out as per IS-14255-1995 BENDING TEST ON THE COMPLETE CABLE : Bending test shall be carried out as per IS-14255-1995
10.00.00
PACKING AND MARKING The cable shall be wound in non-returnable drums conforming to IS: 10418:1982. The drum shall be marked with the following : i. Manufacturer's name ii. Trade mark, if any iii. Drum number or identification number iv. Size of conductors v. Size of messenger vi. Voltage grade vii. Number and lengths of pieces of cable in each drum viii. Gross mass of the packing ix. Net mass of cable x. ISI mark, if any The drums shall be of such construction as to assure delivery of conductor in the field free from displacement and damage and should be able to withstand all stresses due to handling and the stringing operation so that cable surface is not dented, scratched or
RGGVY WORKS TECHNICAL SPECIFICATION VOL-II (PART-B) CHAPTER-II SECTION-E5 LT AERIAL BUNCHED CABLES Page 2 of 4
STANDARD TECHNICAL
CLAUSE NO.
LT AERIAL BUNCHED CABLES damaged in any way during transport and erection. The cable shall be properly lagged on the drums. The cable drum should be suitable for wheel mounting. The normal length of each cable shall be 1 Km. While longer lengths shall be acceptable, shorter lengths not less than 50% of the standard lengths shall be acceptable to the extent of 10% of the ordered quantity.
11.00.00
INSPECTION All tests and inspection shall be made at the place of manufacture unless otherwise especially agreed upon by the manufacturer and purchaser at the time of purchase. The manufacturer shall afford the inspector representing the purchaser all reasonable facilities without charge, to satisfy him that the material is being furnished in accordance with this specification.
12.00.00
Guaranteed Technical Parameters The following gauranteed technical parameters shall be applicable. 1CX1 6+25 Sq mm
Sl.No.
Particulars 1 Applicable standard i Indian Standard ii REC Standard 2 Power Core conductor Nominal cross sectional area (Sq mm) Number of strands(Min) Max.DC resistance at 20 deg C(Ohm/KM) Dia of compacted phase Conductor (mm) Tolerance on Dia of Compacted Phase Conductor Minimum Tensile Strength of each strand (N/Sq mm) 3 Nominal insulation thickness (mm) 4 Messenger wire (Bare) Number of strands(Min) Nominal cross sectional area(Sq mm) Minimum.Breaking load(KN) Max.DC resistance at 20 deg C(Ohm/KM)
3CX16+25 Sq mm
IS:14255/95, IS-8130/84, IS:398(Pt-IV) 32/1984 16 7 1.91 4.4 + 5% 100 1.2 7 25 7.0 1.38
i ii iii
RGGVY WORKS
STANDARD TECHNICAL
LT AERIAL BUNCHED CABLES
CLAUSE NO.
LT AERIAL BUNCHED CABLES iv 5 6 7 8.1 Dia of compacted Conductor (mm) No.of cores(No.) Bare messenger(No.) Identification of power cores Details of power core Conductor Material Flexibility class as per IS:8130/84 Form of conductor Insulation 5.5 + 5% 3 1 By ridges
1 1
H2/H4 Aluminium Class-2 Compacted Circular Cross linked Poly ethelene(XLPE) Black All Aluminium alloy as per IS:398(Pt-IV) Compacted circular 1000 +/- 5 % IS:10418 IS:14255 ,IS:10418 Yes COMPLIED
8.2
Material Colour of insulation 9 Details of messenger wire(Bare) Material Form of conductor 10 Standard Length 11 Size of Drum 12 Packing and Marking Progressive marking of Length, along 13 of cable Type test reports (all mentioned in 14 relevant clause)
Make shall be NESCL Corporate Quality Assurance(CQA) Approved
RGGVY WORKS
STANDARD TECHNICAL
CHAPTER-II SECTION-E5 LT AERIAL BUNCHED CABLES
Page 4 of 4
CLAUSE NO.
11 KV AIR BREAK SWITCHES SCOPE This specification covers design, manufacture, testing and supply of 11 kV, 50 Hz Air Break Switches for outdoor installation.
1.00.00
2.00.00
APPLICABLE STANDARD (i) (ii) REC Specification No. 43/1987. IS:9920 (Pt. I to IV)
3.00.00 3.01.00
RATINGS Rated VoltageRATED VOLTAGE The rated voltage shall be 12 kV.
3.02.00
Rated Normal Current The rated normal current shall be 200 Amps for DT stations & 400Amps for line sectionalisers (T Off points for long lines & for out going feeders from 33/11kV Substations).
3.05.00
Temperature Rise The temperature rise shall not exceed the maximum limits specified below : Temperature rise limit at Ambient temperature not exceeding 40oC Copper contacts (Silver faced) in air 65oC
Terminals of the switch intended to be connect to external conductors by bolts 50oC 3.06.00 Rated short time current The rated short time current shall be 16 kA. 3.07.00 Rated peak withstand current The value of peak current that the switch can withstand in the closed position shall be 40 kA. 3.08.00 Rated mainly active load breaking capacity The rated mainly active load breaking capacity shall be 10A. 3.09.00 Rated line charging breaking capacity The rated line-charging breaking capacity shall be 2.5 A (rms). 3.10.00 Rated cable-charging breaking capacity The rated cable charging breaking capacity shall be 10 A (rms).
RGGVY WORKS STANDARD TECHNICAL SPECIFICATION (REV.- 03) TECHNICAL SPECIFICATION VOL-II (Part-B) CHAPTER-II SECTION-E6
11 KV AIR BREAK SWITCHES
Page 1 of 5
CLAUSE NO.
11 KV AIR BREAK SWITCHES CONSTRUCTIONAL FEATURES The AB switch shall have triple-pole/double pole construction and shall be suitable for horizontal or vertical mounting as required. The switch shall have Two 11 kV post insulators per phase for DT station locations & three 11kV post insulators per phase for line sectionaliser locations suitably mounted on iron angle or channel to enable easy movement of insulators. The angle/ channel supports shall be mounted on a 70mm2 hollow beam suitable for fixing on the double pole structure. Alternatively, the channel shall be mounted on a steel frame made of two channel supports. The switch shall be manually operated with a rocking type arrangement through a 30mm2 G.I coupling rod. All current carrying parts shall be made of silver or nickle-plated 90% elecrtrolytic copper. The arcing horns shall be made of phosphor bronze and shall have springassisted operation. The switch shall have a spring mechanism so as to ensure that the speed of opening of contacts is independent of the speed of manual operation. The spacing between the phases shall be adjustable between 600 to 760 mm. The switch assembly shall be suitable for mounting on H pole structure with center to center distance between poles upto 140 mm. The vertical operating rod shall comprise of 25 mm (nominal bore) Galvanised steel tube (medium class) as per IS:1161-1979. Length of the operating tube shall vary from 4800 mm to 6000 mm depending upon the mounting position of the switch on the structure. Suitable arrangement shall be provided to pad-lock the operating handle in ON and OFF positions. The switch shall be provided with bimetallic connectors on the incoming side to accommodate AAAC of sizes 20, 30 and 50 mm2. On the outgoing side, about 1 metre long flexible coil type cable jumper of not less than 50 mm2 aluminium section shall be provided. All iron parts shall be hot dip galvanised. The tubes shall be galvanised in accordance with IS : 4736 - 1968. TESTS Type Tests The AB Switch shall be subjected to the following type tests in accordance with IS:9920. i) ii) iii) Dielectric test (impulse and one minute wet power frequency withstand voltage tests) Temperature rise test (for contacts and terminals) Short time current and peak withstand current tests
4.00.00 4.01.00
4.02.00
4.03.00
4.04.00
4.05.00 4.06.00
4.07.00 5.00.00 5.01.00
Page 2 of 5
CLAUSE NO.
11 KV AIR BREAK SWITCHES iv) v) vi) Mainly active load breaking capacity test Line charging breaking capacity test Cable charging breaking capacity test
vii) Operation and Mechanical Endurance test 5.02.00 Routine Tests The AB Switches shall be subjected to the following routine tests: i) ii) iii) 5.03.0 Power frequency voltage dry test Measurement of the resistance of main circuit Mechanical Operation test
Acceptance Tests: i. ii. iii. iv. v. Dimensional Verification. Power Frequency Voltage Dry Test. Mechanical Operation Test. Verification of all components. Galvanisation test on MS components
Page 3 of 5
CLAUSE NO.
11 KV AIR BREAK SWITCHES GAURANTEED TECHNICAL PARAMETERS The following gauranteed technical parameters shall be applicable. PART-A Sl No Description 1 Make 2 3 4 5 6 7 a) b) 8 a) b) 9 a) Item Rated voltage System voltage System frequency Rated current One minute pf with stand voltage Between poles & to earth Across the isolating distance Dry lightning impulse with stand voltage Positive Negative Maximum temp rise above an ambient of 40 deg c Copper contacts (silver faced) in air Terminals of the switch intended to be connected to external conductor by bolts Rated peak withstand current Rated mainly active load breaking capacity Rated line charging breaking capacity Rated cable charging breaking capacity Material of arcing horns Particulars Three phase ab switch 12 kv 11kv 50 hz 200a/400a
6.00.00
28 kv rms 32 kv rms
75kvp 85kvp
65 deg c
b) 10 11 12 13 14
50 deg c 40ka 10a 2.5 a rms 10 a rms Phosphor bronze
Page 4 of 5
CLAUSE NO.
11 KV AIR BREAK SWITCHES 15 Material of main contacts 90% electrolytic cu silver plated 25 mm nominal bore galvanised steel tube (medium class) as per is 1161-1979. Length 4800mm to 6000 mm. 30mmx30mm gi coupling rod 11 kv solid core post insulator 280 mm (min) Is 9920 &rec 43/1987 Complied
16 17 18 19
Vertical operating pipe Tandem rod Insulator Creepage distance Reference standard Type test reports (all mentioned in relevant clause)
Page 5 of 5
CLAUSE NO.
PIERCING CONNECTOR SCOPE This specification covers manufacture, design, testing and dispatch of connectors for low voltage Aerial Bunched cables (ABC) to insulated cables.
1.00.00
2.00.00
APPLICABLE STANDARDS The connectors shall comply with the latest versions of the following French Standards or equivalent standard. NF C 33-020/1998 Insulation piercing branch connectors for overhead distributions & services with bundled assembled cores of rated voltage 0.6/1KV
3.00.00 3.06.01
General Requirements The body material shall be of high quality thermoplastic material having long life under exposed (Ultra violet radiation and out door application) condition The piercing plates shall be placed in an slot/groove to maintain proper verticality. The plates shall be made of copper alloy with teethed edge so that the insulation (XLPE/PVC) is smoothly sliced and contact is made with the phase/neutral conductor of ABC line. The dimensions of cable/conductor receptacle for main and tap shall be properly matched with the actual size of conductor used at site. The central bolts / nuts with washer used for tightening the connector, clamp shall be provided with over-torque nut so that excessive tightening is prevented beyond the limit at site. Necessary tests shall be carried out to show this features. Torque data is shown in the drawing. Piercing connector shall be of type tested design. Copy of the test report for the connector from an independent lab shall be attached with the bid. SIZE AND TYPE The connector should be suitable for connection of LT ABC of size 16-35 sq. mm. to 1.5-10 sq. mm. TESTS Type Tests: 1. Mechanical Tests: a) b) c) Checking of electrical continuity & mechanical behavior of the connector. Effect of tightening on the mechanical strength of the main core. Checking of mechanical strength of tap cores.
3.06.02
3.06.03
3.06.04
4.00.00 4.01.00 5.00.00 5.01.00
PIERCING CONNECTOR
Page 1 of 3
CLAUSE NO.
PIERCING CONNECTOR
2. Voltage & Water tightness test. a) Voltage test b) Water tightness test 3. Climatic ageing test 4. Corrosion test 5. Electrical ageing test 5.02.00 Routine Tests: The following tests shall be conducted as per annexure-F of NF C 33-020/1998/ a) Checks i) ii) iii) b) c) 5.03.00 Visual Dimensional Materials
Mechanical tests Voltage test
Acceptance Tests: i) ii) iii) Dimension verification Mechanical Tests. Voltage test
6.00.00 6.01.00 7.00.00
PACKING The connector shall be packed suitably so that it does not get damaged during transit & transportation MARKING The following information shall be marked on the piercing connector a) b) c) d) e) Manufacturers name, brand name or trade mark Type designation & voltage grade Nominal torque to be applied Year of manufacture and Country of manufacture
PIERCING CONNECTOR
Page 2 of 3
CLAUSE NO.
PIERCING CONNECTOR INSPECTION All tests and inspection shall be made at the place of manufacture. The manufacturer shall afford the inspector, representing the purchaser, all necessary facilities (without charge) to satisfy him that the material is being supplied in accordance with the Specification.
8.00.00
PIERCING CONNECTOR
Page 3 of 3
. CLAUSE NO
MISCELLANEOUS ITEMS BOLTS AND NUTS
1.00.00
SCOPE This specification covers manufacture, testing and supply of hot dip galvanized ISI Marked bolts and nuts with hexagonal heads & washers.
2.00.00
APPLICABLE STANDARDS Bolts & nuts of size M12-M24 - IS: 12427 & IS 14394 Bolts & nuts of size M10 & lower - IS: 1363 Galvanization of bolts IS: 1367(part-13) Spring lock washers IS: 3063 Electro galvanizing of spring washers: IS: 1573 Plain washers: IS: 2016 Technical supply conditions for threaded steel fasteners IS: 1367(Part-17) for inspection, sampling & acceptance procedure
3.00.00 3.01.00
GENERAL REQUIREMENTS Bolts having length up to 10 times the diameter of the bolt shall be manufactured by cold forging and thread rolling process to obtain good and reliable mechanical properties and effective dimensional control. Bolts of size M12 to M24 shall conform to IS: 12427 & shall be 5.6 property class, grade C. Bolts of size M10 & lower shall conform to IS: 1363 & shall be 5.6 property class, grade C. Thread length of all the sizes bolts shall be as specified in IS 1363-(Part-1). Fully threaded bolts shall not be acceptable. All the bolts & nuts shall be hot dip galvanized. Flat washers and spring washers shall be provided wherever necessary and shall be of positive lock type. Spring washers shall be hot dip galvanized or electrogalvanized. PRE-DESPATCH INSPECTION The bidder shall arrange to carryout acceptance tests in presence of owners inspecting officer in his own laboratory. In case testing facilities are not available at his works he will make necessary arrangements for carrying out these tests at a Govt. recognized lab at his own expense(s) and will provide all testing arrangement for Owners representative to witness the tests.
3.02.00 3.03.00 3.04.00 3.05.00 3.06.00
4.00.00
TECHNICAL SPECIFICATION VOL II (PART-B)
CHAPTER-II SECTION-E-8 MISCELLANEOUS ITEMS
Page 1 of 43
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MISCELLANEOUS ITEMS Acceptance Tests Sampling & tests shall be done as per IS -1367(Part-17) for all sizes of both bolts & nuts. The following tests shall be carried out as acceptance test. 1. Dimensional particulars (Sampling in accordance with IS: 2614 for both bolts & nuts). 2. 3. 4. 5. 6. 7. 8. Tensile strength test on full size Proof load test on full size bolts Brinell or Rockwell or Vickers Hardness tests for bolts. Shear test Head soundness tests for bolts (no fracture). Thickness & mass of zinc coating measurement for bolt ,nut & washers Uniformity of zinc coating bolt ,nut & washers
4.01.00
5.00.00
MARKINGS On the bolt head, there shall be identification marking of the manufacturer as well as property class If possible property class shall also be marked on Nuts also. Further ISI mark shall be marked on Gunny Bags for proper identifications.
Page 2 of 43
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MISCELLANEOUS ITEMS HOT DIP GALVANISED STEEL SOLID WIRE
1.00.00
SCOPE This specification covers manufacture, testing and supply of hot dip galvanized MS solid wire of sizes 6 mm, 5 mm, 4 mm and 3.15 mm diameters.
2.00.00
APPLICABLE STANDARDS Zinc Zinc shall conform to grade Zn 98.5 specified in IS -13229:1966 & IS: 4826-1979 with up to date amendments. Zinc Coating Zinc coating shall be in accordance with IS: 4826-1979 (Col. 4.2.1) for heavily coated hard quality. Galvanising Galvanizing shall be as per IS 2629-1966, IS: 4826-1979 with up to date amendments. Uniformity of Zinc Coating Uniformity of Zinc coating shall be as per IS 2633-1972 (Col. 4.2.1 to 4.2.3) with up to date amendments. Tensile Properties The tensile strength of the wire after, galvanizing shall be between 55-95 Kg/Sq.mm (heavily coated Hard as per IS: 4826-1979 Tables-1) ensuring MS wire Mechanical properties as per IS-28 : 1972 8.1 to 8.3. Freedom from Defects As per IS : 2629-1966 (Cl.6.1) & 4826-1979 (Col. 4.3) & with up to date amendments, be ensured.
3.00.00
MATERIAL The Mild Steel wire shall have the chemical composition maximum Sulphur 0.055%, Phosphorus 0.055%, Carbon 0.25%.
4.00.00
TESTS During the process of manufacture/ fabrication and all tests for chemical, mechanical, galvanizing as per IS-280-1979, IS1755-1961, IS: 6745-1972 & 48261979 shall be carried out. Test certificate towards, chemical composition (as per above) shall be submitted for each lot offered for inspection. The following tests shall be conducted in presence of owners representative.
Page 3 of 43
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MISCELLANEOUS ITEMS 1. 2. 3. 4. Visual Physical inspection and measurement of specified dimensions. Coating test as per IS:1755-1961, IS:2629-1966, IS:2633-1972, IS:4826-1969 & 1979 IS:6745-1972. Adhesion test as per IS:1755-1961, IS:2629-1966, IS:2633-1972, IS:4826-1969 & 1979 IS:6745-1972. Tensile strength and breaking load and elongation determined as per IS:15211972 with up to date amendments.
5.00.00
PACKING & MARKING Packing shall be as per IS : 280-1979 (Col. 3.1) and each coil shall be between 50100 Kg. Marking shall be as per IS: 280-1972 (Col.14.1 & 14.1.1).
Page 4 of 43
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MISCELLANEOUS ITEMS HOT DIP GALVANISED MS STRANDED WIRE
1.00.00
SCOPE This specification covers manufacture, testing and supply of hot dip galvanized MS stranded wire of sizes 7/4 mm, and 7/3.15 mm diameters.
2.00.00
APPLICABLE STANDARDS Zinc Zinc shall conform to grade Zn 98.5 specified in IS : 13229-1966 & IS : 4826, 1979 with up to date amendments. Zinc Coating Zinc coating shall be in accordance with IS: 4826-1979 (heavily coated hard quality Grade-4 as per Table-1) with up to date amendments. Galvanising Hot dip galvanizing shall be as per IS 2629-1966, IS 4826-1979 with up to date amendments. Uniformity of Zinc Coating Uniformity of Zinc coating shall be as per IS : 2633-1972 (Col. 4.2.1 to 4.2.3) with up to date amendments. Freedom from Defects Freedom from defects be ensured as per IS: 2141-1979 (Clause 4.1.6 respectively).
3.00.00
MATERIAL Wire used for each strand shall have the chemical composition (maximum) Sulphur 0.055% & Phosphorus 0.055%, Carbon 0.25%.
3.01.00
Tensile Properties Tensile properties of each strand ensuring MS Wire mechanical properties as per IS 280-1972 (Cl. 8.1 to 8.3) and after galvanizing each wire shall be of tensile strength minimum 700N/mm2 (71 Kgs/mm2). Tensile strength, bending load, lay & elongation of each wire and full strand shall conform to IS: 2141-1968, IS: 21411972 in the tensile grade given above).
4.00.00
CONSTRUCTION Construction shall be as per IS: 2141-1979 (Cl. 5.3.1 to 5.3.3).
5.00.00
TESTS Tests on wire before manufacture as per IS-2141-1979 (Cl. 7.1 to 7.2.2) shall be done.
Page 5 of 43
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MISCELLANEOUS ITEMS PACKING & MARKING Each coil shall be between 50-100 Kgs. Packed as per IS: 2141-1968 (Cl. 9.1) 65941979 & 2141-1979 (Cl. 11). Marking shall be as per IS: 2141-1968 (Cl. 8.1 to 8.1.1) and IS: 2141-1979 (Cl.10 & 10.1).
6.00.00
7.00.00
GAURANTEED TECHNICAL PARAMETERS The following gauranteed technical parameters shall be applicable. PART-A ITEM NAME:G.I WIRE 5 MM S.No PARAMETERS 1 Size Of G.I Wire Diameter Tolerance Type Of Zinc Coating Minimum Zinc Coating No. Of Dips 2 Tensile Properties Condition Tensile Strength 4 Indian Standards Adopted UNIT mm % g/m2 Minute Values 5.00 +2.5 Heavily Coated 275 3 x 1 , 1 x 1/2 Hard 550 to 900 IS 13229,IS:280/2 006,IS2629,IS 2633 IS:4826/1979
N/mm2(Mpa)
ITEM NAME:G.I WIRE 4 MM S.No PARAMETERS 1 Size Of G.I Wire Diameter Tolerance Type Of Zinc Coating Minimum Zinc Coating No. Of Dips 2 Tensile Properties Condition Tensile Strength
UNIT mm % g/m2 Minute
Values 4.00 +2.5 Heavily Coated 260 3x1 Hard 550 to 900
N/mm2(Mpa)
Page 6 of 43
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MISCELLANEOUS ITEMS 4 Indian Standards Adopted IS 13229,IS:280/2006,IS2629, IS 2633 IS:4826/1979
ITEM NAME:G.I WIRE 3.15 MM S.No PARAMETERS 1 Size Of G.I Wire Diameter Tolerance Type Of Zinc Coating Minimum Zinc Coating No. Of Dips 2 Tensile Properties Condition Tensile Strength 4 Indian Standards Adopted
UNIT mm % g/m2 Minute
Values 3.15 +2.5 Heavily Coated 240 3x1 Hard 550 to 900 IS 13229,IS:280/2006,IS2629, IS 2633 IS:4826/1979
N/mm2(Mpa)
Page 7 of 43
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MISCELLANEOUS ITEMS
ITEM NAME:G.I STAY WIRE (7/3.15MM) Grade-4 S.No PARAMETERS UNIT Values 1 Single Wire Before Stranding Nominal Diameter mm Minimum Breaking KN Load Minimum Mass Of g/m2 Zinc Coating Number of Dips Minute 2 G.I Stay Wire Minimum Tensile N/mm2 Strength(Grade-4) Lay Length mm
3.15 5.46 240 3x1 700
Lay Direction Minimum Breaking Load Minimum Elongation 3 Chemical Compositon (Max.) 4 Standards Adopted
KN % % %
12 to 18 times the Strand Diameter Min.113.4 &Max.170.1 Right Hand 34.00 6.00 S - 0.06 P - 0.06 IS:2141/1992,IS 2633,IS 2629 IS:4826/1979
Page 8 of 43
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MISCELLANEOUS ITEMS
ITEM NAME:G.I STAY WIRE (7/4MM) Grade-4 S.No PARAMETERS UNIT Values 1 Single Wire Before Stranding Nominal Diameter mm Minimum Breaking Load KN Minimum Mass Of Zinc Coating Number of Dips 2 G.I Stay Wire Minimum Tensile Strength(Grade-4) Lay Length g/m2 Minute N/mm2 mm
4.00 8.80 260 3x1 700
Lay Direction Minimum Breaking Load Minimum Elongation 3 Chemical Compositon (Max.) 4 Standards Adopted
KN % % %
12 to 18 times the Strand Diameter Min.113.4 &Max.170.1 Right Hand 54.90 6.00 S - 0.06 P - 0.06 IS:2141/1992,IS 2633,IS 2629 IS:4826/1979 COMPLIED
Page 9 of 43
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MISCELLANEOUS ITEMS CLAMPS & CONNECTORS
1.00.00
SCOPE This specification covers manufacture, testing and despatch of clamps and connectors. (Piercing type, UDC type etc.)
2.00.00
APPLICABLE STANDARDS Clamps & connectors shall conform to IS: 5561. The clamps and connectors shall be made of materials listed below: For connecting AAAC conductors Aluminium alloy casting, conforming to designation A6 of IS: 617 and shall be tested for all tests as per IS: 617. Bimetallic connectors made from aluminium alloy casting conforming to designation A6 of IS:617 with 2 mm thick Bimetallic liner and shall be tested as per IS:617. Galvanised mild steel. Hot dip galvanised mild steel for sizes M12 and above, and electro-galvanised for sizes below M12. Electro-galvanised mild steel suitable for at least service condition 4 as per IS:1573. Piercing type connector as per enclosed termination to drawing.
For connecting equipment terminals made of copper with AAAC conductor For connecting GS shield wire Bolts, Nuts & plain washers
Spring washers
For taping of service connection from LT ABC lines / pole top distribution box For tapping of service wire connection from LT over head conductor 3.00.00 3.01.00 GENERAL REQUIREMENTS
Connector as per REC Construction Standard E-38.
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 current carrying part of a clamp or connector shall be less than 10 mm thick. For Bimetallic clamps or connectors, copper alloy liner of minimum 2 mm thickness shall be provided. Flexible connectors, braids or laminated strips made up of copper/aluminium for the terminal clamps for equipment shall be suitable for both expansion or through (fixed/ sliding) type connection of IPS Aluminium tube as required. In both the cases the clamp height (top of the mounting pad to center line of the tube) should be same.
3.02.00
Page 10 of 43
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MISCELLANEOUS ITEMS Size of the terminal/conductor for which the clamp/connector is suitable shall be embossed/punched (i.e. indelibly marked) on each components of the clamp/connector, except on the hardware. 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. Clamps & connectors shall conform to type tests and shall be subjected to routine and acceptance tests on minimum 3 samples per lot as per IS: 5561. Type tests report for all clamps and connectors for temperature rise test, tensile test, shall be furnished by the Contractor.
3.03.00
3.04.00
3.05.00
Page 11 of 43
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MISCELLANEOUS ITEMS EARTHING CONDUCTOR (GS FLAT)
1.00.00
SCOPE This specification covers manufacture, testing and supply of Galvanised Steel Flat for Earthing arrangements.
2.00.00
APPLICABLE STANDARDS Materials shall conform to the latest applicable Indian standards. In case bidders offer Steel Section and supports conforming to any other international specifications which shall be equivalent or better than IS, the same is also acceptable. S.No. 1 2 3 Standard No. IS: 2062 Grade A Quality IS: 2062 IS: 1852 Title Specification for M.S. Channel and M.S. Flat Chemical and of material Physical Angles, M.S.
composition
Rolling and Cutting Tolerances for Hot Rolled Steel products
3.00.00
RAW MATERIAL The Steel Sections shall be re-rolled from the BILLETS/INGOTS of tested quality as per latest version of IS: 2830 or to any equivalent International Standard and shall be arranged by the bidder from their own sources. The Chemical composition and Physical properties of the finished materials shall be as per the relevant standards. Unless otherwise specified all the channels shall be ISLC as per Indian Standard.
4.00.00
TEST Steel Sections shall be tested in IS approved Laboratory or standard Laboratory of the Bidder country having all facilities available for conducting all the tests as prescribed in relevant IS or IEC or to any equivalent International Standard or from any recognized and reputable International laboratory or Institutions. The Bidders are required to specifically indicate that; (i) (ii) They hold valid IS (or equivalent IEC) License. Steel Sections offered are bearing requisite IS certification or equivalent IEC marks.
The Bidders are required to submit a copy of the valid IS (or equivalent IEC) License clearly indicating size and range of product against respective ISS or any equivalent International Standards along with their offer.
RGGVY WORKS STANDARD TECHNICAL SPECIFICATION (REV.- 03) TECHNICAL SPECIFICATION VOL II (PART-B) CHAPTER-II SECTION-E-8 MISCELLANEOUS ITEMS Page 12 of 43
. CLAUSE NO
MISCELLANEOUS ITEMS PHYSICAL & CHEMICAL PROPERTIES Length The GS Flat to be supplied shall be in 5.5 metres to 13 metres lengths. Weighment The weighment of GS Flat shall be witnessed by the consignee at the time of taking delivery. The weight recorded in the material receipt certificate issued by the consignees shall be final.
5.00.00
5.01.00
Chemical Composition and Physical Properties of M.S. Angles, M.S. Channels and M.S. Flat conforming to IS : 2062/84L composition Chemical Composition 1 2 3 4 5 6 C Mn S P SI For Fe 410 WA Grade 0.23% 1.5% 0.050% 0.050% 0.40% 0.42% MAX. MAX. MAX. MAX. MAX. MAX.
CE (Carbon Equivalent)
5.02.00
Mechanical Properties 1. 2. Tensile strength Kgf/mm2 42, N/Min, Yield stress Min. for thickness/diameter < 20 mm 20 40 mm 3. 4. 40 mm Elongation % Bend Test (Internal Dia) 410 26 kgf/m2 OR 250 N/mm2 24 Kgf/mm2 OR 240 N/mm2 23 kgf/mm2 OR 230 N/mm2 23% Min-3t (t is the thickness of the material)
6.00.00
MARKING It is desirable that the Bidder should put his identification marks on the finished materials. The mark shall be in legible English letters given with marking dies of minimum 18 mm size.
Page 13 of 43
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MISCELLANEOUS ITEMS INSPECTION AND TEST CERTIFICATES The materials to be supplied will be subject to inspection and approval by the purchasers representative before dispatch and / or on arrival at the destination. Inspection before dispatch shall not, however, relieve the bidder of his responsibility to supply the Steel Sections strictly in accordance with the specification. (i) The bidder shall abide by all the statutory provisions, acts such as the Indian Electricity Act, Indian Factory Act, Indian Boiler Act etc., and corresponding rules and regulations as may be applicable and as amended from time to time. The purchasers representative shall be entitled at all reasonable time during manufacture to inspect, examine and test at the bidders premises the materials and workmanship of the Steel Sections to be supplied.
7.00.00
(ii)
(iii) As soon as the Steel Sections are ready for testing, the bidder shall intimate the purchaser well in advance, so that action may be taken for getting the material inspected. The materials shall not be dispatched unless waiver of inspection is obtained or inspected by the purchasers authorized representative. (iv) Test certificates shall be in accordance with latest version of the relevant Indian Standards or any equivalent International Standards. (v) The acceptance of any batch/lot shall in no way relieve the bidder of any of his responsibilities for meeting all the requirements of the specification and shall not prevent subsequent rejection of any item if the same is later found defective.
All conductors burred in earth and concrete and above ground level shall be galvanised steel. Galvanised steel shall be subject to four one minute dips in copper sulphate solution as per IS: 2633 /1922. Method of galvanizing: S. No. 1 2 Tests Dip test Mass of zinc coating For GS Flat 4 dips of 1 minute each 300 gram/Sq.m minimum
Pre despatch inspection shall be performed to witness following tests: 1. 2. 3. 4. 5. Freedom from defects, Verification of dimensions Galvanization tests Mechanical tests Chemical composition tests
These tests are to be performed and certified at Govt. recognized laboratory.
Page 14 of 43
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MISCELLANEOUS ITEMS CABLE GLANDS AND LUGS
1.00.00
SCOPE This specification covers manufacture, design and supply of Cable Glands and Lugs.
2.00.00
APPLICABLE STANDARDS Cable glands : BS 6121 Cable lugs shall conform to IS : 8309 and 8394 suitable for aluminium conductor.
3.00.00 3.01.00
GENERAL REQUIREMENTS Cable glands and Lugs shall be Double compression type, tinned/Nickel plated (coating thickness not less than 20 microns in case of tin and 10 to 15 microns in case of nickel) brass cable glands for all power cables. They shall provide dust and weather proof terminations. 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. Required number of packing glands to close unused openings in gland plates shall also be provided. The cable glands shall be tested as per BS: 6121. The cable glands shall also be duly tested for dust proof and weather proof termination. Cables lugs shall be crimping type conforming to IS: 8309 and 8394 suitable for aluminum conductor. The cable lugs shall suit the type of terminals provided. The cable lugs shall be of Dowell make or equivalent.
3.02.00
Page 15 of 43
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MISCELLANEOUS ITEMS GALVANISED MILD STEEL CHANNEL, ANGLE AND FLAT
1.00.00
SCOPE This specification covers design, manufacture, testing and dispatch to Owners stores of Galvanized M.S. channel, angle and flat for use in structures & steel sections used in manufacture of AB switches, HG fuses, , stay clamps & other items for use in distribution system .
2.00.00
APPLICABLE STANDARDS Angles & Channels shall be rolled sections only with standard cross sections as specified in IS:SP6-1. Materials shall conform to the latest applicable Indian standards. In case bidders offer Steel Section and supports conforming to any other international specifications which shall be equivalent or better than IS, the same is also acceptable. S.No. 1 2 3 Standard No. Title
IS: 2062 Grade A Quality Specification for M.S. Angles, M.S. Channel and M.S. Flat IS: 2062 IS: 1852 Chemical and Physical composition of material Rolling and Cutting Tolerances for Hot Rolled Steel products
3.00.00 3.01.00
GENERAL REQUIREMENTS Raw Material The Steel Sections shall be re-rolled from the billets/ingots of tested quality as per latest version of IS: 2830 or to any equivalent International Standard.
3.02.00
Length The GS Flat to be supplied shall be in 5.5 metres to 13 metres lengths.
3.03.00
Chemical Composition and Physical Properties of M.S. Angles, M.S. Channels, and M.S. Flat conforming to IS : Conforming to IS : 2062/84.
Page 16 of 43
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MISCELLANEOUS ITEMS Chemical Composition Chemical Composition 1 2 3 4 5 6 C Mn S P SI For Fe 410 WA Grade 0.23% 1.5% 0.050% 0.050% 0.40% 0.42% MAX. MAX. MAX. MAX. MAX. MAX.
CE (Carbon Equivalent)
3.04.00
Mechanical Properties 1. 2. Tensile strength Kgf/mm2 Yield stress Min. for thickness/diameter < 20 mm 20 40 mm >40 mm 3. 4. Elongation % Bend Test (Internal Dia) 26 kgf/m2 OR 250 N/mm2 24 Kgf/mm2 OR 240 N/mm2 23 kgf/mm2 OR 230 N/mm2 23% Min-3t (tis the thickness of the material) -42 410
3.05.00
Tolerance Variation in ordered quantity for any destination and over-all ordered quantity shall be only to the extent of 2%. Rolling and weight tolerances shall be as per latest version of IS: 1852 or to any equivalent International Standard.
4.00.00
Galvanisation Zinc Zinc shall conform to grade Zn 99.9 specified in IS 209-1966 & IS: 4826-1979 with up to date amendments. Zinc Coating Zinc coating shall be in accordance with IS: 4826-1979 (Col. 4.2.1) for heavily coated hard quality. Galvanising Galvanizing shall be as per IS 2629-1966, IS: 4826-1979 with up to date amendments.
Page 17 of 43
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MISCELLANEOUS ITEMS
Uniformity of Zinc Coating Uniformity of Zinc coating shall be as per IS 2633-1972 (Col. 4.2.1 to 4.2.3) with up to date amendments. 4.00.00 TEST Steel Sections shall be tested in IS approved/ NABL accredited Laboratory or at manufacturers own laboratory having all facilities available for conducting all the tests as prescribed in relevant IS. 5.00.00 MARKING Manufacturer shall put his identification marks on the finished materials. The mark shall be in legible English letters given with marking dies of minimum 18 mm size. 6.00.00 INSPECTION AND TEST CERTIFICATES The materials to be supplied will be subject to inspection and approval by the purchasers representative before dispatch and/or on arrival at the destination. Inspection before dispatch shall not, however, relieve the bidder of his responsibility to supply the Steel Sections strictly in accordance with the specification. 1. The purchasers representative shall be entitled at all reasonable time during manufacture to inspect, examine and test at the bidders premises the materials and workmanship of the Steel Sections to be supplied. As soon as the Steel Sections are ready for testing, the bidder shall intimate the purchaser well in advance, so that action may be taken for getting the material inspected. The materials shall not be dispatched unless waiver of inspection is obtained or inspected by the purchasers authorized representative. Test certificates shall be in accordance with latest version of the relevant Indian Standards or any equivalent International Standards. The acceptance of any batch/lot shall in no way relieve the bidder of any of his responsibilities for meeting all the requirements of the specification and shall not prevent subsequent rejection of any item if the same is later found defective.
2.
3. 4.
Page 18 of 43
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MISCELLANEOUS ITEMS COMPOSITE SPACER FOR LT LINE
1.00.00
SCOPE This specification covers details of LT line spacers to overcome the problem of midspan clashing of conductors. The specification covers two types of spacers: Spiral type spacers. Composite spacers.
2.00.00
ATMOSPHERIC CONDITIONS LT line spacers shall be suitable for tropical climate with a maximum ambient air temp. of 500 C, humidity of 100% and wind pressure up to 150-kg/ m2.
3.00.00 3.01.00
GENERAL REQUIREMENTS Material Spiral type spacers shall be made of high quality PVC. The composite spacers shall be made polypropylene and shall be made of single mould except the clamping pieces. The fly nuts and studs shall be made of engineering grade nylon. The studs shall be properly fixed in position at the molding stage.
3.02.00
Shape and Dimensions The shape and dimensions of spiral type and composite spacers are shown in diagram no. Unless otherwise specified by the owner, the spacer shall be suitable for holding conductors having diameters ranging from 20 mm2 to 100 mm2.
4.00.00 4.01.00
APPLICATION Normally only one set of spiral type spacers (number of spacers will depend upon the number of conductors) or one single composite spacer in the middle of span should be adequate. However, where necessary, additional spacer(s) may be used in each span. The spiral type spacer shall be fixed between two adjacent conductors by twist the spiral ends around the conductors manually. The spacers shall automatically grip the conductors and remain in position. One spiral type spacer shall hold two line conductors and two spacers shall hold three conductors and so on.
4.02.00
4.03.00
Page 19 of 43
. CLAUSE NO
MISCELLANEOUS ITEMS The composite spacer is fixed by sliding the line conductors in the grooves and tightening the fly nuts manually. Only one composite spacer is required to hold a number of conductors depending upon its design. Both spiral type and composite spacers are suitable for vertical and horizontal configuration on conductors. However, the purchaser should clearly indicate the spacing between the adjacent conductors to enable the manufacturer to supply right type of spacers. TESTS LT spacers shall comply with the following test requirement:
4.04.00
4.05.00
5.00.00
5.01.00 5.01.01
Type tests Dry power frequency withstand voltage test : Spacer shall withstand dry power frequency test voltage of 23 kV when tested in accordance with IS: 1445- 1977 with suitable modifications to simulate the actual method of application in the field.
5.01.02
Wet power frequency withstand voltage test : The spacers shall withstand a wet power frequency test voltage of 10 kV when tested in accordance with IS: 1445-1977 with suitable modifications to simulate actual method of application in field.
5.01.03
Ageing/tensile test : Three specimens of LT spacers shall be maintained at a temp 700 (+) (-) 20C for a period of 24 hours. After this treatment, the specimens shall not show any deformity and after cooling, shall have a minimum tensile strength of 500 kg.
5.01.04
Dimensional verification : The dimensions for spiral type spacers shall have the following tolerances/range of variation: i) Length 3 mm of specified conductor spacing ii) Spacer rod dia 13 to 14 mm iii) Spiral hole dia 5 to 6 mm Length of each spiral and overall spiral length: Indicated dimensions (+) (-) 5 mm
The dimensions for composite spacers shall have the following tolerance: i) Overall length (+) (-) 5 mm
TECHNICAL SPECIFICATION VOL II (PART-B) CHAPTER-II SECTION-E-8 MISCELLANEOUS ITEMS Page 20 of 43
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MISCELLANEOUS ITEMS ii) iii) Each conductor spacing Other dimension (+) (-) 3 mm (+) 1 mm
5.02.00
Acceptance tests Visual examination : The spacers have fine and uniform finish. Ageing/tensile test : As defined above, Dimensional verification : As defined above,
6.00.00
PACKING The spacers shall be suitably packed I wooden boxes suitable for easy but rough handling and acceptable by rail/ road transport. Each box shall contain not more than 500 pieces.
7.00.00
MARKING Each spacer shall be embossed with the information like manufacturers name and trade mark and year of manufacture.
Page 21 of 43
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MISCELLANEOUS ITEMS GS STAY SETS
1.00.00
SCOPE This specification covers design, manufacture, testing and despatch of GS Stay Sets of 16 mm and 25 mm dia.
2.00.00 2.01.00
GENERAL REQUIREMENTS 16 mm Dia Stay Sets (Galvanized) for 11KV & LT line This stay sets (Line Guy set) will consist of the following components:-
2.01.01
Anchor Rod with one washer and Nut Overall length of rod should be 1800 mm to be made out of 16 mm dia GS Rod, one end threaded upto 40mm length with a pitch of 5 threads per cm and provided with one square GS washer of size 40x40x1.6mm and one GS hexagonal nut conforming to IS:1367:1967 & IS:1363:1967. Both washer and nut to suit threaded rod of 16mm dia. The other end of the rod to be made into a round eye having an inner dia of 40mm with best quality welding.
2.01.02
Anchor Plate Size 200 x 200 x 6 mm To be made out of GS plate of 6 mm thickness. The anchor plate should have at its centre 18 mm dia hole.
2.01.03
Turn Buckle & Eye Bolt with 2 Nuts To be made of 16mm dia GS Rod having an overall length of 450 mm, one end of the rod to be threaded upto 300 mm length with a pitch of 5 threads per cm and provided with two GS Hexagonal nuts of suitable size conforming to IS:1363:1967 & IS:1367:1967. The other end of rod shall be rounded into a circular eye of 40 mm inner dia with proper and good quality welding.
2.01.04
Bow with Welded Angle To be made out of 16mm dia GS rod. The finished bow shall have an overall length of 995 mm and height of 450 mm, the apex or top of the bow shall be bent at an angle of 10 R. The other end shall be welded with proper and good quality welding to a GS angle 180 mm long having a dimension of 50x50x6 mm. The angle shall have 3 holes of 18 mm dia each.
2.01.05
Thimble To be made on 1.5 mm thick GS sheet into a size of 75x22x40 mm and shape as per standard shall be supplied.
Page 22 of 43
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MISCELLANEOUS ITEMS Average Weight of Finished 16mm Stay Sets shall be at least 7.702 Kg. (Minimum) (Excluding Nuts Thimbles and Washers) 8.445 Kg. (Maximum). The size of the GS stay wire shall be 7/3.15 mm 20 mm Dia Stays Sets for 33 kV Lines (Galvanised) The Stay Set (Line Guy Set) will consist of the following components :
2.01.06
2.01.07 2.02.00
2.02.01
Anchor Rod with one Washer and Nut Overall length of Rod should be 1800mm to be made out of 20mm dia GS Rod, one end threaded upto 40mm length with a pitch of a threads per cm. And provided with one square G.S. Washer of Size 50x50x1.6mm and one GS Hexagonal nut conforming to IS:1367:1967 & IS:1363:1967. Both washer & nut to suit the threaded rod of 20mm. The other end of the rod to be made into a round eye having an inner dia of 40mm with best quality welding. Dimensional and other details are indicated and submitted by bidders for owners approval before start of manufacturing.
2.02.02
Anchor Plate of Size 200x200x6mm To be made out of G.S. Plate of8mm thickness. The anchor plate to have at its centre 22mm dia hole.
2.02.03
Turn Buckle, Eye Bolt with 2 Nuts To be made of 20 mm dia G.S. Rod having an overall length of 450 mm. One end of the rod to be threaded upto 300 mm length with a pitch of 4 threads per cm. The 20mm dia bolt so made shall be provided with two G.S. Hexagonal nuts of suitable size conforming to IS:1637/1967 & IS:1363/1967. The other end of the rod shall be rounded into a circular eye of 40mm inner dia with proper and good quality of welding.
2.02.04
Bow with Welded Channel To be made out of 20mm dia G.S. Rod. The finished bow shall have and overall length of 995 mm ad height of 450 mm. The apex or top of the bow shall be bent at an angle of 10R. The other end shall be welded with proper and good quality welding to a G.S. Channel 200 mm long having a dimension of 100x50x6 mm. The Channel shall have 2 holes of 18 mm dia and 22 dia hole at its centre .
2.02.05
Thimble 2 Nos. To be made of 1.5 mm thick G.S. sheet into a size of 75x22x40 mm and shape as per standard.
Page 23 of 43
. CLAUSE NO
MISCELLANEOUS ITEMS The size of the GS stay wire shall be 7/4mm Galvanising The complete assembly shall be hot dip galvanised.
2.02.06 2.03.00
2.04.00
Welding The minimum strength of welding provided on various components of 16 mm and 20 mm dia stay sets shall be 3100 kg. & 4900 kg respectively. Minimum 6mm filet weld or its equivalent weld area should be deposited in all positions of the job i.e. at any point of the weld length. The welding shall be conforming to relevant IS: 823/1964 or its latest amendment.
2.05.00
Threading The threads on the Anchor Rods, Eye Bolts and Nuts shall be as per specification IS: 4218:1967 (ISO Metric Screw Threads). The Nuts shall be conforming to the requirements of IS: 1367:1967 and have dimension as per IS 1363:1967. The mechanical property requirement of fasteners shall confirm to the properly clause 4.6 each for anchor rods and Eye bolt and property clause 4 for nuts as per IS: 1367:1967. Average weight of finished 20 mm Stays Set : 14.523 Kg. (Min.) (Excluding Nuts Thimble & Washer) : 15.569 Kg. (Max.)
3.00.00
TESTS The contractor shall be required to conduct testing of materials at Govt./Recognized testing laboratory during pre dispatch inspection for Tensile Load of 3100 Kg/4900 Kg. applied for one minute on the welding & maintained for one minute for 16 mm and 20 mm dia stay sets respectively.
4.00.00
IDENTIFICATION MARK All stay sets should carry the identification mark of word AREP works by NTPC and size of the stay set. This should be engraved on the stay plate and on stay rods to ensure proper identification of the materials. The nuts should be of a size compatible with threaded portion of rods and there should be no play or slippage of nuts. Welding wherever required should be perfect and should not give way after erection.
5.00.00
TOLERANCES
Page 24 of 43
. CLAUSE NO
MISCELLANEOUS ITEMS The tolerances for various components of the stay sets are indicated below subject to the condition that the average weight of finished stay sets of 16mm dia excluding nuts, thimbles and washers shall not be less than the weight specified above :-
Sl. No 1
Item
Applicable for
Fabrication Section dimension & dimension Tolerances Tolerances 16mm 200x200mm +1% thick+12.5%5%
Material & GS plate 6mm thick
Anchor Both 33KV & Plate 11 KV Line Anchor 11 Line Rod KV
Round 16mm dia Length 1800mm GS dia +0.5% Rounded 16mm +5%- 3% Eye 40 mm inside dia + 3%. Threading 40mm+11%-5 GS Round 20mm dia + Length 20mm dia 1800mm+0.5% 3%- 2% Rounded Eye 40 mm inside dia + 3%. Threading 40mm+11%-5 16mm dia Length 995mm+1%16mm +5%- 3% dia GS Round 16mm dia
33 Line
KV
Turn Buckle Bow
11 Line
KV
Channel length GS Channel 180mm+1% 100x50x6mm 33 Line KV 20mm dia + Length 995mm+1%16mm 3%- 2% dia GS Round 20mm dia
Channel length GS Channel 200mm+1% 100x50x6mm 4 Eye Bolt Rod 11 Line KV 16mm dia Length 450mm GS Round +1% Threading 16mm dia +5%- 3% 300mm+1% Round Eye 40mm inside
. CLAUSE NO
MISCELLANEOUS ITEMS dia+3% 33 Line KV Round 20mm dia + Length 450mm GS dia +1% Threading 20mm 3%- 2% 300mm+1% Round Eye 40mm inside dia+3%
Page 26 of 43
. CLAUSE NO
MISCELLANEOUS ITEMS DANGER PLATE
1.00.00
SCOPE This Specification covers manufacture, testing and supply to the owners stores of Danger Notice Plates to be displayed in accordance with Rule No. 35 of Indian Electricity Rules, 1956.
2.00.00
APPLICABLE STANDARDS The danger Notice Plates shall comply with IS: 2551-1982and REC Spec. No. 57/1993 or the latest version thereof
3.00.00 3.01.00
DIMENSIONS Two sizes of Danger Notice as follows are recommended: a) b) For display at 415 V installations 200 x 150 mm 250 x 200 mm
For display at 11 KV (or higher voltages) installations -
3.02.00 4.00.00
The corner of the plate shall be rounded off. LETTERINGS All leterings shall certainly spaced. The dimension of the letters, figures and their respective position shall be as shown in Fig. 1 to 4 of IS 2551. The size of letters in the words in each languages and spacing earmarked for them.
5.00.00 5.01.00
LANGUAGES Under Rule No. 35 of Indian Electricity Rules, 1956, the owner of every medium, high and extra high voltage installation is required to affix permanently in a conspicuous position a danger notice in Hindi or English and, in addition, in the local languages, with the sign of skull and bones. The type and sizes of lettering to be done in Hindi is indicated in the specimen danger notice plates shown in Fig. 2 and 4 and those in English are shown in Figs. 1 and 3 of IS 2551 Adequate space has been provided in the specimen danger notice for having the letterings in local languages for the equivalent of Danger : 415 11000 and volts. MATERIAL AND FINISH The plates shall be made from mild steel sheet of at least 1.6 mm thick and vitreous enameled white, with letters, figures and the conventional skull and cross- bones in
5.02.00
5.03.00
6.00.00
Page 27 of 43
. CLAUSE NO
MISCELLANEOUS ITEMS signal red colour (refer IS:5-1978) on the front side. The rear side of the plate shall also be enamelled.
7.00.00
TESTS The following tests shall be carried out: i) ii) iii) Visual examination as per IS: 2551-1982. Dimensional check as per IS: 2551-1982. Test for weather proofness as per IS:8709-1977 (or its latest version)
8.00.00
MARKING Makers name and trade mark and the purchasers name shall be marked in such a manner and position on the plates that it does not interfere with the other information.
9.00.00
PACKING The plates shall be packed in wooden crates suitable for rough handling and acceptable for rail / road transport.
Page 28 of 43
. CLAUSE NO
MISCELLANEOUS ITEMS HELICALLY FORMED FITTINGS FOR 11 KV AND LT LINES
1.00.00
SCOPE This Standard specifies the requirements and tests for helically formed fittings for use on 11 KV and LT overhead lines. The following types of fittings are covered:a) b) c) d) e) f) g) Conductor dead end fittings Distribution ties, side ties and double ties Conductor splices Guy grip dead-ends Tap connectors Service grip dead-ends Lashing rods
2.00.00 2.01.00
GENERAL REQUIREMENTS Aluminium alloy, aluminium-clad steel and galvanised steel wires having required mechanical strength, corrosion resistance and formability, depending on the type of application shall be employed in the manufacture of the fittings. The material of the formed fittings shall be compatible with the conductors with which it is used. In case of formed wires, no joints shall be permitted except those in the base rod or wire before final drawing. Each formed set shall be marked with indelible and distinct colour to indicate starting/cross-over point of application to facilitate its application on the conductor. The ends of the individual wires of the formed fittings shall be suitably deburred to provide a smooth finish so as to avoid any damage to the conductor due to sharp edges.
2.02.00
2.03.00
2.04.00
Page 29 of 43
. CLAUSE NO
MISCELLANEOUS ITEMS Suitable grit shall be applied to the gripping section of the formed fitting (except lashing rods) in order to enhance its gripping strength. PROPERTIES OF WIRES Materials of the wires used in the manufacture of the fittings covered by this specification shall have the mechanical and electrical properties as specified in Tables 1,2 and 3. Materials used for chloroprene pad shall have the properties specified in Table 4. Table 1 Aluminium Alloy Wires Test 1. Visual Requirements a) b) c) d) a) b) 3. 4. 5. 6. Tensile strength of formed wires Elongation of finished wire Conductivity of finished wire Wrap test Wire diameter (mm) Upto 3.07 From 3.08 to 3.45 From 3.46 to 3.71 From 3.72 to 4.24 From 4.25 and above No scratches No pealing off No speed crack No cut crack Diameter Tolerance (+) .000 mm (-) .025 mm Flattening (+) .000 mm (-) .076 mm
2.05.00
3.00.00 3.01.00
2.
Dimensions after forming
35 Kg/mm2 Min. 2% in a gauge length of 50 mm Min. 39% as per IACS Min. number of twists on a mandrel of its own dia without fracture at a rate of 15 turn per minute 18 16 14 12 10
Page 30 of 43
. CLAUSE NO
MISCELLANEOUS ITEMS Table 2 Aluminium Clad Steel Wires Test Visual Dimensional Tensile strength Weight of coating Wrap test (on a mandrel 2 times the dia of the sample and at the rate of 15 turns/minute) Adherence of coating (in a close helix not exceeding 15 turns/minute) around a cylindrical mandrel having a diameter prescribed in table 2c Table 2a Wire diameter (mm) Ultimate tensile strength (minimum) Mpa 1280 1240 1210 1170 1140 Table 2b Wire diameter (mm) 1.270 to 1.521 including 1.524 to 1.902 including 1.905 to 2.283 including 2.286 to 2.639 including 2.642 to 3.045 including 3.048 to 3.553 including 3.556 to 4.569 including 4.572 to 4.826 including Min. weight of aluminium coating on uncoated wire surface (gms/m2) 70 76 79 85 92 98 104 116 Ultimate elongation (Min.) percent in 254 mm 3.0 3.5 4.0 4.0 4.0 Requirements Free from splints, scale, inequalities, flaws and other irregularities Roundness to () 0.013 mm As per table 2a below As per table 2b below After close helix, the sample should not fracture No cracking or flacking to such an extent that the aluminium coating can be removed by rabbing with the bare fingers.
1.270 to 2.283 including 2.286 to 3.045 including 3.048 to 3.515 including 3.518 to 3.782 including 3.785 to 4.826 including
Page 31 of 43
. CLAUSE NO
MISCELLANEOUS ITEMS Table 2c Wire diameter 1.270 to 2.283 including 2.286 to 3.553 including 3.556 to 4.826 including Min. ratio of mandrel diameter to wire diameter 3 4 5
Test Visual Dimensional
Table 3 Zinc coated steel wire Requirements Free from splints, scale, inequalities and other irregularities Roundness to () 0.013 mm As per table 3a below As per table 3b below After close helix of minimum 8 turns, the sample should not fracture No cracking or flacking to such an extent that zinc coating can be removed by rabbing with the bare fingers.
Tensile strength of finished wire Weight of zinc coating Wrap test (on a mandrel 2 times the dia of the sample and at the rate of 15 turns/minute) Adherence of coating (in a close helix not exceeding 15 turns/minute) around a cylindrical mandrel having a diameter prescribed in table 3c. Table 3a Wire diameter (mm)
Ultimate tensile strength (minimum) Mpa 1450 1410 1410 1380 Table 3b
Elongation in 200 mm gauge length minimum (%) mm 3.0 3.5 4.0 4.0
1.270 to 2.283 including 2.286 to 3.045 including 3.048 to 3.053 including 3.556 to 4.022 including Wire diameter (mm) 1.270 to 1.521 including 1.524 to 1.902 including 1.905 to 2.283 including 2.286 to 2.639 including 2.642 to 3.045 including
Minimum weight of zinc coating on uncoated wire surface (gms/m2) 183 198 214 229 244
. CLAUSE NO
MISCELLANEOUS ITEMS 3.048 to 3.553 including 3.556 to 4.69 including 4.572 to 4.822 including Table 3c Wire diameter (mm) 1.270 to 2.283 including 2.286 to 3.553 including 3.556 to 4.822 including Ratio of mandrel diameter to wire diameter 3 4 5 259 274 305
Table 4 Properties for Chloroprene pad Chloroprene cushion shall have following properties : Tensile Strength Minimum 100 Kg/cm2 Tensile strength (after ageing) Loss of maximum 25% of the test value obtained in 1(a) Elongation Elongation (after ageing) Shore hardness A Shore hardness (after ageing) 250% minimum Loss of maximum 25% of the test value obtained in 2(a) 65 () 5 () 15% of test values obtained in 3 (a)
Note : Ageing should be carried out for 70 hours at 100oC. 4.00.00 REQUIREMENTS APPLICATIONS OF FORMED FITTINGS FOR VARIOUS
4.01.00 4.01.01
Conductor Dead-end fittings Formed conductor dead-end fitting for 11 KV lines consists of the following parts for use with disc insulators of clevis and tongue type: a) Cross arms strap for attaching the fittings to the pole on one side and the disc insulator on the other. These fittings shall conform to the REC Specifications 3/1993. Aluminium alloy die cast thimble clevis for attaching the fitting to the tongue of disc insulator on one end and for accommodating loop of the helically formed fitting at the other end in its smooth internal contour. The
b)
. CLAUSE NO
MISCELLANEOUS ITEMS thimble clevis is attached to the insulator through a steel cotter pin used with a non-ferrous split pin of brass or stainless steel. The thimble clevis shall have clevis dimensions as per IS : 2486 (Part II)-1989 and shall have the minimum failing load strength of 3000 kg. c) Helically formed fitting acting as the dead-end grip.
4.01.02
The die-cast aluminium alloy thimble clevis shall be manufactured with alloy A6 Designation of IS : 617 - 1975. Nuts and bolts used shall be of galvanised steel conforming to IS:1364 - 1967 and cotter pins conforming to IS : 2004 -1978. Spring washers used shall be electrogalvanised. The fitting for LT lines shall comprise of the helically formed fitting to suit the LT shackle insulator as per REC Specification 4/1972. The fittings shall be made to suit the following conductor sizes for 11 KV/LT Lines conforming to REC Specification 1/1971(R-1993) and each fitting shall have a clear identification mark on PVC/metallic/plastic tag, indicating size of the conductor and voltage. The following colour code shall be used for the tag as also for the starting/cross-over marks for quick identification: 20 mm2 ACSR(Squirrel) 30 mm2 ACSR(Weasel) 50 mm2 ACSR (Rabbit) 50 mm2 ACSR (Rabbit) 50 mm2 AAC (Ant) Blue Red Yellow Brown Grey
4.01.03
4.01.04
4.01.05
4.02.00 4.02.01
Distribution ties side ties and double ties Helically formed ties are used to hold the conductor to pin insulators or shackle insulators. Chloroprene pad shall be provided with the formed ties for use on 11 kV lines to avoid abrasion of the conductor The conductor sizes and voltage class shall be clearly marked on each fitting and the fittings shall also be identified by color code as per clause 4.1.5. To ensure proper fitting of 11 KV pin insulator ties, the purchaser shall furnish fulldimensions of the insulator top particularly the crown diameter, neck diameter etc. See page 4 of REC specification 3/1971 (R-1993).
4.02.02
4.02.03
4.02.04
. CLAUSE NO
MISCELLANEOUS ITEMS Conductor Splices Conductor splices for ACSR conductors shall consist of (i) galvanized steel formed splice for steel core (ii) aluminium alloy formed filler rod (iii) aluminium alloy formed splice for the aluminium strands of the conductor. For AAC conductor, splice is formed with aluminium alloy only. Repair Splice: Repair splices are non-tension splices and are used where some of the outer strands of the conductor are damaged. Guy Grip Dead-End Guy grip dead ends have one leg shorter than the other and are suitable for gripping the guy wire. These grips are applied on one side into the thimble eye of the stay rod and on the other side to the guy wire. These can also be used directly with guy insulators. The fittings shall be made of two sizes to suit stay wires of 7/3.15mm(7/10SWG) and 7/2.5 mm (7/12SWG) having UTS values 3625 kg and 2300 kg respectively. The fittings shall be clearly identified on a PVC/mettalic/plastic tag for the size of stay wire with which these are to be used and, in addition, the following colour codes for the tag as well as the corss-over marks shall be adopted for proper identification: Guy grip for 7/3.15 mm stay wire - Green Guy grip for 7/2.5 mm stay wire - Black
4.03.00 4.03.01
4.03.02
4.04.00 4.04.01
4.04.02
4.04.03
4.04.04
The guy grip shall be supplied complete with thimble to suit the fitting. Thimble shall be made of hot-dipped galvanized steel. Note: The guy grips to be used with guy insulators shall take into account the standard sizes of insulators as per REC specification No.21/1981 and the type and size of the guy insulator shall be clearly specified by the purchaser.
4.05.00
Tap Connectors: Tap connectors consist of helically formed aluminium alloy wires for non-tension tapping of conductors and cables from the main line. The sizes of conductors/cables for which these tap connectors are to be used have to be clearly specified by the purchaser. Service Grip Dead End: Service grip dead-ends are used with metallic knob to hold one or more service bearer wires.
4.06.00
Page 35 of 43
. CLAUSE NO
MISCELLANEOUS ITEMS Lashing Rods: Lashing rods are helically formed wires to secure the bearer wire to the service cable. The number of lashing rods will depend on the length of service. DIMENSIONAL FITTINGS REQUIREMENTS OF THE FINISHED FORMED
4.07.00
5.00.00
5.01.00 5.02.00
The lay of the helix shall be right hand. The diameter and number of formed rods used per set of fittings to be used on various sizes of conductors shall be as per the approved drawings. Tolerances of formed fittings: The various requirements of the helically formed fitting shall be within the following toleranaces: Item a) b) c) d) Pitch length Internal diameter Length of individual rod Difference in length + 1% (-) 3% () 1% () 1% between the longest and the shortest rod in an individual set Tolerances + 0.6 mm (-)0.12 mm
5.03.00
6.00.00 6.01.00
TESTS Type Tests: The following tests shall constitute the type tests on the finished fittings: S.No. 1. 2. 3. 4. 5. 6. 7. 8. 9. Test Visual examination Verification of dimension Tensile strength test Electrical resistance test Wrapping test Slip strength test Resilence test Unbalanced holding Strength Test Fatigue test Applicable to All fittings All fittings All fittings All aluminium alloy fittings All fittings Conductor dead-end, guy grip and splices Conductor dead-end, guy grip and conductor splices Ties only Conductor dead-end, ties and splices
CHAPTER-II SECTION-E-8 MISCELLANEOUS ITEMS Page 36 of 43
. CLAUSE NO
MISCELLANEOUS ITEMS 10. 11. 12. 13. Hardwares and fittings using GI wire Pull-off strength test Ties only Electrical & Mechanical Test Tap Connectors Tests for other requirements as per Tables 1,2, 3 & 4. Galvanising test
Acceptance Test: The following shall constitute the acceptance test: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Visual examination Verification of dimension Tensile Strength test Electrical resistance test Wrapping test Slip Strength test Resilence test Unbalanced load Galvanisation test Pull-off strength Electrical & Mechanical tests on tap connectors The tests for other requirements as per Tables 1,2,3 & 4 on the individual wires used in making the helically formed fittings and chloroprene pad (where used).
6.03.00
Routine Tests: The following shall constitute the routine tests: a) b) Visual examination Verification of dimensions
7.00.00 7.01.00
TEST PROCEDURE Visual Examination: All fittings and individual wires shall be checked visually for good workmanship, smooth finish and other requirements indicated in Table 1, 2 and 3. Verification of dimensions: The dimensions shall be checked as specified in the tables 1, 2, 3 and clause 5. Tensile Strength Test: Individual wire of the helically formed wires shall be straightened by light hammering and tested for tensile strength and elongation in accordance within the
7.02.00
7.03.00 7.03.01
. CLAUSE NO
MISCELLANEOUS ITEMS IS:398(Part II)-1976. The tensile strength and the elongation of the formed wires shall not be less than the values specified in tables 1, 2 and 3.
7.03.02
For thimbles and hardwares other than formed fittings: The dead-end clevis thimble and straps shall be tested for tensile strength in accordance with the requirements of mechanical failing load as per IS:2486(Part I)1993.
7.04.00
Electrical Resistance Test: This test shall be done on straightened aluminium alloy formed wires only. The conductivity of the wires should not be less than 39% IACS. Wrapping Test: The individual wires of the formed fittings shall be tested as specified in tables 1, 2 and 3. The wires should not break or show fracture when tested as above. Slip Strength Test: For the conductor dead-end and guy grip dead-end, the test shall be made in accordance with IS:2486(Part I)-1993 and the value of slip/breaking strength shall not be less than 85% of the breaking strength of the conductor for conductor dead-end fitting and 100% for guy wires dead end fittings. In case of tension splices, the test shall be carried out as per IS:2121. No slippage or damage to the fitting shall occur at a value less than 100% of breaking load of the conductor. This test should be repeated after the resilence test. Reslience Test: A set of helically formed fitting is wrapped and un-wrapped on a piece of conductor 3 times successively. The helical fitting should not lose its resilence even after three applications and should be able to pass the slip strength test requirements mentioned in 7.6 thereafter. Unbalanced Holding test: Unbalanced holding strength is the ability of the formed ties to maintain a constant and uniform grip on the conductor when intermittent and repeated unbalanced loads impose a tension imbalance in the span. These imbalances occur due to wind induced motion, impacts, ice conditions and more so when the conductor is broken. The test is intended to simulate the broken wire condition. A span of minimum 20 meters tensioned for 40% of UTS of the conductor shall be erected in the laboratory and a pin insulator along with the insulator tie under test shall be applied in the middle of span. The conductor used for this purpose shall be of the specific size with which the insulator tie is to be used. The test set up shall be such that it should be possible to apply a pull on one of the two dead ends of the conductor. For the purpose of this test, a steel replica of the insulator will be used. During the test, tension on one side of the pin insulator shall be suddenly released and effect observed. No slippage or damage to the fitting shall occur. After releasing tension
7.05.00
7.06.00
7.07.00
7.08.00
Page 38 of 43
. CLAUSE NO
MISCELLANEOUS ITEMS from the other end, the fitting should retain the original form. This test will not only check the holding strength of the fitting but will also prove the resilence of the fitting in the event of broken wire. The test shall be repeated. After releasing the conductor tension on one side, pulling force shall be slowly applied on the other dead-end to pull the conductor till slippage/damage occurs. This force shall not be less than 320 kg.
7.09.00
Fatigue Test: The fittings should be subjected to fatigue test along with the conductor by imparting 10 million cycles of peak to peak amplitude at a frequency above 30 cycles for minimum span length of 20 meters, at 40% of UTS of conductor. The amplitude of the vibrations at the antinodal points should be atleast 50% of the diameter of the conductor. The test should be carried out for 10 million cycles as continuously as possible after which the conductor fitting and insulator should be examined. There should be no damage to the conductor or the insulator where the fitting is attached. The fitting should also be able to withstand the test without any damage. Galvanising Test: Galvanising test should be carried out in accordance with IS:4826-1979 for uniformity and IS:6745-1972 for weight of zinc coating and the fittings will meet the requirements of Table 3. Pull-Off Strength Test: This test is intended to simulate the conductor pull-off conditions created by various factors including elevation difference of the supporting structures on the two sides of the tie. A span of minimum 20 metres tensioned for 40% of UTS of the conductor shall be erected in the laboratory with a conductor of the specified size with which the fitting is intended to be used. A steel replica of pin insulator alongwith the insulator tie under test shall be applied in the middle of span so that a suitable pull-off force can be applied on the pin by means of a machine. The pull-off strength of the tie shall not be less than 200 Kg. for all the three sizes of ACSR. Electrical & Mechanical Test on Tap Connectors: The tap Connectors shall conform to all the electrical and mechanical properties as per IS:5561. PACKING AND MARKING All helically formed items covered under this specification shall be carefully handled to prevent distortion and damage. These items shall be packed and stored in suitable cartons. Different colour codes shall be adopted for different conductor sizes and catalogue number and range of outside diameter of the conductor shall be indicated on the packing.
7.10.00
7.11.00
7.12.00
8.00.00 8.01.00
8.02.00
Page 39 of 43
. CLAUSE NO
MISCELLANEOUS ITEMS Clevis thimbles and other hardwares for conductor dead-ends shall be packed in wooden crates with all necessary markings. The packings of the fittings should carry the following informations. a) b) c) d) e) Purchasers name Manufacturers name and trade mark Size of conductor, line voltage (when required) and numbers Batch number, date, month and year of manufacture Any other marking agreed to between manufacturer and user.
8.03.00
8.04.00
Page 40 of 43
. CLAUSE NO
MISCELLANEOUS ITEMS CROSS-ARMS FOR 33KV AND 11KV OVERHEAD POWER LINES
100.00 1.00.01 1.00.02 2.00.00 2.00.01
V SHAPE M.S. CROSS ARMS WITH CLAMPS X-arms shall be made out of 100 x 50 x 6 mm M.S. Channel for 33kv and 75x40 X6mm for 11kV. The cross arms & clamps shall be hot dip galvanized conforming to IS-2633/72. SHAPE & SIZE The cross arms shall have two holes of 22 mm dia (for 11Kv line) and 26 mm dia (for 33kv line) for fixing of pin insulators. The center-to centre distance between the holes shall be 1070 mm (for 11kv) and 1525 mm (for 33kv ) and holes shall be in the middle of the top width of cross arms. MARKING The following information shall be marked on each cross arm: a) b) Manufacturers name or trademark. Year of manufacture
3.00.00
Page 41 of 43
. CLAUSE NO
MISCELLANEOUS ITEMS HOT DIP GALVANISED STEEL BARBED WIRE
1.00.00
SCOPE This specification covers manufacture, testing and supply of hot dip galvanized MS barbed wire of type A-1(Iowa). Covers the requirements for two types of galvanized steel barbed wire with two strands of wire.
2.00.00
APPLICABLE STANDARDS Zinc Zinc shall conform to grade Zn 98.5 specified in IS 13229:1991with up to date amendments. Zinc Coating Zinc coating shall be in accordance with IS: 4826 for medium coated wire. Galvanising Galvanizing shall be as per IS: 2629, IS: 4826 with up to date amendments. Uniformity of Zinc Coating Uniformity of Zinc coating shall be as per IS 2633 with up to date amendments. Tensile Properties The tensile strength of the line wire after, galvanizing shall be between 390-590 N/mm2. Minimum Breaking Load of completed barbed wire shall conform to IS:278. Freedom from Defects The line and point wires shall be circular in section, free from scales and other defects and shall be uniformly galvanized. The line wire shall be in continuous lengths and shall not contain any welds other than those in the rod before it is drawn. The distance between two successive weldings in the line wire of finished barbed wire shall not be less than 15 m. There shall be no splicings.
3.00.00
MATERIAL The galvanized barbed wire shall be manufactured from galvanized mild steel wire conforming to IS : 280. The barbed wire shall be formed by twisting together two line wires, one or both containing the barbs. The barbs shall be so finished that the four points are set and located or locked as far as possible at right angles to each. The barbs shall have a length of not less than 13 mm and not more than 18 mm.
Page 42 of 43
. CLAUSE NO
MISCELLANEOUS ITEMS TYPE TESTS All type Tests Shall conform to IS:278
4.00.00
5.00.00
PACKING & MARKING Packing and Marking shall be as per IS : 278. Unless otherwise agreed to between the supplier and the purchaser, the barbed wire shall be supplied in metal or wooden reels.
6.00.00
GAURANTEED TECHNICAL PARAMETERS The following gauranteed technical parameters shall be applicable. S.No PARAMETERS 1 Diameter a)Line Wire b)Point Wire 2 Tolerance in Diameter Of Wire 3 Distance Between Two Barbs 4 Tolerance in Distance b/w Barbs 5 Lengths Of Barbs 6 No. of Lays b/w Barbs 7 Tensile Strength Of Line Wire 8 Minimum Breaking Load Of Complete Barbed Wire 9 Minimum Mass Of Zinc Coating a)Line Wire b)Point Wire 10 Number of Dips 11 Packing 12 Standards Adopted Type test reports (all COMPLIED mentioned in relevant clause) Make shall be NESCL Corporate Quality Assurance (CQA) approved. UNIT mm mm mm mm mm mm Nos. N/mm2 KN Values 2.5 2.5 +0.08 75 +12 13 to 18 2 to 7 390-590 3.7
g/m2 g/m2 Minute
120 120 1 x 1 , 1 x 1/2 Bounded Four Sides with G.I Wire IS:278/1978 IS:4826/1979
Page 43 of 43
CLAUSE NO.
33 & 11 kV COMPOSITE INSULATOR SCOPE This specification covers design, manufacture, testing and supply of composite insulators for use in the 11 kV/33 kV overhead transmission lines and substations. The composite insulators shall be of the following type: Long rod insulators for conductors in tension application at angle/cut points. The insulators shall be of ball and socket type or tongue & Clevis type, as desired by the purchaser. Line post insulators or pin insulators for straight line locations.
1.00.00
2.00.00 2.01.00
APPLICABLE STANDARDS Standards Following Indian/International Standards, which shall mean latest revision, with amendments/changes adopted and published, unless specifically stated otherwise in the Specification, shall be referred while accessing conformity of insulators with these specifications. In the event of supply of insulators conforming to standards other than specified, the Bidder 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 Bidder and those specified in this document will be provided by the Supplier to establish equivalence. Sl. No. 1 2 3 4 Indian Standard IS:731 IS:2071 IS:2486 International Standard Definition, test methods and acceptance IEC:61109 criteria for composite insulators for a.c. overhead lines above 1000 V Porcelain insulators for overhead Power IEC:60383 lines with a nominal voltage greater than 1000 V Methods of High Voltage Testing IEC:60060-1 Specification for Insulator fittings for IEC:60120 Overhead Power Lines with a nominal IEC:60372 voltage greater than 1000 V General Requirements and Tests Dimensional Requirements Locking Devices Thermal Mechanical Performance test and IEC:60575 mechanical performance test on string insulator units Guide for the selection of insulators in IEC:60815 respect of polluted conditions Characteristics of string insulator units of IEC:60433 the long rod type Hydrophobicity Classification Guide STRI guide1.92/1
TECHNICAL SPECIFICATION VOL-II (PART-B) CHAPTER-II SECTION-E9 33& 11kV COMPOSITE INSULATOR Page 1 of 14
Title
5 6 7 8
IS:13134 -
CLAUSE NO.
33 & 11 kV COMPOSITE INSULATOR 9 10 11 12 13 14 15 16 17 18 19 IS:8263 IS:4759 IS:2629 IS:6745 IS:3203 IS:2633 IS:4699 Radio interference characteristics of overhead power lines and high-voltage equipment Methods of RI Test of HV insulators Standard for Insulators- CompositeDistribution Dead-end Type Hot dip zinc coatings on structural steel & other allied products Recommended Practice for Hot, Dip Galvanisation for iron and steel Determination of Weight of Zinc Coating on Zinc coated iron and steel articles Methods of testing of local thickness of electroplated coatings Testing of Uniformity of Coating of zinc coated articles Standard specification for glass fiber strands Standard test method for compositional analysis by Thermogravimetry Specification for refined secondary Zinc CISPR:18-2 Part 2 IEC:60437 ANSI C29.132000 ISO:1459 ISO:1461 ISO-1461 (E) ISO:1460 ISO:2178
ASTMD 578-05 ASTM E 113103
3.00.00 3.01.00
Technical Description of Composite Insulators Service condition The polymer insulators to be supplied shall be suitable for satisfactory continuous operation under conditions as specified below: Maximum ambient temperature Minimum ambient temperature Relative humidity : : : 50C -5C 0 to 100 %
3.02.00 3.03.00
Composite insulators long rod type for tension locations and pin/post type for suspension locations T he insulators shall be suitable for 3, 50 Hz, effectively earthed 11 kV and 33 kV O/H distribution system in a moderately/heavily polluted atmosphere. Long rod insulators shall be ball & socket or tongue & clevis type as specified. Bidder must be an indigenous manufacturer and supplier of composite insulators of rating 33 kV or above OR must have developed proven in house technology and manufacturing process for composite insulators of above rating OR possess technical collaboration/association with a manufacturer of composite insulators of rating 33 kV or above. The Bidder shall furnish necessary evidence in support of the above along with the bid, which can be in the form of certification from the utilities concerned, or any other documents to the satisfaction of the owner.
3.04.00
CLAUSE NO.
33 & 11 kV COMPOSITE INSULATOR Insulators shall have shed with good self-cleaning properties. Insulator shed profile; spacing, projection etc. and selection in respect of polluted conditions shall be generally in accordance with the recommendation of IEC-60815/IS: 13134. The size of Composite insulator, minimum Creepage distance and mechanical strength along with hardware fittings shall be as follows: Type of Composite insulators Nominal System voltage kV (rms) Wet Power Frequency Withstand voltage kV (rms) Minimum Creepage Distance (mm) Normal & moderately Polluted (20mm/kV) Heavily polluted (25 mm/kV) Min. failing load kN 45 70 5 10
3.05.00
3.06.00
Highest System voltage kV (rms)
Impulse Withstand voltage kV (rms)
Lon g rod insul ator ii Post/ pin Insul ator 3.07.00
11 33 11 33
12 36 12 36
9 27 9 27
35 75 35 75
75 170 75 170
240 720 240 720
320 900 320 900
16 16
Dimensional Tolerance of Composite Insulators The tolerances on all dimensions e.g. diameter, length and Creepage distance shall be allowed as follows in line with-IEC 61109: (0.04d+1.5) mm when d300 mm. (0.25d+6) mm when d300 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.
3.08.00
Interchangeability The composite insulators including the end fitting connection shall be of standard design suitable for use with the hardware fittings of any make conforming to relevant IEC/IS standards.
CHAPTER-II SECTION-E9 33& 11kV COMPOSITE INSULATOR
Page 3 of 14
Pin ball shank diameter mm
Visible Discharge test voltage kV (rms)
SL. No.
CLAUSE NO.
33 & 11 kV COMPOSITE INSULATOR Corona and RI Performance 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 not generate any radio interference beyond specified limit under the operation conditions.
3.09.00
3.10.00
Maintenance The composite insulators offered shall be suitable for use of hot line maintenance technique so that usual hot line operations can be carried out with ease, speed and safety.
4.00.00 4.01.00
BASIC FEATURES Design and construction The composite insulator shall have a core, housing & weather shed of insulating material and steel/aluminum hardware components for attaching it to the support/conductor.
4.02.00
Core It shall be a glass-fiber reinforced epoxy resign rod of high strength (FPR rod). Glass fibers and resign shall be optimized in the FRP rod. Glass fibers shall be Boron free electrically corrosion resistant (ECR) glass fiber or Boron free E-Glass and shall exhibit both high electrical integrity and high resistance to acid corrosion. The matrix of the FRP rod shall be Hydrolysis resistant. The FRP rod shall be manufactured through Pultrusion process. The FRP rod shall be void free.
4.03.00
Housing (Sheath) The FRP rod shall be covered by a seamless sheath of a silicone elastometic compound or silicone alloy compound of a thickness of 3mm minimum. It should protect the FRP rod against environmental influences, external pollution and humidity. It shall be extruded or directly molded on the core and shall have chemical bonding with the FRP rod. The strength of the bond shall be greater than the tearing strength of the polymer. Sheath material in the bulk as well as in the sealing/bonding area shall be free from voids.
4.04.00
Weathersheds The composite polymer Weathersheds made of silicone elastometic compound or silicon alloy shall be firmly bonded to the sheath, vulcanized to the sheath or molded as part of the sheath and shall be free from imperfections. The Weathersheds should have silicon content of minimum 30 % by weight. The strength of the weathershed to
Page 4 of 14
CLAUSE NO.
33 & 11 kV COMPOSITE INSULATOR sheath interface shall be greater than the tearing strength of the polymer. The interface shall be greater than the tearing strength of the polymer. The interface, if any, between sheds and sheath (housing) shall be free from voids.
4.05.00
End Fittings End fittings transmit the mechanical load to the core. They shall be made of spheroidal graphite cast iron, malleable cast iron or forged steel or aluminum alloy. They shall be connected to the rod by means of a controlled compression technique. The gap between fitting and sheath shall be sealed by a flexible silicone elastometic compound or silicone alloy compound sealant. System or attachment of end fitting to the rod shall provide superior sealing performance between housing, i.e. seamless sheath and metal connection. The sealing must be moisture proof. The dimensions of end fittings of insulators shall be in accordance with the standard dimensions stated in IS:2486/IEC:60120
5.00.00 5.01.00
Workmanship All the materials shall be of latest design and conform to the best engineering practices adopted in the high voltage field. Bidders shall offer only such insulators as are guaranteed by them to be satisfactory and suitable for continued good service in power transmission lines. 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. 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. Weathersheds shall be uniform in quality. They shall be clean, sound, smooth and shall be free from 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 supported by test documents. All surfaces of the metal parts shall be perfectly smooth without 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 610 gm/ sq .m. Or 87m thickness and shall be in accordance with the requirement of IS: 4759. The zinc used for galvanizing shall be of purity 99.5%
5.02.00
5.03.00
5.04.00
5.05.00
5.06.00
5.07.00
CLAUSE NO.
33 & 11 kV COMPOSITE INSULATOR as per IS: 4699. 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 four successive dips each lasting for one (1) minute duration under the standard preece test. The galvanizing shall be carried out only after any machining.
6.00.00 6.01.00
Equipment Marking Each insulator unit shall be legibly and indelibly marked with the following details as per IEC-61109: (a) Month & Year of manufacture. (b) Min. failing load/guaranteed mechanical strength in kilo Newton followed by the word kN to facilitate easy identification. (c) Manufacturers name/Trade mark One 10 mm thick ring or 20 mm thick spot of suitable quality of paint shall be marked on the end fitting of each composite long rod of particular strength in case of 33 kV insulators for easy identification in case both types of insulators are procured by the utility. The paint shall not have any deteriorating effect on the insulator performance. Following codes shall be used as identification mark: For For 45 kN long rod unit 70 kN long rod unit : : Blue Red
6.02.00
7.00.00 7.01.00 7.02.00
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 (3 copies) of each insulator unit including a cross sectional view of the long rod insulator unit. The drawing shall include but not be limited to the following information: a) Long rod diameter with manufacturing tolerances b) Minimum Creepage distance with positive tolerance c) Protected Creepage distance d) Eccentricity of the long rod unit i) Axial run out ii) Radial run out e) f) g) h) Unit mechanical and electrical characteristics Size and weight of ball and socket/tongue & Clevis Weight of composite long rod units Materials i) Identification mark ii) Manufacturers catalogue number
Page 6 of 14
CLAUSE NO.
33 & 11 kV COMPOSITE INSULATOR After placement of award, the Supplier shall submit full dimensioned manufacturing insulator drawings containing all the details in four (4) copies to Owner for approval. After getting approval from Owner and successful completion of all the type test, the Supplier shall submit 10 more copies of the drawing to the Owner for further distribution and field use. After placement of award the Supplier shall also submit fully dimensioned insulator crate drawing for different type of insulators for approval of the owner. Tests and Standards Insulators offered shall be manufactured with the same configuration & raw materials as used in the insulators for which design & type test reports are submitted. The manufacturer shall submit a certificate for the same. The design & type test reports submitted shall not be more that 05 years old.
7.03.00
7.04.00 8.00.00
8.01.00
Design Tests Manufacturer should submit test reports for Design Test as per IEC-61109 (clause-5) along with the bid. Additionally following tests shall be carried out or reports for the tests shall be submitted after award of contract: UV Test: The test shall be carried out in line with clause 7.2 of ANSI C29.13
8.02.00
Type Tests The following type tests shall be conducted on a suitable number of individual insulator units, components, materials or complete strings:
8.02.01
The bidder shall submit type test reports as per IEC 61109 along with the bid. Additional type tests as required above shall be carried out by the manufacturer, after Sl. No. 1 2 3 4 Description of type test Dry lightning impulse withstand voltage test Wet power frequency test Mechanical load-time test Radio interference test Test procedure/standard As per IEC 61109 (clause 6.1)
As per IEC 61109 (clause 6.2) As per IEC 61109 (clause 6.4) As per IEC 61109 (clause 6.5) revised 5 Recovery of Hydrophobicity test Annexure-B This test may be repeated every 3 yrs by the manufacturer 6 Chemical composition test for Annexure-B Or any other test silicon content method acceptable to the owner 7 Brittle fracture resistance test Annexure-B award of contract for which no additional charges shall be payable. In case, the tests have already been carried out, the manufacturer shall submit reports for the same.
Page 7 of 14
CLAUSE NO.
33 & 11 kV COMPOSITE INSULATOR It shall be the option of the owner to accept the insulators based on type test reports submitted by the manufacturer. The owner shall be free to repeat the type test & may witness the same. Note: The owner, for the purpose of facilitating the type tests, may ask the bidders to quote test charges separately.
8.02.02
8.02.03 8.03.00
All the type test given in Clause No. 8.2 in addition to routine & acceptance test shall be carried out on insulator along with hardware fittings wherever required. Acceptance (sample) Tests For Composite Insulators (a) (b) (c) (d) Verification of dimensions : Verification of the locking system : (if applicable) Galvanizing test : Verification of the specified mechanical load : Clause 7.2 IEC:61109, Clause 7.3 IEC:61109, IS: 2633/Is:6745 Clause 7.4 IEC:61109,
8.04.00
Routine Tests Sl. No. 1 2 3 Description Identification of marking Visual inspection Mechanical routine Test Standard As per IEC:61109 Clause 8.1 As per IEC:61109 Clause 8.2 As per IEC:61109 Clause 8.3
8.05.00
Tests During Manufacture Following tests shall also be carried out on all components as applicable (a) (b) (c ) Chemical analysis of zinc used for galvanizing Chemical analysis, mechanical, metallographic test and magnetic particle inspection for malleable castings. Chemical analysis, hardness tests and magnetic particle inspection for forgings.
8.06.00 8.06.01
Sample Batch for Type Testing The bidder shall offer material for sample selection for type testing only after getting Quality Assurance Programmer approved by the Owner. 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 Owner. Additional Tests The Owner reserves the right at his own expenses, for carrying out any other test(s) of reasonable nature carried out at Suppliers premises, at site, or in any other place in
8.07.00 8.07.00
CLAUSE NO.
33 & 11 kV COMPOSITE INSULATOR addition to the aforesaid type, acceptance and routine tests to satisfy himself that the material comply with the Specifications.
8.08.00
The Owner 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 Suppliers premises or at any other test center. 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 Owner. Co-ordination for Testing The Supplier shall have to co-ordinate testing of insulators with hardware fittings to be supplied by other Supplier and shall have to guarantee overall satisfactory performance of the insulators with the hardware fittings. The bidder shall intimate the Owner about carrying out of the type tests along with detailed testing programme at least 3 weeks in advance of the scheduled date of testing during which the Owner will arrange to depute his representative to be present at the time of carrying out the tests. Test Reports At least three copies of type test reports shall be furnished. One copy shall be Returned duly certified by the owner, only after which the commercial production of the concerned material shall start. Copies of acceptance test reports shall be furnished in at least three (3) copies. One copy shall be returned duly certified by the owner, 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 Owners 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 Owner. Inspection The Owners representative shall at all times be entitled to have entitled 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 sub-suppliers 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. The Owner shall select samples at random from the packed lot for carrying
8.09.00 8.09.01
8.09.10
8.10.00 8.10.01
8.10.02
8.10.03 8.10.04 9.00.00 9.00.01
9.00.02
CLAUSE NO.
33 & 11 kV COMPOSITE INSULATOR out acceptance tests. The lot offered for inspection shall be homogeneous and shall contain insulators manufactured in 3-4 consecutive weeks.
9.00.03
The Supplier shall keep the Owner 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. 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 owner in writing. In the later case also the material shall be dispatched only after satisfactory testing specified herein has been completed. The acceptance of any quantity of material shall in 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 All insulators shall be packed in strong corrugated box of min. 7 ply duty paletted or wooden crates. The gross weight of the crates along with the material shall not normally exceed 100 Kg to avoid handling problem. The crates shall be suitable for outdoor storage under wet climate during rainy season. 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. 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 wooden case/crate/corrugated box shall have all the markings stenciled on it in indelible ink. The bidder shall provide instructions regarding handling storage precautions to be taken at site.
9.00.04
9.00.05
10.00.00 10.01.00
10.02.00
10.03.00
10.04.00
10.05.00
Page 10 of 14
CLAUSE NO.
33 & 11 kV COMPOSITE INSULATOR Tests on Insulator Units
RIV Test (Dry) The insulator string along with complete hardware fittings shall have a radio interference voltage level below 100 micro volts at one MHz when subjected to 50 Hz AC voltage of 10 kV & 30 kV for 11 kV & 33 kV class insulators respectively under dry condition. The test procedure shall be in accordance with IS: 8263/IEC: 437/CISPR 18-2.
Brittle Fracture Resistance Test Brittle fracture test shall be carried out on naked rod along with end fittings by applying In HNO3 acid (63 g conc. HNO3 added to 937 g water) to the 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. Test arrangement should ensure continuous wetting of the rod with Nitric acid. 2 Recovery of Hydrophobicity & Corona Test The test shall be carried out on 4 mm thick samples of 5 cm x 7 cm. i. The surface of selected samples shall be cleaned with isopropyl alcohol. Allow the surface to dry and spray with water. Record the Hydrophobicity classification in line with STRI guide for Hydrophobicity classification (Extract enclosed at Annexure-D). Dry the sample surface. ii. The sample shall subjected to mechanical stress by bending the sample over a ground iii. electrode. Corona is continuously generated by applying 12 kV to a needle like electrode placed 1 mm above the sample surface. Tentative arrangement shall be as shown in Annexure-E. The test shall be done for 100 hrs. iv. Immediately after the corona treatment, spray the surface with water and record the HC classification. Dry the surface and repeat the corona treatment as at clause 2 above. Note HC classification. Repeat the cycle for 1000 hrs. or until an HC of 6 or 7 is obtained. Dry the sample surface. v. Allow the sample to recover and repeat 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.
Page 11 of 14
CLAUSE NO.
33 & 11 kV COMPOSITE INSULATOR Chemical Composition Test for Silicon Content The content of Silicon in the composite polymer shall be evaluated by EDX (Energy Dispersion X-ray) Analysis or Thermo-gravimetric analysis. The test may be carried out at CPRI or any other NABL accredited laboratory.
Page 12 of 14
CLAUSE NO.
33 & 11 kV COMPOSITE INSULATOR (PART-B) Guaranteed Technical Particulars of Composite Insulator Name of Manufacturer Address of works : : Unit 11 kV 45 kN 33 kV 45 kN 33 kV 70 kN
Sl. Description No. 1 Type of Insulator 2 Standard according to which the insulators manufactured and tested 3 Name of material used in manufacture of the insulator with class/guide (a) Material of core (FRP rod) i) E-glass or ECR-glass ii) Boron content (b) Material of housing & weathersheds (silicon content by weight) ( c) Material of end fittings (d) Sealing compound for end fittings 4 Colour 5 Electrical characteristics: (a) Nominal system voltage (b) Highest system voltage ( c) Dry Power frequency withstand voltage (d) Wet Power frequency withstand voltage (e) Dry flashover voltage (f) Wet flashover voltage (g) Dry lighting impulse withstand voltage Positive (h) Dry lighting impulse flashover voltage a) Positive b) Negative (i) RIV at 1 MHz when energized at 10 kV/30 kV (rms) under dry condition (j) Creepage distance (Min.) 6 Mechanical characteristics: (a) Minimum failing load
kV (rms) kV (rms) kV (rms) kV (rms) kV (rms) kV (rms) kV (Peak) kV (Peak) kV (Peak) kV (Peak) Microvolt mm kN
CHAPTER-II SECTION-E9 33& 11kV COMPOSITE INSULATOR Page 13 of 14
CLAUSE NO.
33 & 11 kV COMPOSITE INSULATOR 7 (i) (ii) (iii) (iv) (v) (vi) Sl. No. Dimensions of insulator Weight: Dia. Of FRP rod: Length of FRP rod Dia. Of Weathersheds Thickness of housing Dry arc distance Description
Kg. mm mm mm mm mm
Dimensioned drawings of insulator (including weight with tolerance in weight) enclosed. 8 Mentioned of fixing of sheds to housing (specify): Single mould or Modular construction (injection moulding/compression moulding) 9 No of weathersheds 10 Type of sheds: i) Aerodynamic ii) With underribs 11 Packing details (a) Type of packing (b) No. of insulators in each pack ( c) Gross weight of package 12 Any other particulars which the bidder may like to give
Page 14 of 14
CLAUSE NO.
11 KV AERIAL BUNCHED CABLES SCOPE This Specification covers design, manufacture, testing and despatch to Owners stores of cross linked polyethene(XLPE) insulated aluminium conductor Cross linked polyethylene (XLPE) insulated aluminum 11 kV Aerial Bunched Cable comprising 3 single core cables twisted around a bare aluminum aluminum alloy messenger wire, which will carry the weight of the cable, for use in distribution overhead lines. Size of the cable shall be 3x35+70.
1.00.00
2.00.00
APPLICABLE STANDARDS The 11 kV Aerial Bunched Cable shall comply to latest version of the following Standards : i) ii) iii) iv) v) IS:7098 (Part-II)Cross linked Polyethylene Insulated PVC Sheathed Cables. IS:8130-Conductors for Insulated Cables. IS:398 (Part-IV)-Aluminium Alloy Conductors and REC Specification No. 64/1993. IS: 5831 (Type ST-2) - Specification for PVC insulation and sheath of electrical cables. REC Specification No.64/1993.
3.00.00 3.00.01
GENERAL REQUIREMENTS General Construction Conductor screen and insulation screen shall be extruded semi-conductoring compound and shall be applied along with XLPE insulation in a single operation by triple extrusion process. The method of curing shall be dry curing / gas curing / steam curing.
3.01.00 3.01.01 3.01.02
Single-Core Cable The cable conductors shall be of round, stranded and compacted Aluminium Conductor Screen The conductor screen shall be of extruded semi-conducting cross linked polyethylene compound of thickness not less than 0.5 mm.
3.01.03
Insulation The insulation shall be of extruded cross linked polyethylene (XLPE) and its properties shall conform to IS:7098 (Part-II).
3.01.04
Insulation Screen The insulation screen shall comprise extruded semi-conducting compound. Thickness of the screen shall be not less than 0.6 mm.
11 KV AERIAL BUNCHED CABLES
Page 1 of 3
CLAUSE NO.
11 KV AERIAL BUNCHED CABLES Metallic Screen The metallic screen shall consist of aluminium tape/sheath of thickness not less than 0.2mm.
3.01.05
3.01.06
Outer Sheath The outer sheath shall be light grey coloured polyethylene. The nominal thickness of sheath shall be 1.8mm and it shall conform to the technical requirements of IS:10810 .
3.02.00 3.02.01
Messenger The bare messenger wire shall be of size 70mm2 (nominal area) aluminium alloy, generally conforming to IS:398 (Part-IV)-1979, comprising of 7 strands and shall be suitably compacted to have smooth round surface to avoid damage to the outer insulating sheath of single-core phase cables twisted around the messenger. There shall be no joints in any wire of the stranded messenger conductor except those made in the base rod or wires before finally drawing. TESTS tests shall be carried out on the single-core cables as per (Part-II). PACKING AND MARKING Packing Cables shall be supplied in wooden drums conforming to IS:10418. The standard length of the bunched cable in each drum shall be 1 Km () 10%.
3.02.02 4.00.00 4.01.00 5.00.00 5.01.00
5.02.00
Marking The cable drum shall carry the information as per the requirements of IS:7098 (PartII). Suitable identification marks shall be given on the outer sheath to clearly distinguish three phases of the bunched cable.
6.00.00 6.01.00
INSPECTION All the tests and inspection shall be made at the place of manufacture. The manufacturers shall afford the inspector representing the purchaser all reasonable facilities without charge, to satisfy him that material is being furnished in accordance with the Specification. The purchaser has the right to have tests carried out at his own cost by an independent agency whenever there is a dispute regarding the quality of supply.
6.02.00
Page 2 of 3
CLAUSE NO.
11 KV AERIAL BUNCHED CABLES Guaranteed Technical parameter The following guaranteed technical parameters shall be applicable. PART-A Sl.No. Particulars 1 Applicable standard Indian Standard REC Standard Power Core conductor No.of cores(No.) Nominal cross sectional area(sq mm) /No of strands Max.DC resistance at 20 deg C(Ohm/KM) Identification of power cores Max. SC current for 1 sec. kA Max. continuous load (Amps.) Messenger wire (Bare) No. of cores in Bare messenger Nominal cross sectional area(Sq mm) / No. of strands/ Diameter. off each strand in mm ) Breaking load(KN) Insulation Nominal thickness(mm) Details of power core Material Flexibility class as per IS:8130/84 Form of conductor Insulation Material Colour of insulation 7 Details of messenger wire(Bare) All Aluminium alloy as per IS:398(Pt-IV) Material Form of conductor Compacted circular Type test reports (all mentioned in relevant COMPLIED clause) Make shall be NESCL Corporate Quality Assurance(CQA) Approved a b
7.00.00
3CX35+70 Sq mm-11KV IS:7098(Pt-II)/85,IS8130/84,IS:398(Pt-IV) 64/1993 3 35/6 0.868 By ridges 3.4 106 1 70/7/3.5 20 3.6 H2/H4 Aluminium Class-2 Compacted circular Cross linked Poly ethelene(XLPE) Black
4 5
6 a b
Page 3 of 3
CLAUSE NO.
GENERAL CONSTRUCTIONAL PRACTICES DT STATION
1.00.00
DISTRIBUTION TRANSFORMER The bidder shall supply, install, test & commission 11kV/250V 1Phase & 11kV/433V, 3Phase distribution transformers. The details of the work related to Distribution Transformer are given below:
1.01.00
Erection of Transformer DT structure shall have the following configuration: 1) Single Pole DT structure on PCC Pole of 9mtr with D.O fuse shall be used for inline location single phase (tapping from two phases of 11KV line) DTs. Two phases shall be tapped for a particular location. Transposing of phases shall be adopted at various locations for proper load distribution. 2) Double Pole DT structure on PCC Pole of 9mtr with D.O fuse shall be used for dead end location single phase (tapping from two phases of 11KV line) DTs. 3) Three phase DTs. shall be mounted on 9mtr double pole structure with HG fuse & AB switch as per REC construction standard s F2/F3/ F4 depending on the location
1.03.00
Erection of, AB Switch & HG Fuse & Other items The erection of AB Switch & HG Fuse , DO fuse & all other sundry items like connecting cable from transformer to LTDB, etc are in contractor scope. The connecting cable from transformer to LTDB & LTDB to LT line shall be routed through GI pipe of suitable dia with proper clamping arrangement The equipment & accessories shall be checked for proper alignment and tightness after installation.
1.04.00 1.05.00
Earthing Arrangement for Transformer Stations Earthing arrangement for DT shall be as per REC Construction Standard F-10. Pipe earthing shall be used to earth LT neutral, LA and the DT body at each DT location. Thus, three such pits shall be built for each transformer. The location of earth pits and connections to various earth pits shall be as per REC Construction Standard F-5. The bidder shall furnish detailed earthing system drawing for the DT stations for review and approval. The earth resistivity achieved shall be less than the stipulated value as per the relevant codes of practice and shall be measured and recorded as per approved erection and commissioning procedures. Electrical Connections The HT side connections shall be made with AAA Conductor of suitable rating. LT side connections shall be made with LT PVC cables. Cable glands of IS marks shall be used for all the cable entries in distribution box. The cable shall be routed through GI pipe which shall be properly clamped to the pole.
1.06.00
1.07.00
RGG VY WORKS STANDARD TECHNICAL SPECIFICATION (REV.- 03)
TECHNICAL SPECIFICATION VOL-II (PART-C)
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CLAUSE NO.
The contractor shall properly dress all the LT cables emanating from distribution box. The contractor shall provided all jointing material i.e. sleeves etc. and carry out all jointing works. 1.08.00 Protection & Isolation (a) HT side The DTs shall be fitted with LAs to protect the transformer from any electrical surge. AB switch along with HG fuse or DO fuse shall be used to protect and isolate transformers on HT side in case of over current & earth faults. The contractor shall specify the rating of the fuse element in the bid for each rating of transformer. (b) LT side Electric power from the transformer is drawn through the incomer MCCBs of suitable rating provided in LTDB to protect the transformer from the faults occurring on LT systems. 1.09.00 1.10.00 Connection of DT to LT Lines To bare conductor line For connection from LTDB, 1.1 kV PVC insulated cables shall be used along with cable glands & lugs of appropriate size. The other end of the cable shall be properly dressed/clamped to the overhead conductor, using PG clamp of appropriate size & type. 1.11.00 To ABC Line For extension of DT-LV side connection, through MCCB to overhead ABC Line, phase conductors shall be taken directly to LTDB & terminated. Neutral conductor shall be extended using insulated AB cable & PG clamp from line to LTDB 1.12.00 Sign Board A sign board of size 1 foot X 1 foot of 2.5mm MS sheet shall be placed on the transformer or at a suitable location in every DT station mentioning the following with suitable letter size.The back ground colour shall be white & letters shall be of black colour.
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CLAUSE NO.
Rajeev Gandhi Grameen Vidyuti Karan Yojana ( Government of India) NTPC Electric Supply Co. LTd. Date of Commissioning11000V/440/250V KVA Village name:
The language of the sign board shall be vernacular.
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CLAUSE NO.
1/3 PHASE, DISTRIBUTION TRANSFORMER SCOPE OF WORK This specification covers design, engineering, manufacture, inspection, testing at manufacturers works including type testing before dispatch, supply delivery at destination, storage at site, erection & commissioning as indicated elsewhere in the specification, single phase distribution transformer (of sealed type) and three phase distribution transformers of double wound, oil filled, naturally cooled, 50 Hz, outdoor type for use in rural electrification system. APPLICABLE STANDARDS Distribution transformers shall comply with the latest version of following Standards along with the amendments. All the parameters and description of 10 kVA transformer shall be complying to this specification requirement. Standard to be referred for 10 kVA rating DTs shall be generally same as those, applicable for 16 kVA DTs, indicated in the standards. i. ii. iii. iv. v. vi. vii. viii. IS 1180 : Part 1 : Outdoor type three-phase distribution transformers up to and including 100 kVA 11 kV:Part 1 Non-sealed IS 1180 : Part 2 : Outdoor type three-phase distribution transformers up to and including 100 kVA 11 kV:Part 2 Sealed IS 3347: Dimensions for Porcelain Transformer Bushings IS 335 : New insulating oils IS 2099 : Bushings for alternating voltages above 1 000 Volts IS 9335 : Cellulosic papers for electrical purposes IS 1576 : Solid pressboard for electrical purposes - specification REC Specification 2/1971. (Revised 1997)
1.01.00 1.02.00
2.00.00 2.01.00
3.00.00
RATINGS AND TYPE The kVA ratings and types of distribution transformer shall be as follows : kVA Ratings 10 16 16 25 No. of Phases Single phase Single phase Three phase Three phase Nominal System Voltage (ph-ph) 11 kV 11 kV 11 kV 11 kV No Load Voltage Ratio 11/0.250 kV (Ph-E) 11/0.250 kV (Ph-E) 11/0.433 kV (Ph-Ph) 11/0.433 kV (Ph-Ph)
4.00.00
CLIMATIC CONDITIONS
TECHNICAL SPECIFICATION VOL-II (Part-C) CHAPTER-II SECTION-E1
1 PHASE DISTRIBUTION
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TRANSFORMER
CLAUSE NO.
1/3 PHASE, DISTRIBUTION TRANSFORMER i. Temperature: 10oC to +55o C (in shade) ii. Humidity: upto 95% RH non-condensing iii. Average annual rainfall: 150 cm. (if not specified otherwise) iv. Max. Wind Pressure: 150-kg/sq. m. v. Max. Altitude above MSL: 1000 meters (if not specified otherwise)
5.00.00 5.01.00
WINDING CONNECTIONS & VECTORS For single phase distribution transformer, the primary winding shall be fed with 11 kV (ph-ph) and secondary winding shall feed 250 V. For three phase distribution transformer, the primary winding shall be connected in delta and secondary winding in star so as to yield vector notation of Dyn11. TAPS Turns ratio of Distribution transformer shall be fixed. No taps are to be provided on these transformers.
6.00.00
7.00.00 7.01.00 7.01.01 7.01.02
WINDING Material Super enamel covered copper conductor/ DPC copper conductor shall be used. Current density of copper conductor for HV and LV winding shall be not more than 2.5 A/mm2. Conductor used for HV and LV winding shall be from continuous wire without any joint or brazing, as far as possible. Angle shaped End Rings made from pre-compressed board should preferably be used between the end coils and core. Construction of winding shall be adequately designed to withstand the short circuit test not withstanding the type of conductor being used. CORE The type of Core and Core material shall be as given below: i. ii. The core shall be wound type. The design of magnetic circuit shall be such as to avoid static discharges development of short circuit paths within itself or in the earthed clamping structure. Stage level inspection for core construction shall be carried out by the owner.
7.01.03 7.01.04 7.01.05 8.00.00 8.01.00
iii.
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1/3 PHASE, DISTRIBUTION TRANSFORMER iv. v. Each lamination shall be insulated such that it will not deteriorate due to mechanical pressure and the action of hot transformer oil. The core shall be constructed from new high grade, non-ageing Cold Rolled Grain Oriented (CRGO) silicon steel laminations conforming to grade M4 or better. The bidder shall provide saturation curve of the core material proposed to be used. The bidder shall offer the core for inspection and approval by the purchaser during the manufacturing stage. Bidders call notice for the purpose shall be accompanied with the following documents as applicable as a proof towards use of prime core material: a. Invoice of the supplier b. Mills test certificate c. Packing list d. Bill of lading e. Bill of entry certificate to customs vii. Core material shall be directly procured either from the manufacturer or through their accredited marketing organization of repute and not through any agent. The complete design of core must ensure permanency of the core losses with CONTINUOUS WORKING of the transformers. The value of the flux density allowed in the design and grade of lamination used shall be clearly stated in the offer. viii. All parts of the core shall be of robust design, capable of withstanding any shocks to which they may be subjected during handling, lifting, transportation installation and service. Clamping of core and winding assembly with tank should be done by angle iron pieces, welded to tank walls and not to be done with flat iron pieces. ix. Adequate arrangement shall be provided to enable the core and winding to be properly supported. Use of seconds CRGO steel for core construction is strictly prohibited.
vi.
9.00.00 9.01.00
PERMISSIBLE FLUX DENSITY & OVERFLUX The flux density at rated voltage and frequency shall not exceed 1.69 tesla. 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 and frequency variation of +5% shall not exceed 1.9 Tesla. The transformer shall be suitable for over fluxing due to combined effect of voltage and frequency. The supplier shall furnish necessary design data in support of this
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TRANSFORMER
CLAUSE NO.
1/3 PHASE, DISTRIBUTION TRANSFORMER stipulation. The no-load current at Rated Voltage and at 112.5 percent Rated Voltage shall not exceed values given below:KVA Rating 10 16 25 Percentage of Rated full Load Current At 100% Rated Voltage 4.7 4.1 3.5 At 112.5% Rated Voltage 9 8.0 7
9.02.00 10.00.00
The core and coil assembly shall be securely held in position to avoid any movement under short-circuit conditions. SYSTEM SHORT CIRCUIT LEVEL The transformer shall be rated for a maximum fault level as per IS;2026.
11.00.00 11.01.00 11.01.01
TRANSFORMER TANK Construction The transformer tank shall be made of good quality steel sheet of adequate thickness and shall be suitably stiffened to provide sturdy and robust construction to withstand extreme pressure conditions. The tank shall be capable of withstanding pressure upto (+) 80 Kpa and (-) 70 Kpa (gauge pressure) without any deformation. The tank cover shall have plasticised surface at the top to guard against birdage faults. Alternatively, suitable insulating shrouds shall be provided on the bushing terminals. Tank Sealing (For Single Phase Transformer only) Transformer cover shall be sealed with a continuous (without break) oil resistant high quality nitrile rubber gasket on the top of the tank rim and the cover should be suitably clamped or bolted with G.I fasteners to provide a uniform pressure on the rubber seal. The space on the top of the oil shall be filled with nitrogen conforming to commercial grade as per IS : 1747 or dry air. The nitrogen/ dry air plus the oil volume inside the tank shall be such that even under the extreme operating conditions, the pressure generated inside the tank does not exceed (+) or (-) 40 Kpa. Pressure Relief Device (For Sealed Type, 1 Ph DTs) Pressure relief device shall be provided. Alternatively, self-venting type of cover assembly is also acceptable.
11.01.02
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11.01.05
11.02.00
11.03.00
Sealing Gaskets
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TRANSFORMER
CLAUSE NO.
1/3 PHASE, DISTRIBUTION TRANSFORMER All sealing washers/gaskets shall be made of oil and heat resistant nitrile rubber. Gaskets made of natural rubber or cork sheet are not permissible. Rubberised cork sealing gaskets may be accepted, subject to clearance for quality.
11.04.00 11.04.01 11.04.02
Conservator For 16 & 25 kVA Transformers, manufacturers may adopt sealed or conservator type designas per their standard practice. The conservator shall be provided with a drain plug and a filling hole with cover. In addition, the cover of main tank shall be provided with an air release plug to enable trapped air to be released 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 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. Each transformer shall be fitted with a breather in which Silica gel is the dehydrating agent. The breather is so designed that the passage of air through the Silica gel and the external atmosphere is not continuously in contact with silica gel. PAINTING PROCEDURE The paint material and procedure for the distribution transformer shall be as per details given below:
11.04.03
11.05.00
12.00.00
12.01.00
All paints shall be applied in accordance with the paint manufacturers recommendations. Particular attention shall be paid to the following : a) b) c) d) e) Proper storage to avoid exposure as well as extremes of temperature. Surface preparation prior to painting. Mixing and thinning Application of paints and the recommended limit on time intervals between coats. Shelf life for storage.
12.02.00
All paints, when applied in normal full coat, shall be free from runs, sags, wrinkles, patchiness, brush marks or other defects.
TECHNICAL SPECIFICATION VOL-II (Part-C)
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1/3 PHASE, DISTRIBUTION TRANSFORMER All primers shall be well marked into the surface, particularly in areas where painting is evident, and the first priming coat shall be applied as soon as possible after cleaning. The paint shall be applied by airless spray according to the manufacturers recommendations. However, wherever airless spray is not possible, conventional spray be used with prior approval of purchaser. The supplier shall, prior to painting protect nameplates, lettering gauges, sight glasses, light fittings and similar such items. Cleaning and Surface Preparation After all machining, forming and welding has been completed, all steel work surfaces shall be thoroughly cleaned of rust, scale, welding slag or spatter and other contamination prior to any painting. Steel surfaces shall be prepared by Sand / Shot blast cleaning or Chemical cleaning and process including Phosphating to the appropriate quality. The Pressure and Volume of the compressed air supply for the blast cleaning shall meet the work requirements and shall be sufficiently free from all water contamination prior to any painting. Chipping, scraping and steel wire brushing using manual or power driven tools cannot remove firmly adherent mill-scale and shall only be used where blast cleaning is impractical. Protective Coating As soon as all items have been cleaned and within four hours of the subsequent drying, they shall be given suitable anticorrosion protection.
12.03.00
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12.05.02 12.06.00
12.07.00
12.08.00
12.09.00 12.09.01 12.09.02 12.09.03
Paint Material Followings are the type of paints that may be suitably used for the items to be painted at shop and supply of matching paint to site: Heat resistant paint (Hot oil proof) for inside surface. For external surfaces one coat of Thermo Setting Paint or 2 coats of Zinc chromate followed by 2 coats of Synthetic Enamel paint. The color of the finishing coats shall be dark admiral gray conforming to No. 632 of IS 5:1961. Painting Procedure All painting shall be carried out in conformity with both specifications and with the paint manufacturers recommendations. All paints in any one particular system, whether shop or site applied, shall originate from one paint manufacturer. Particular attention shall be paid to the manufacturers instructions on storage, mixing, thinning and pot life. The paint shall only be applied in the manner detailed
12.10.00 12.10.01
12.10.02
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CLAUSE NO.
1/3 PHASE, DISTRIBUTION TRANSFORMER by the manufacturer e.g. brush, roller, conventional or airless spray and shall be applied under the manufacturers recommended conditions. Minimum and maximum time intervals between coats shall be closely followed.
12.10.03
All prepared steel surfaces should be primed before visible re-rusting occurs or within 4 hours whichever is sooner. Chemical treated steel surfaces shall be primed a s soon as the surface is dry and while the surface is warm. Where the quality of film is impaired by excess film thickness (wrinkling, mud cracking or general softness) the supplier shall remove the unsatisfactory paint coatings and apply another. As a general rule, dry film thickness should not exceed the specified minimum dry film thickness by more than 25 %. In all instances, where two or more coats of the same paints are specifies, such coatings may or may not be of contrasting colors. Paint applied to items that are not be painted, shall be removed at suppliers expense, leaving the surface clean, un-stained and undamaged. Damages Paint Work Any damage occurring to any part of the painting scheme shall be made good to the same standard of corrosion protection and appearance as that originally employed. Any damaged paint work shall be made good as follows: The damaged area, together with an area extending 25 mm around its boundary, shall be cleaned down to bare metal. A priming coat shall immediately applied, followed by a full paint finish equal to that originally applied and extending 50 mm around the perimeter of the originally damaged. The repainted surface shall present a smooth surface. This shall be obtained by carefully chamfering the paint edges before & after priming. Dry Film Thickness To the maximum extent practicable, the coats shall be applied as a continuous film of uniform thickness and free of pores. Over-spray, skips, runs, sags and drips should be avoided. The different coats may or may not be of same color. Each coat of paint shall allowed to hardened before the next is applied as per manufacturers recommendations. Particular attention must be paid to full film thickness at edges. The requirement for the dry film thickness (DFT) of paint and the material to be used shall be as given below:
12.10.04
12.10.05 12.11.00 12.11.01 12.11.02 12.11.03 12.11.04
12.11.05 12.12.00 12.12.01
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TRANSFORMER
CLAUSE NO.
1/3 PHASE, DISTRIBUTION TRANSFORMER
Sl. No. 1. a)
Paint type
Area to be painted Inside Inside Outside
No. of coats 01 01 01
Total dry film thickness(min.) 20 microns 20 microns 60 microns
Powder paint Thermo setting powder
2. a)
Liquid Paint Epoxy Zinc chromite (primer) Synthetic Enamel (Finish Coat) or by Urethene(Finish Coat) Hot Oil paint/Varnish Outside 01 30 microns
b)
Outside
02
35 microns
c)
Inside
01
35 microns/ 10 microns
13.00.00 13.01.00 13.02.00 13.03.00 13.03.01 13.03.02 13.04.00
TRANSFORMER OIL New insulating oil of petroleum origin shall be used. The oil shall be of low viscosity type and completely free from additives. Transformer oil shall comply with REC specification : 39/1985 & IS : 335. The requirements have been given in two parts. For new transformer oil in drums / tankers. For oil after it is filled in the transformer (the values shall be applicable after 3 days from the date of filling). New Oil The important characteristics of new oil shall be as follows: Characteristics Requirement
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1/3 PHASE, DISTRIBUTION TRANSFORMER 1. 2. Flash point Pensky Marten (closed), Min. Neutralization value a) Total acidity, Max. b) Inorganic acidity/alkalinity 3. 4 Corrosive Sulphur Electric Strength (breakdown voltage) Min. a) New unfiltered oil b) New oil after filtration 5. 6. Dielectric dissipation factor (tan delta) at 900 C (Max.) Specific resistance (resistivity) a) At 900 C (Min.) b) At 270 C (Min.) 7. Oxidation stability a) Neutralization value after oxidation (Max.) b) Total sludge after oxidation (Max.) 8. Ageing Characteristics a)Specific resistance (resistivity) i) ii) at 270 C at 900 C 2.5x10 12 ohm-cm (Min.) 0.2x10 12 ohm-cm (Min.) 0.20 Max. 0.05 Max. 0.4mg KOH/g 0.10% by weight 30x1012 ohm-cm 500x1012 ohm-cm 30KV(ms) 50KV(ms) 0.005 0.03mg KOH/g Nil Non - Corrosive 1400 C
b) Dielectric dissipation factor (tan delta) at 900C c) Total acidity in mg KOH/g d) Total sludge 13.05.00 Characteristics of oil in the Transformer
The important characteristics of the transformer oil after it is filled in the transformer (after 3 days of filling) shall be as follows: Characteristics 1. 2. 3. 4. 5. Electric strength (Breakdown voltage) Dielection dissipation factor (tan deltla) at 900C Specific delta resistance (resistivity) at 270 C (Ohm-cm) Flash point, P.M (Closed) Interfacial tension at 270 C
Specification 30xKV Min. 0.01 Max. 10x1012 1400C (Min.) 0.03 N/m (Min.)
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1/3 PHASE, DISTRIBUTION TRANSFORMER 6. 7. Neutralization value (total acidity) Water content, PPM 0.05 mg KOH/g(Max.) 35 (Max.)
13.06.00
Tests All tests to verify the characteristics as incorporated in this specification shall be carried out in accordance with IS:335-1983 or its latest version.
14.00.00 14.01.00
TERMINAL ARRANGEMEMT The transformer shall be fitted on high voltage and low voltage sides with outdoor type bushings of appropriate voltage and current ratings. The single phase DTs shall have 2 HV bushings & 2 LV Bushings. The three phase transformers shall have three HV bushings and four LV bushings. LV Neutral Terminal of bushing shall be connected to earth externally. All bushings shall conform to IS : 1347 and 2099. The bushings shall not have arcing horns. The high voltage bushings shall conform to IS 2099 : 1986. The low voltage bushings shall conform to IS-7421 : 1974. Alternatively the low voltage side may be made suitable for adoption of PVC cable of suitable size. The terminal arrangements shall be such that it shall be possible to replace the bushings (external) without opening the cover and also without affecting the sealing of the transformer. HV Bushing The dimensions of the outer bushing shall conform to IS 3347 (part 3/Sec 1) : 1972. The internal bushing shall be of either porcelain or tough insulating material, HGSREC (II) like epoxy and shall have embedded stem. For typical arrangement, Appendix - II of REC specification No. 2/1971 (R-1997) can be referred.Any other superior design is also acceptable. The same may be explained in detail.
14.02.00
14.03.00
14.04.00
14.05.00
LV Bushing The LV Bushing shall be of two parts, internal part shall be either epoxy or porcelain.. For details, Appendix-II of REC specification No. 2/1971 (R-1997) can be referred.
14.06.00 14.06.01
Bushing Terminals Both HV and LV bushing stems shall conform to the requirement of IS : 3347. The bushing terminals shall be of clamp type to directly receive aluminium conductors (cables) without requiring use of lugs. The terminals shall be directly screwed on to the stem to ensure effective sealing of the bushings.
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14.06.02
The design of internal bushings shall be such as to provide adequate creepage distance in accordance with 7.1 of IS 2099 : 1986 and minimum clearance as given below: HV side Internal External Phase to phase Phase to earth 127 mm 76 mm 255 mm 140 mm LV side Internal External 45 mm 20 mm 75 mm 40 mm
14.06.03 15.00.00 15.01.00
All sealing washers/ gaskets shall be made of oil and heat-resistant nitrile rubber. SURGE ARRESTER FOR DTs Applicable Standards The surge arrestors shall comply IS:3070 Part-III latest amendment and REC Specification No. 10/1976.
15.02.00
Electric Requirements i) ii) iii) Nominal system voltage Highest system voltage Frequency 11 kV 12 kV 50 Hz
15.03.00
Atmospheric Conditions The atmosphere at places is laden with dust in suspension during the dry months and subject to fog in cold months. The temperature variation between the daily minimum and maximum is large. Heavy lightning is usual in the area during the month of May to November. The area is also subjected to heavy monsoon rains 80% to 90% of the annual precipitation during the months of June to October.
15.04.00 15.04.01 15.04.02
Design Requirements Surge Arrestor Surge arrestor offered shall be of type tested (according to the relevant IS) & proved design, copy of the test report not older than two years to be attached for the SA with the bid.In case type test report is not submitted, owner reserves the right to carry out type test the cost of which shall be borne by the bidder. The Technical requirements have been detailed out below : Sl.No. Particulars Requirements
15.04.03
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1/3 PHASE, DISTRIBUTION TRANSFORMER 1. 2. 3. 4. 5. 6. 7. 8. 9. Nominal system voltage Type of Arrestor Applicable standard Rated Arrestor voltage kV rms Maximum continuous operating voltage kV rms Nominal discharge current rating (8/20 micro sec) kA Minimum discharge capability (kA/kV) Long duration discharge class Maximum residual voltage at nominal discharge current of 8/20 micro sec. wave, kV peak Maximum steep current impulse residual voltage at nominal discharge current, kV Peak Minimum prospective symmetrical current (kA) Impulse high current short duration discharge of 4/10 micro sec. Wave (kAP) Max. radio interference voltage at 1000 Hz (micro volts) Overall temporary over voltage withstand capacity (KV rms) 1.0 Sec. 10.0 Sec. 100.0 Sec. Impulse withstand voltage (KVP) Current impulse withstand level 10 9.5 75 18 impulse of long duration current 75 Amp. Peak for 1000 micro secs. 11 kV Metal Oxide IEC-99/4 IS:3070 Part-III latest amendment 9 7.2 5.0 As per long duration discharge class 2 of IEC 99/4 2
32
10.
38 15
11. 12.
65 -
13. 14. a) b) c) 15. 16.
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1/3 PHASE, DISTRIBUTION TRANSFORMER 17. Disconnecting device (Arrestor disconnector) As per required specification
IS:3070 (Part-II)-1985 Cl. 2.43, IS 3070 18. 19. 20. Min. creepage distance of porcelain housing (mm) Top & Bottom metal cap Terminal arrangement 300 Hot Dip Galvanized Built in clamping type can be adjusted for Horizontal & Vertical Power off to suit conductor save squirrel to carbon The base of L.A. shall be provided with two separate terminal / distinctly marked for connection to earth
21.
Earthing Terminal
15.04.04
Residual voltage at nominal discharge current of 8/20 micro sec. wave is specified above, however, it is preferred still lower residual voltage to ensure better protection. Each and every individual unit of surge arrestor shall be hermetically sealed and fully protected against ingress of moisture for which suitable rubber gaskets with effective sealing system should be used. The hermetic seal shall be effective for ensure life time service of arresters and under the service conditions specified. The agency shall furnish sectional view showing details of sealing employed. Manufacturers should device a suitable routine production testing to verify the efficiency of sealing. All the units of arresters of same rating shall be interchangeable type without adversely affecting the performance. Application of LA The 11 kV arrestor provided on Distribution Transformer shall protect the equipment system against lightning surges. These shall be connected in series with the ground lead and should not affect the sealing system of the arrestor. The earthing connection of the transformer and associated Surge arrestor shall be provided as per procedure, described for D.T sub-station in this specification. Drawings The Bidder shall furnish two sets of following drawings for owners approval before commencing the erection of Distribution Transformer. General outline drawings of
15.04.05
15.04.06
15.05.00 15.05.01
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TRANSFORMER
CLAUSE NO.
1/3 PHASE, DISTRIBUTION TRANSFORMER the complete equipment with technical parameters, Drawings showing clearance from ground and other live objects and between adjustment poles of surge arresters required at various heights of surge arrestors. a. Drawings showing details of mounting structure and of surge arresters. b.Drawing showing details of line and ground terminals and connection.
16.00.00 16.01.00 16.01.01 16.01.02
FITTINGS The following standard fittings shall be provided for both single phase and three phase distribution transformers. Nitrogen or Dry air filling device/pipe welded to cover, capable of reuse. An extended pipe for filling of oil at the top with welded cover. The pipe shall be suitably threaded over a sufficient length so that it may be possible to provide a refilling connection after removing the welded cover. 11 kV Lightning Arresters: High surge capacity 9 kV, 5 kA lightning arrester conforming to relevant Indian Standard Specification shall be mounted on each phase of the transformer, clamped securely to the tank, to protect the transformer and associated line equipment from the occasional high voltage surges resulting from lightning or switching operations. The earthing terminal of the lightning arresters shall be connected solidly to the transformer tank earthing terminal. For single phase DTr, 2 Nos. LA to be properly mounted with adequate clearance. Two earthing terminals Two lifting lugs (on Tank body) Rating and terminal marking plate(s). The following standard fittings shall be provided for three phase distribution transformers only. Oil level gauge indicating three positions of oil marked as follows: i. Minimum (-50C) ii. 300C iii. Maximum (980C)
16.01.03
16.01.04 16.01.05 16.01.06 16.02.00 16.02.01
16.02.02 16.02.03 16.02.04
Plain breathing device comprising an inverted U-pipe with wire gauze at the open end or Silica gel breather. Drain-cum-Sampling valve (Steel) of the type shown in Fig. 1 welded to the tank. The special tool for operating this value shall be supplied with the transformer. Thermometer pocket
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CLAUSE NO.
1/3 PHASE, DISTRIBUTION TRANSFORMER MOUNTING ARRANGEMENT The under-base of all transformers shall be provided with two 75x40mm channels 460mm long with holes (at a centre-to-centre distance of 415mm) to make them suitable for fixing on a platform or plinth. For mounting dimensions, Fig 3 of REC specification 2 / 1971 can be referred. RATING AND TERMINAL MARKING PLATE The transformer shall be provided with non-detachable rating marking plate(s) of weather proof material, fitted in a visible position and showing the complete information given in Clause No. 15.2 of IS : 2026 (PartI)1977. LIMITS OF TEMPERATURE RISE The temperature rise shall not exceed the limits of 550C (measured by resistance) for transformer windings and 450C (measured by thermometer) in top oil above the ambient temperature of 500C, when tested in accordance with IS: 2026 (Part-2). LOSSES AND IMPEDENCE VALUES The bidder shall furnish the maximum guaranteed values of no load and load losses (at 750C) with no plus tolerance in the data requirement sheet and also in relevant Schedule of Bid Proposal Sheets. Loss Capitalisation Factors For the purpose of evaluation of transformers , the best of the individual parameters for iron and copper losses for same rating of transformers quoted by any of the bidder in relevant schedule of BPS vol. IB shall be taken as the base and the difference between this and those quoted by the other bidders multiplied by the evaluation factor and the number of transformer included in the scope shall be used to arrive at the adjustment on the basis of per kW differential losses in Rupees indicated in relevant clauses of SCC. This adjustment cost shall be added to Bid price. The following Capitalisation formula shall be used: Capitalised cost of TRF = Initial cost of TRF + Rs. A x WI + Rs. B x Wc Where: WI = Iron loss in KW & A = for iron loss 1,92,873 / K-Watt WC = Copper loss in KW & B = for copper loss 25,459 / K-Watt
17.00.00 17.01.00
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20.02.00
20.03.00
Condition for Losses Exceeding Guaranteed Values This shall be as per the conditions specified in relevant clause of Special Conditions of Contract for the package.
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CLAUSE NO.
Impedance values The percentage impedance at 750C shall be as per values specified in IS:1180. For 10kVA Single phase DT the percentage impedance at 750C shall be 4.5%. Tolerance shall be as specified in IS:1180 21.00.00 21.01.00 TESTS Routine & Acceptance Test Routine & acceptance test shall be done as per IS: 1180 21.02.00 23.02.01 Type Test The supplier shall offer transformers of identical design & rating which has been type tested & tested for short circuit with stand capability as per relevant IS. The type test & test for short circuit withstand should have been conducted within last five years from a national test house or from similar reputed test house. The bidder shall furnish type test reports for each type rating. If the type tests & test to with stand short circuit test conducted within last five years is incomplete or not conducted within last five years the party shall arrange to carry out such tests at his own cost & risk in the presence of employer/owners representative. Manufacturers shall have, in his works, all the facilities and testing equipment for conducting the Routine Tests as per standards. The test instruments shall be duly calibrated by an independent lab of National repute. The calibration certificate shall be not earlier than 24 months, on the date of testing and shall be produced to owners inspector, on demand. DRAWINGS, DOCUMENTS AND DATA SHEETS The following is the general list of the documents and drawings that are to be submitted for approval by the owner : i. ii. iii. Work Schedule (Master Network) Plan Detailed GA drawings, cross sectional, view showing various parts and data sheet of DT. Detailed drawing and mounting arrangement of surge arrester with connection arrangement and earthing.
23.02.02
22.00.00
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TRANSFORMER
CLAUSE NO.
1/3 PHASE, DISTRIBUTION TRANSFORMER iv. v. Drawings and data sheet of each of sub-assemblies/fittings provided on the Transformer. Installation, operation and maintenance manual of DT. The above activity shall be coordinated as per the work schedule for completion of engg. activity described in the bid document. The manufacturing of the transformer shall commence only after approval is given by the owners Engineer on the GA drawing & data sheet for major items and DT.
23.00.00 23.01.00
INSPECTION All routine tests and inspection shall be made at the place of manufacture unless otherwise especially agreed upon by the manufacturer and purchaser at the time of purchase. The manufacturer shall provide the inspector, representing the purchaser, all the data, drawings and calculations without approved to satisfy him that material is being used in accordance with the specification and relevant standards. The purchaser has the right to have any tests carried out at his own cost, by an independent agency, whenever there is a dispute regarding the quality of supply. GENERAL TECHNICAL PARTICULARS: GTP of Distribution Transformers are enclosed herewith in two parts (Part A and Part B). The successful bidder shall supply Distribution Transformers as per Part A of GTP and additional details which are stipulated in Part B of the GTP shall be filled and submitted for review and approval along with the bid. Make shall be NESCL Corporate Quality Assurance (CQA) approved. Part A:
23.02.00 24.00.0
Page 17 of 20
TRANSFORMER
CLAUSE NO.
Part B
Sl.No ..
Description Continuous max. rating as per this specification. 10 KVA /16 kVA (1-ph) 16 KVA (3-ph) 25 KVA (3-ph) 11/0.433 kV
1 2 3
Nominal Voltage ratio of transformer Method of Connection HV / LV Max.HotSpotTemp.Deg.C.(Ambientai rtemp.on which above is based) 115.90C over maximum ambient of Deg.C. 500C 4 a) Max. Observable Oil temp. Deg.C. (ambient air temp. on which above is based) Deg.C b) Max. Winding Temperature at an 450C ambient temp. of 550C 5 % Impedance voltage at normal ratio 6 between HV & LV windings 4.5% +/- 10% Tol Type of transformers, shell type/core 7 type wound core SHELL TYPE Wound Core Impulse test voltage level HV Windings 75kV peak 8 LV Windings NA 9 Characteristics of transformer oil As per IS:335 Whether transformer will be 10 transported with oil? YES Name of the manufacturer and place 11 manufacturer 12 13 14 Fixed losses at normal voltage ratio (watts) at 750C(Max.) Load losses at normal voltage (watts) at 750C(Max.) ratio
11/0.433 11/0.25 kV kV Delta/Star
Total losses at normal voltage ratio (watts) at 750C(Max.)
Page 18 of 20
TRANSFORMER
CLAUSE NO.
1/3 PHASE, DISTRIBUTION TRANSFORMER 15 Efficiency at normal voltage i) Unity Power Factor a) At 50% Load b) At 75% Load c) At full Load ii) 0.8 Power Factor a) At 50% Load b) At 75% Load c) At full Load Regulation as percentage of normal voltage. a) At unity power factor% b) At 0.8 Power factor lagging% Type of Insulation used in a) HV Windings b) LV Windings Type of Insulation used in a) Core bolts b) Core bolt washers c) End plates d) Core lamination Total content of oil in liters 21 23 Type of transformers tank I) Approx. overall dimensions a) Height mm b) Breadth mm c) Width mm ii) Tank dimensions a) Diameter mm b) Height mm Weight of insulated conductor a) HV (min.) kg. b) LV (min.) kg. Weight of core (min.) kg. Weight of complete transformer arranged for transport kg. a) With oil b) Without oil Tank cover sealing 28 29 30 Core window height (App.) Watts
16
17
18
19
20
24 25 26
27 Gasket material Painting i)External
ii) Internal
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TRANSFORMER
CLAUSE NO.
1/3 PHASE, DISTRIBUTION TRANSFORMER 31 32 No. of L.V. Turns (App.) 33 34 35 36 No. of LV Coils/phase 37 No. of HV coils. phase 38 Height of LV Windings 39 Height of HV Windings 40 ID/OD of LV Winding 41 ID/OD of HV Winding(app.) 42 Size of the duct in LV winding 43 43 44 HV winding to LV clearance 45 HV winding to tank clearance 46 Calculated impendence 47 HV to earth creepage distance mm % mm mm Size of the duct in HV winding mm Size of the duct between mm HV Z& LV mm mm mm mm mm No. of H V turns (App.) Wt. Of the LV winding for Transformer (App/job) Wt. Of the HV winding for Transformer (App/job) kg. kg. Center to center distance core of the
Page 20 of 20
TRANSFORMER
CLAUSE NO.
CT OPERATED STATIC ENERGY METER FOR 3 PHASE DT
1.00.00
SCOPE This specification covers design, engineering, manufacture, inspection, testing at manufacturers works including type testing before dispatch, supply and delivery of three phase 4 wire 0.5 class for kWh & 1.0 for kVARh tri-vector meters with Time of the Day register, load profile data record MD register suitable for both unbalanced and balanced load.
2.00.00
APPLICABLE STANDARDS Sl. No. 1. 3. 4. 5. 6. Standards IS : 14697 IEC : 62056-21 (Latest Version) IEC : 61000-4-5 (2001-04) IEC : 61358 ANSI/IPC-A-610 Description Specification for AC Static Transformer operated Watt Hour & VAR-Hour meters, classes 0.2 S & 0.5 S Data exchange for Meter Reading and Direct Local Data Exchange For Electro Magnetic Compatibility Testing and Measurement techniques, Surge immunity test Criteria for selection for tests LIKE Acceptance, Inspection. Workmanship standard for Acceptability of Electronic Assemblies (A standard developed by Institute for Interconnecting and packaging Circuits).
2.01.00 2.01.02
General Requirements Climatic Conditions i) Temperature : ii) Humidity : iii) Max. Altitude above MSL : 10oC to 55o C (in shade) Upto 95% RH non-condensing 500 meters
3.00.00 3.01.00
DESIGN AND CONSTRUCTIONAL FEATURES Location & Mounting Energy Meter enclosure shall be IP51.DT meters shall be supplied suitable for outdoor installation in a CRCA sheet enclosure
RGGVY WORKS
STANDARD TECHNICAL
TECHNICAL SPECIFICATION VOL-II (PART - C)
CHAPTER-III SECTION-E2 CT Operated Static Energy Meter
Page 1 of 15
CLAUSE NO.
(LT DB), having IP54 degree of protection. Direct Sunrays shall be falling on the LT DB and Energy Meter shall be designed to withstand temperature inside enclosed box. CT for the energy meter shall be housed in LTDB & shall be of 0.5 accuracy class. 3.02.00 Design Meter shall be designed with application specific integrated circuit (ASIC) or micro controller; shall have no moving part; electronic components shall be assembled on printed circuit board using surface mounting technology (SMT).Factory calibration using high accuracy software based test bench shall be used considering the error of standard in over all accuracy as per table 1 of IS 12346. Assembly of electronic components shall be as per ANSI/IPC-A-610 standard. Internal power supply circuit shall be designed using highly reliable components. Critical components such as metering ICs (ASIC), Microcontroller etc. shall be procured from STACK or IECQ registered suppliers. Current Transformer shall be used for Phase and Neutral circuit to achieve isolation against external interference /electrical spikes. 3.03.00 Manufacturing Process, Assembly and Testing Meters shall be manufactured using latest and state of the art technology and methods prevalent in electronics industry. All inward flow of major components and sub assembly parts (CT, PT, RTCs/Crystal, LCDs, LEDs, power circuit electronic components etc.) shall have batch and source identification. Multi-layer PCB assembly with PTH (Plated through Hole) using surface mounted component shall have adequate track clearance for power circuits. SMT component shall be assembled using automatic pick-and-place machines with in process 7 stages, Re-flow Soldering oven, for stabilized setting of the components on PCB. For soldered PCBs, cleaning and washing of cards, after wave soldering process is to be carried out as a standard practice. Assembly line of the manufacturing system shall have provision for testing of subassembled cards. Manual placing of components and soldering, to be minimized to items, which cannot be handled by automatic machine.
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STANDARD TECHNICAL
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CLAUSE NO.
CT OPERATED STATIC ENERGY METER FOR 3 PHASE DT Handling of PCB with ICs/C-MOS components, to be restricted to bare minimum and precautions to prevent ESD failure to be provided. Complete assembled and soldered PCB should under go functional testing using computerized Automatic Test Equipment. Test points should be provided to check the performance of each block/stage of the meter circuitry. Testing at intermediate and final stage to be carried out with testing instruments, duly calibrated with reference standard, with traceability of source and date.
3.04.00
Displays LCD to be suitable for temperature withstand of 600 C; 7 digits, parameter identifier, backlit Liquid Crystal Display (LCD) of minimum 10 mm height, wide viewing angle. Auto display cycling and push button operation required with persistence time of 12 Seconds. Sequence of display of various instantaneous electrical parameters shall be as desired by Owner at the time of order. Normal display shall be Active energy value, on release of push button, at any of the display parameter during scrolling.
3.05.00
Calibration of Meter Meters shall be factory calibrated using high accuracy test bench. Energy Meter shall have test output device, accessible from the front, and be capable of being monitored with suitable testing equipment while in operation at site. Resolution of the device shall enable the starting current test in less than 10 minutes. Accuracy of test bench at works shall be as per the guidelines provided in IS : 12346(Table-1).
3.06.00
Self-Diagnostic Features The meter shall have self-diagnostic features to check its circuits for any malfunctioning. The bidder shall furnish the details of the self-diagnostic features.
3.07.00 3.07.01 3.07.01a)
Construction Meter Case and Cover To ensure high reliability, long trouble free life, safety against electric shock, spread of fire and effects of excessive temperature, the meter casing and cover shall be made of high quality industrial grade polycarbonate material having adequate strength, which is unbreakable, corrosion resistant & inert to chemicals, flame retardant, immune to ultra violet radiation and meet UV ageing test as per relevant ASTM standards.
RGGVY WORKS TECHNICAL SPECIFICATION VOL-II (PART - C) CHAPTER-III SECTION-E2 CT Operated Static Energy Meter Page 3 of 15
STANDARD TECHNICAL
CLAUSE NO.
3.07.01b) 3.07.01c) 3.07.01d) 3.07.01e) 3.08.00 3.08.01 3.08.03 3.09.00 3.09.01
The bidder shall indicate hardness, melting temperature and tensile yield strength of the material and necessary test certificate of the same shall be furnished. The polycarbonate material used shall conform to the test requirement of heat deflection test as per ISO : 75 and glow wire test as per the relevant Standard. The meter shall be provided with adequate shielding to withstand external magnetic influence from all directions as per latest amendments of CBIP 88 report. Meter cover shall be continuously ultra sonically welded with meter base from all sides. Sealing Arrangement Necessary provision shall be kept for fixing one utility seal out of the two seals stated above. Terminal block shall be provided with separate sealing facility by testing /commercial group of power utility/distribution company. Terminal Block and Cover The terminal block shall have adequate insulating properties and mechanical strength. The terminal block shall be made from best quality non-hygroscopic, flame retardant polycarbonate material (capable of passing the flammability tests give in IS :11731) with nickel-plated brass studs for connecting terminals. The terminal block base shall be of same material as meter case or any other superior industrial plastic material having sufficient thickness to cover its back and provide enough strength for the purpose of tightening of screws. Clamping screws should be provided inside the terminal cover and should have metallic sleeve moulded within the block to avoid damage during tightening of the screws. The terminals in the terminal block shall be of long socket type suitable for connection of cables with aluminium conductors along with suitable lugs (lugs to be provided by the supplier) having cross sectional area, with adequate length. Double screw arrangement shall be provided to achieve adequate termination. All terminals and connecting screws and washers shall be of tinned / nickel plated brass material. The terminal cover shall be transparent with minimum thickness 2.5 mm and the material shall be same as that of meter case. It shall be of extended type and accommodate, in addition to the terminal block, a suitable length of external cable along with its insulation.
3.09.02
3.09.03
3.09.04
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STANDARD TECHNICAL
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CLAUSE NO.
3.10.00 3.10.01
Name Plate and Marking: Every meter shall have a nameplate clearly visible and indelible and distinctly marked in accordance with The following information shall appear on a nameplate preferably placed within the meter. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Manufacturers name & trade-mark and place of manufacture. Serial number and year of manufacture. Designation of type. Number of phases and number of wires for which the meter is suitable. Guarantee period. Owners name & meter number. Principal unit in which the meter records. Reference voltage & frequency in Hz. Basic current and rated maximum current. Meter constant (pulse rate of testing signal). Class index. Project Name.
13. BIS marking as per statutory requirement . 3.11.00 Fixing and Connection Arrangement Manufacturer shall ensure following technical points: Meter shall be suitable for mounting on Distribution Box of LT (LTDB) side of Distribution Transformer. Mounting/fixing arrangement drawing to be properly coordinated to match with LTDB. Terminals shall be designed to carry Imax continuously and under this condition the temperature at the terminal block shall not exceed 700 C with ambient temperature within operating temperature range as defined by IS 14697. 4.00.00 4.01.00 OPERATIONAL REQUIREMENTS The meter shall have BIS mark of certification and shall meet the requirement of Central Electrically Authority Regulations, 2006 for Installation & Operation of Meters. Performance under Influence Quantities As per IS 14697. Accuracy for measurement & display of instantaneous quantities shall conform to IS14697.
4.02.00
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STANDARD TECHNICAL
Page 5 of 15
CLAUSE NO.
CT OPERATED STATIC ENERGY METER FOR 3 PHASE DT Abnormality of events e) Reversal of CT polarity Meter shall record correctly in forward direction with any one, two or all three phases CTs reversed. CT open shall also be recorded. The meter shall be capable to record power on/off events in the meter memory. All potential failure should record as power off event.
f) Power on/off
a) Phase sequence reversal
b) External magnetic influence
The meter shall keep working accurately irrespective of the phase sequence of the supply. The metering system shall be provided with adequate magnetic shielding so that any external magnetic field (AC Electro Magnet or DC Magnet ) as per the values specified in IS 14697(with latest amendments) applied on the metering system shall not affect the proper functioning and recording of energy as per error limits prescribed by CBIP. The meter shall be capable of detecting and recording phase wise occurrence and restoration with date and time in the cases of Potential failure (one phase or two phases) even at zero current. All potential missing cases shall be considered as power failure. Meter shall also detect and log cases of voltage unbalance (from 5% for more than 5 minutes of more-programmable), not when missing potential exists. The meter shall be capable of detecting and recording occurrence and restoration with date and time of Current unbalance (30% of more for more than 15 minutesprogrammable.)
c) Missing Potential & Potential imbalance
d) Current imbalance
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STANDARD TECHNICAL
Page 6 of 15
CLAUSE NO.
CT OPERATED STATIC ENERGY METER FOR 3 PHASE DT Additional Technical Features Output Device i) Energy Meter shall have test output, accessible from the front, and be capable of being monitored with suitable testing equipment while in operation at site. Operation indicator must be visible from the front. This may be same as pulsed output, continuously flashing.. Test output device shall be provided in the form of LED/LCD.
4.02.00 4.02.01
ii)
iii)
Resolution of the test output device shall be sufficient to enable the starting current test in less than 10 minutes. Nameplate shall indicate the impulse/ Unit with appropriate resolution. 4.02.02 Cumulative Energy Register Meter should have provision for automatic recording of cumulative kWh & MD KW at say 24.00 hours on the last day of the month for each of the past six calendar months and same to be stored in the register/memory. 4.03.00 Temperature Conditions As per Is 14697; Meter to perform satisfactorily under Non-Air Conditioned environment in HT sub-station with Indoor switchgear in some of the locations. 4.04.01 Real Time Internal Clock (RTC) of Energy Meter RTC shall be pre-programmed for 30 Years Day/date without any necessity for correction. Maximum drift shall not exceed +/- 300 Seconds per year. Time & date setting shall only be possible through one of the following: Common Meter Reading Instrument (CMRI) 4.04.02 Clock Day/Date Synchronisation Synchronisation of Energy Meter RTC Time/Date shall be possible thro password/Key code enabled command from MRI/CMRI supplied with the meter.
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STANDARD TECHNICAL
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CLAUSE NO.
CT OPERATED STATIC ENERGY METER FOR 3 PHASE DT Quantities to be Measured & Displayed Minimum display capability a) b) c) Cumulative energy-kWh,kVAh & kVARh in primary value of CTR Maximum demand in kVA with occurrence in date and time Date and time
4.05.00 4.05.01
Parameters to be recorded a) b) c) d) e) Half hourly logging or phase wise kW,kVA,kVAR, OVERALL pf Phase wise Current and voltage Half hourly logging of kWh (cumulative) MD reset count, frequency, time & date, RTC battery health; Duration of power availability of power outage in minutes during each half hour duration. TOD time slot register wise kWh Maximum kVA or kW demand with elapsed time.
f) g)
In addition, present status of abnormality shall also be possible to be displayed. Tamper details shall be stored in internal memory for retrieval by authorized personnel through either of the following: i) Common Meter Reading Instrument (CMRI) and this shall need password enabling.
4.06.00
Demand Integration Period (DIP) i) Energy Meter shall continuously monitor and calculate the average maximum demand for each demand interval time of 30 minutes and maximum of these in a calendar month shall be stored along with date and time when it occurred; It shall however be possible to change the demand integration period (DIP), from 30 to 15 minutes at site, with proper security; The Maximum demand of past six months shall be stored in the memory with date and time.
TECHNICAL SPECIFICATION VOL-II (PART - C) CHAPTER-III SECTION-E2 CT Operated Static Energy Meter Page 8 of 15
ii)
iii)
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STANDARD TECHNICAL
CLAUSE NO.
CT OPERATED STATIC ENERGY METER FOR 3 PHASE DT It shall be also possible to retrieve this data through communication port and MRI. Time of Day (TOD) Registers 6 different TOD energy registers as per clause G-8 of IS 14697 are required. Time block settings shall be advised to the supplier at least 4 weeks before commencing delivery. Change of time period for TOD metering shall be with password enabling from CMRI or from base computer for LAN operated meters. iv)
4.07.00
4.08.00
Load Survey Data Registers Storage in Non volatile memory for 40 days, 30 minute demand of any four parameters out of kW, kVA, kVAR (or Pf), Average of 3 voltages and phase currents shall be provided. It shall also be possible to analyse the following: o If DT is overloaded its duration alongwith Peakloading in kVA Phasewise instantaneous value in each half hour beyond presetlimit Phasewise average half hour value alongwith its duration beyond preset limit Values of kW & kVAR for each half hour period shall be logged phase wise. With this data, loading profile of DT shall be plotted. MIS reports showing individual DT wise overloading, neutral current above 10% of rated current, DT loaded less than 25% of rating shall be possible through the software supplied. o If DT has unbalanced loading Phase wise currents shall be logged/plotted for each half hour interval. Phase wise unbalance (in%) shall be obtained for each phase by summating the weighted unbalance for each half hour period. o Neutral current for 3 phase DT The software shall show the magnitude of neutral current for each half hour interval. o Minimum & maximum reactive power flow for each half hour interval for planning installation of capacitors Base & peak capacitor requirement for each DT shall be calculated based on the kVAR data logged. o No.& hours of supply interruption o Occurances of furse failure on HT side of DT Voltage data shall be used to produce information an reliability of power supply. o Nos. of LT faults DT has been subjected to alongwith identification of phase & type of fault Voltage data shall be used to produce information on no. of LT faults. By analyzing the phase current, power factor etc., it shall be possible to indicate the type of fault in LT system.
RGGVY WORKS TECHNICAL SPECIFICATION VOL-II (PART - C) CHAPTER-III SECTION-E2 CT Operated Static Energy Meter Page 9 of 15
STANDARD TECHNICAL
CLAUSE NO.
CT OPERATED STATIC ENERGY METER FOR 3 PHASE DT Communication Facilities & Standards Data architecture and communication protocols shall enable easy multi-vendor exchange of data without usage of any converting/translating equipment. For this, the data structure adopted within the energy meter shall be on an internationally acceptable method. The data structure/coding details shall be furnished to the Owner. All necessary software required for down loading the information to a user friendly Windows/LINUX based operating system of Base billing computer system, Substation data logger PC system thro CMRI as well as LAN shall be furnished in required number of copies (On CD) without any additional cost to the Owner. a) Energy meter shall have a galvanically isolated optical communication port as per IEC 62056-21 or any other internationally accepted port in front of the meter for data transfer to or from a hand held data Collection Device (Common Meter Reading Instrument CMRI - conforming to CBIP technical report-111) with proper security and without error.
4.09.00
4.10.00
Tamper Monitoring and Recording Meters shall at least be immune to tampers elaborated in IS 14697, ANNEX G-10. All types of tampers for which meter is made immune, shall be listed by the bidder. These tampers records shall be recorded or stored in the meter memory. Further, compliance to these are to be demonstrated by the bidder during acceptance test by successful bidder.
4.11.00
5.00.00 5.01.00
Inspection, Testing and Dispatch Type Tests i) The meter offered should have successfully passed all type tests described in the IS 14697 . Type test certificate shall be submitted along with the offer and the same shall not be more than 36 months old on the date of opening tender.. In case the test report(fully or partially) is not meeting the requirement tests are to be carried out at no extra cost in owners presence.
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STANDARD TECHNICAL
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CLAUSE NO.
CT OPERATED STATIC ENERGY METER FOR 3 PHASE DT Acceptance and Routine Tests i) Criteria for selection for such tests and performance requirements shall be as per IS 14697
5.02.00
5.03.00 5.03.01
Quality Assurance Plan The bidder (manufacturer) shall have a comprehensive quality assurance program at all stages of manufacture for ensuring products giving reliable, trouble free performance. The bidders (manufacturers) quality assurance plan shall be submitted along with bid document, which would be reviewed in detail by the owner in case of award and accepted with modifications, as felt necessary. A sampler manufacturing quality plan document is enclosed in this specification. The bidders quality assurance programme shall generally cover the following. i) ii) iii) iv) v) Bidder organization structure for the management and implementation of the proposed quality assurance programme. Quality System Manual. Design Control System. Documentation Control System. The procedure for purchase of materials, parts, components, source inspection, incoming raw-material inspection, verification of materials purchased etc. System for process controls and fabrication and assembly controls.
5.03.02
vi)
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STANDARD TECHNICAL
Page 11 of 15
CLAUSE NO.
5.03.04
Owner reserves the right to carry out quality audit and quality surveillance of the systems and procedure of the bidders quality management & control activities. The bidders shall provide all necessary assistance to enable the owner to carry out such audit & surveillance. MANUFACTURING AND TESTING FACILITIES The following Manufacturing and testing facilities shall be available. i. The factory shall be completely dust proof. ii. The testing rooms shall be temperature and humidity controlled as per relevant Standards. iii. The testing and calibrating equipment should be automatic and all test equipment shall have their valid calibration certificates iv. Power supplies used in testing equipment shall be distortion free with sinusoidal waveforms and maintaining constant voltage current and frequency as per the relevant Standards.
6.00.00 6.01.00
6.02.00
During the manufacturing of the meters following minimum checks shall be carried out. a. b. c. d. e. f. Meter frame dimension tolerance shall be minimum. The pressure coil shall be made totally encapsulated and care shall be taken to avoid ingress of dust and moisture inside the coil. The assembly of parts shall be done with the help of jigs and fixtures so that human errors are eliminated. The meters shall be batch tested on automatic, computerized test bench and the results shall be printed directly without any human errors. The current coil shall be made with the help of jigs and fixtures. The potential coil shall be made with automatic computerized machine.
7.00.00
One copy of test report, approved data sheet and operating manual shall be despatched with the meter. 4 copies of these documents shall be submitted to owners engineering department for record. Guaranteed Technical parameter(GTP) The meters shall be supplied as per the GTP enclosed at Annexure-A Annexure-A
8.00.00
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STANDARD TECHNICAL
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CLAUSE NO.
Sr Description No 1 Type 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Standard to which the meter conforms: Guarantee Period from the date of first Installation Rated Voltage: Basic Current(Ib): Meter shall display in Primary Quantity as per adopted CT Ratio Maximum Continuous Current : Frequency Range: Power Factor Range Completely type tested as per Indian Standard IS Minimum Starting Current : Accuracy class. : Test Output device Operation indicator Power consumption in voltage and current circuit Limits of error at all Power factor of unity/0.5 at multiples of rated currents. Compliance to IS-14697 for Change in error due to a) Variation in frequency: b) Variation in Temperature c) Variation in Voltage One minute Power frequency withstand Voltage : Should be Compliant to EMC & EMI as per Basic insulation level: Impulse withstand Voltage Current rating of the terminal: External Magnetic Influence
THREE PHASE METER Static Three Phase ,CT operated meter for unbalance load current IS-14697:1999 24 Months 3 X 240 Volts(Phase to Neutral) 5A as per CT Secondary CT ratio (50/5),Yes (2Ib) 50Hz +/- 5% 0.5 lag-Unity-0.8 lead 14697 0.1% of Ib 0.5 Class for kWh & 1.0 for kVARh LED LED/LCD As per IS-14697 As per IS-14697
As per IS-14697 As per IS-14697 As per IS-14697 As per IS-14697 As per IS-14697 As per IS-14697 As per IS-14697 As per IS-14697
18 18 19 20 21
Formatted Table
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STANDARD TECHNICAL
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CLAUSE NO.
22 23
Maximum size of cable, which can be connected at terminals: Terminals to be bi-metallic and suitable for Aluminum / copper Cables Terminal Block material
16 Sq mm YES The material of which the terminal block is made shall be capable of passing the test given in ISO 751(1993) and ISO 75-2(1993) for a temperature of 135C and a pressure of 1.8 Mpa(Method A) The test will be carried out accordinng to IS 11000 (Part2 /Sec1)With the following temperature Terminal Block 960 15C,Terminal cover and Meter case 650 10C,Duration of Application 30 S 1S As per Technical Specification IP-51
24 Resistance to Heat and Fire
25 26 27 28 29
Details of meter case: Degree of protection against dust and water : Details of alpha-numeric LCD display i.No. of digits Tamper protection features (List out)
30 32 34 35
Whether test output provided Meter & Terminal Cover sealing Type Test Certificate
36 37 38
Programming of TOD & MD Integration Period for 15/30 min in field through CMRI with password facility TOD wise kwh YES , kwh P hasewise KVAR ,KW & KVA, YES Overall PF, MD reset count, frequency, time & date, RTC battery health Parameter shall be available in Data Collection.
7(Height Of Digit Not Less than 10 mm) Voltage failure,Current unbalnce,Curent bypass,Current reversal,Magnetic logging LED Provision of Meter Cover and Terminal cover sealing is given Type Test Certificate is not be more than 03 years old. YES
Formatted Table
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STANDARD TECHNICAL
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CLAUSE NO.
39 41
MD configuration Meter Communication Port Software: Necessary software shall be supplied with meter for data downloading With help of CMRI /BCS
KW - MD1 and KVA- MD2 for 30 /15 minutes ; can be configured. Optical port Necessary software shall be supplied with meter for data downloading With help of CMRI /BCS List Enclosed
42 43 Display Parameter and sequence of display in Push button and auto scroll mode (Listout)
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STANDARD TECHNICAL
Page 15 of 15
CLAUSE NO.
1.00.00
SCOPE This specification covers design, engineering, manufacture, inspection, testing at manufacturers works including type testing before dispatch, supply and delivery of Single phase 2 wire 0.5 class CT operated energy meters with Time of the Day register, load profile data record MD register suitable for both unbalanced and balanced load.
2.00.00
APPLICABLE STANDARDS Sl. No. 1. 3. 4. 5. 6. Standards IS : 14697 IEC : 62056-21 (Latest Version) IEC : 61000-4-5 (2001-04) IEC : 61358 ANSI/IPC-A-610 Description Specification for AC Static Transformer operated Watt Hour & VAR-Hour meters, classes 0.2 S & 0.5 S Data exchange for Meter Reading and Direct Local Data Exchange For Electro Magnetic Compatibility Testing and Measurement techniques, Surge immunity test Criteria for selection for tests LIKE Acceptance, Inspection. Workmanship standard for Acceptability of Electronic Assemblies (A standard developed by Institute for Interconnecting and packaging Circuits).
2.01.00 2.01.02
General Requirements Climatic Conditions i) Temperature : ii) Humidity : iii) Max. Altitude above MSL : 10oC to 55o C (in shade) Upto 95% RH non-condensing 500 meters
3.00.00 3.01.00
DESIGN AND CONSTRUCTIONAL FEATURES Location & Mounting Energy Meter enclosure shall be IP51.DT meters shall be supplied suitable for outdoor installation in a CRCA sheet enclosure
RGGVY WORKS
STANDARD TECHNICAL
TECHNICAL SPECIFICATION VOL-II-B (Part - C)
Page 1 of 15
CLAUSE NO.
(LT DB), having IP54 degree of protection. Direct Sunrays shall be falling on the LT DB and Energy Meter shall be designed to withstand temperature inside enclosed box. CT for the energy meter shall be housed in LTDB & shall be of 0.5 accuracy class. 3.02.00 Design Meter shall be designed with application specific integrated circuit (ASIC) or micro controller; shall have no moving part; electronic components shall be assembled on printed circuit board using surface mounting technology (SMT).Factory calibration using high accuracy software based test bench shall be used considering the error of standard in over all accuracy as per table 1 of IS 12346. Assembly of electronic components shall be as per ANSI/IPC-A-610 standard. Internal power supply circuit shall be designed using highly reliable components. Critical components such as metering ICs (ASIC), Microcontroller etc. shall be procured from STACK or IECQ registered suppliers. Current Transformer shall be used for Phase and Neutral circuit to achieve isolation against external interference /electrical spikes. 3.03.00 Manufacturing Process, Assembly and Testing Meters shall be manufactured using latest and state of the art technology and methods prevalent in electronics industry. All inward flow of major components and sub assembly parts (CT, PT, RTCs/Crystal, LCDs, LEDs, power circuit electronic components etc.) shall have batch and source identification. Multi-layer PCB assembly with PTH (Plated through Hole) using surface mounted component shall have adequate track clearance for power circuits. SMT component shall be assembled using automatic pick-and-place machines with in process 7 stages, Re-flow Soldering oven, for stabilized setting of the components on PCB. For soldered PCBs, cleaning and washing of cards, after wave soldering process is to be carried out as a standard practice. Assembly line of the manufacturing system shall have provision for testing of subassembled cards. Manual placing of components and soldering, to be minimized to items, which cannot be handled by automatic machine.
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STANDARD TECHNICAL
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CLAUSE NO.
CT OPERATED STATIC ENERGY METER FOR 1 PHASE DT Handling of PCB with ICs/C-MOS components, to be restricted to bare minimum and precautions to prevent ESD failure to be provided. Complete assembled and soldered PCB should under go functional testing using computerized Automatic Test Equipment. Test points should be provided to check the performance of each block/stage of the meter circuitry. Testing at intermediate and final stage to be carried out with testing instruments, duly calibrated with reference standard, with traceability of source and date.
3.04.00
Displays LCD to be suitable for temperature withstand of 600 C; 7 digits, parameter identifier, backlit Liquid Crystal Display (LCD) of minimum 10 mm height, wide viewing angle. Auto display cycling and push button operation required with persistence time of 12 Seconds. Sequence of display of various instantaneous electrical parameters shall be as desired by Owner at the time of order. Normal display shall be Active energy value, on release of push button, at any of the display parameter during scrolling.
3.05.00
Calibration of Meter Meters shall be factory calibrated using high accuracy test bench. Energy Meter shall have test output device, accessible from the front, and be capable of being monitored with suitable testing equipment while in operation at site. Resolution of the device shall enable the starting current test in less than 10 minutes. Accuracy of test bench at works shall be as per the guidelines provided in IS : 12346(Table-1).
3.06.00
Self-Diagnostic Features The meter shall have self-diagnostic features to check its circuits for any malfunctioning. The bidder shall furnish the details of the self-diagnostic features.
3.07.00 3.07.01 3.07.01a)
Construction Meter Case and Cover To ensure high reliability, long trouble free life, safety against electric shock, spread of fire and effects of excessive temperature, the meter
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CLAUSE NO.
casing and cover shall be made of high quality industrial grade polycarbonate material having adequate strength, which is unbreakable, corrosion resistant & inert to chemicals, flame retardant, immune to ultra violet radiation and meet UV ageing test as per relevant ASTM standards. 3.07.01b) 3.07.01c) 3.07.01d) 3.07.01e) 3.08.00 3.08.01 3.08.03 3.09.00 3.09.01 The bidder shall indicate hardness, melting temperature and tensile yield strength of the material and necessary test certificate of the same shall be furnished. The polycarbonate material used shall conform to the test requirement of heat deflection test as per ISO : 75 and glow wire test as per the relevant Standard. The meter shall be provided with adequate shielding to withstand external magnetic influence from all directions as per latest amendments of CBIP 88 report. Meter cover shall be continuously ultra sonically welded with meter base from all sides. Sealing Arrangement Necessary provision shall be kept for fixing one utility seal out of the two seals stated above. Terminal block shall be provided with separate sealing facility by testing /commercial group of power utility/distribution company. Terminal Block and Cover The terminal block shall have adequate insulating properties and mechanical strength. The terminal block shall be made from best quality non-hygroscopic, flame retardant polycarbonate material (capable of passing the flammability tests give in IS :11731) with nickel-plated brass studs for connecting terminals. The terminal block base shall be of same material as meter case or any other superior industrial plastic material having sufficient thickness to cover its back and provide enough strength for the purpose of tightening of screws. Clamping screws should be provided inside the terminal cover and should have metallic sleeve moulded within the block to avoid damage during tightening of the screws. The terminals in the terminal block shall be of long socket type suitable for connection of cables with aluminium conductors along with suitable lugs (lugs to be provided by the supplier) having cross sectional area, with adequate length. Double screw arrangement shall be provided to achieve adequate termination. All terminals and connecting screws and washers shall be of tinned / nickel plated brass material.
3.09.02
3.09.03
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3.09.04
The terminal cover shall be transparent with minimum thickness 2.5 mm and the material shall be same as that of meter case. It shall be of extended type and accommodate, in addition to the terminal block, a suitable length of external cable along with its insulation. Name Plate and Marking: Every meter shall have a nameplate clearly visible and indelible and distinctly marked in accordance with The following information shall appear on a nameplate preferably placed within the meter. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Manufacturers name & trade-mark and place of manufacture. Serial number and year of manufacture. Designation of type. Number of phases and number of wires for which the meter is suitable. Guarantee period. Owners name & meter number. Principal unit in which the meter records. Reference voltage & frequency in Hz. Basic current and rated maximum current. Meter constant (pulse rate of testing signal). Class index. Project Name.
3.10.00 3.10.01
13. BIS marking as per statutory requirement . 3.11.00 Fixing and Connection Arrangement Manufacturer shall ensure following technical points: Meter shall be suitable for mounting on Distribution Box of LT (LTDB) side of Distribution Transformer. Mounting/fixing arrangement drawing to be properly coordinated to match with LTDB. Terminals shall be designed to carry Imax continuously and under this condition the temperature at the terminal block shall not exceed 700 C with ambient temperature within operating temperature range as defined by IS 14697.
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CT OPERATED STATIC ENERGY METER FOR 1 PHASE DT OPERATIONAL REQUIREMENTS The meter shall have BIS mark of certification and shall meet the requirement of Central Electrically Authority Regulations, 2006 for Installation & Operation of Meters. Performance under Influence Quantities As per IS 14697. Accuracy for measurement & display of instantaneous quantities shall conform to IS14697. ABNORMALITY OF EVENTS The meter shall keep working accurately (recording energy in forward direction), irrespective of swapping of phase & neutral The metering system shall be provide with adequate magnetic shielding so that any external magnetic field (AC Electro Magnet or DC Magnet) as per the values specified in IS 14697 (with latest amendments) applied on the metering system shall not affect the proper functioning and recording of energy as per error limits prescribed. The meter shall be capable to record power on /off events in the meter memory. All potential failure should record as power off events.
4.00.00 4.01.00
4.02.00
a) Phase/Neutral current reversal or Phase & neutral interchange
b) External magnetic influence
d) Power on/off
4.03.00 4.03.01
Additional Technical Features Output Device i) Energy Meter shall have test output, accessible from the front, and be capable of being monitored with suitable testing equipment while in operation at site.
ii)
Operation indicator must be visible from the front. This may be same as pulsed output, continuously flashing. Test output device shall be provided in the form of LED/LCD.
iii)
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CT OPERATED STATIC ENERGY METER FOR 1 PHASE DT Resolution of the test output device shall be sufficient to enable the starting current test in less than 10 minutes. Nameplate shall indicate the impulse/ Unit with appropriate resolution.
4.03.02
Cumulative Energy Register Meter should have provision for automatic recording of cumulative kWh & MD KW at say 24.00 hours on the last day of the month for each of the past six calendar months and same to be stored in the register/memory.
4.04.00
Temperature Conditions As per Is 14697; Meter to perform satisfactorily under Non-Air Conditioned environment in HT sub-station with Indoor switchgear in some of the locations.
4.45.01
Real Time Internal Clock (RTC) of Energy Meter
RTC shall be pre-programmed for 30 Years Day/date without any necessity for correction. Maximum drift shall not exceed +/- 300 Seconds per year. Time & date setting shall only be possible through one of the following: Common Meter Reading Instrument (CMRI) 4.05.02 Clock Day/Date Synchronisation Synchronisation of Energy Meter RTC Time/Date shall be possible thro password/Key code enabled command from MRI/CMRI supplied with the meter. 4.06.00 4.06.01 4.06.02 4.06.03 4.06.04 4.07.00 Quantities to be Measured & Displayed Minimum display capability a) Cumulative energy-kWh,kVAh in primary value of CTR b) Maximum demand in kVA with occurrence in date and time c) Date and time
Parameters to be recorded a) b) Half hourly logging of kW,kVA, OVERALL pf Current and voltage
TECHNICAL SPECIFICATION VOL-II-B (Part - C) CHAPTER-III SECTION-E3 CT Operated Static Energy Meter Page 7 of 15
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c) d) e)
Half hourly logging of kWh (cumulative) MD reset count, frequency, time & date, RTC battery health; Duration of power availability or power outage in minutes during each half hour duration. TOD time slot register wise kWh, Maximum kVA or kW demand with elapsed time.
f) g)
In addition, present status of abnormality shall also be possible to be displayed. Tamper details shall be stored in internal memory for retrieval by authorized personnel through either of the following: i) Common Meter Reading Instrument (CMRI) and this shall need password enabling.
4.08.00
Demand Integration Period (DIP) i) Energy Meter shall continuously monitor and calculate the average maximum demand for each demand interval time of 30 minutes and maximum of these in a calendar month shall be stored along with date and time when it occurred.
ii)
It shall however be possible to change the demand integration period (DIP), from 30 to 15 minutes at site, with proper security; The Maximum demand of past six months shall be stored in the memory with date and time.
iii)
4.09.00
It shall be also possible to retrieve this data through communication port and MRI. Time of Day (TOD) Registers 6 different TOD energy registers as per clause G-8 of IS 14697 are required. Time block settings shall be advised to the supplier at least 4 weeks before commencing delivery. Change of time period for TOD metering shall be with password enabling from CMRI or from base computer for LAN operated meters.
iv)
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4.10.00
Load Survey Data Registers Storage in Non volatile memory for 60 days, 30 minute demand of any four parameters out of kW, kVA, kVAR (or Pf), Average of 3 voltages and phase currents shall be provided. It shall also be possible to analyse the following: If DT is overloaded ,its duration alongwitho Peakloading Iin kVA Insantaneous value in each half hour beyond preset limit Average half hour value alongwith its duration beyond preset limit Values of kW & kVA for each half hour period shall be logged. With this data loading profile of DT shall be plotted with MIS report showing individual DT wise overloading, DT loaded less than 25% of rating shall be possible through the software supplied. Minimum & maximum reactive power flow for each half hour interval for planning installation of capoacitors Base & peak capacitor requirement for each DT shall be calculated based on the kVA data logged. No. & hours of supply interruption Occurances of fuse failure on HT side of DT Voltage data shall be used to produce information on reliability of power supply. Nos. of LT faults DT has been subjected to alongwith identification of type of fault Voltage data shall be used to produce information on no. of LT faults. By analyzing the current, power factor etc., it shll be possible to indicate the type of fault in LT system.
5.00.00
Communication Facilities & Standards Data architecture and communication protocols shall enable easy multi-vendor exchange of data without usage of any converting/translating equipment. For this, the data structure adopted within the energy meter shall be on an internationally acceptable method. The data structure/coding details shall be furnished to the Owner. All necessary software required for down loading the information to a user friendly Windows/LINUX based operating system of Base billing computer system, Substation data logger PC system thro
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CLAUSE NO.
CMRI as well as LAN shall be furnished in required number of copies (On CD) without any additional cost to the Owner. a) Energy meter shall have a galvanically isolated optical communication port as per IEC 62056-21 or any other internationally accepted port in front of the meter for data transfer to or from a hand held data Collection Device (Common Meter Reading Instrument CMRI - conforming to CBIP technical report-111) with proper security and without error.
6.00.00
Tamper Monitoring and Recording Meters shall at least be immune to tampers elaborated in IS 14697, ANNEX G-10,as applicable for single phase energy meter. All types of tampers for which meter is made immune, shall be listed by the bidder. These tampers records shall be recorded or stored in the meter memory. Further, compliance to these are to be demonstrated by the bidder during acceptance test by successful bidder.
7.00.00
8.00.00 8.00.01
Inspection, Testing and Dispatch Type Tests i) The meter offered should have successfully passed all type tests described in the IS 14697 . Type test certificate shall be submitted along with the offer and the same shall not be more than 36 months old on the date of opening tender.. In case the test report(fully or partially) is not meeting the requirement tests are to be carried out at no extra cost in owners presence. Acceptance and Routine Tests i) Criteria for selection for such tests and performance requirements shall be as per IS 14697
8.00.02
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CLAUSE NO.
CT OPERATED STATIC ENERGY METER FOR 1 PHASE DT Quality Assurance Plan The bidder (manufacturer) shall have a comprehensive quality assurance program at all stages of manufacture for ensuring products giving reliable, trouble free performance. The bidders (manufacturers) quality assurance plan shall be submitted along with bid document, which would be reviewed in detail by the owner in case of award and accepted with modifications, as felt necessary. A sampler manufacturing quality plan document is enclosed in this specification. The bidders quality assurance programme shall generally cover the following. i) ii) iii) iv) v) Bidder organization structure for the management and implementation of the proposed quality assurance programme. Quality System Manual. Design Control System. Documentation Control System. The procedure for purchase of materials, parts, components, source inspection, incoming raw-material inspection, verification of materials purchased etc. System for process controls and fabrication and assembly controls.
9.00.00 9.00.01
9.00.02
vi)
9.00.04
Owner reserves the right to carry out quality audit and quality surveillance of the systems and procedure of the bidders quality management & control activities. The bidders shall provide all necessary assistance to enable the owner to carry out such audit & surveillance.
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10.00.00 10.00.01
MANUFACTURING AND TESTING FACILITIES The following Manufacturing and testing facilities shall be available. i. The factory shall be completely dust proof. ii. The testing rooms shall be temperature and humidity controlled as per relevant Standards. iii. The testing and calibrating equipment should be automatic and all test equipment shall have their valid calibration certificates iv. Power supplies used in testing equipment shall be distortion free with sinusoidal waveforms and maintaining constant voltage current and frequency as per the relevant Standards.
10.00.02
During the manufacturing of the meters following minimum checks shall be carried out. a. b. c. d. e. f. Meter frame dimension tolerance shall be minimum. The pressure coil shall be made totally encapsulated and care shall be taken to avoid ingress of dust and moisture inside the coil. The assembly of parts shall be done with the help of jigs and fixtures so that human errors are eliminated. The meters shall be batch tested on automatic, computerized test bench and the results shall be printed directly without any human errors. The current coil shall be made with the help of jigs and fixtures. The potential coil shall be made with automatic computerized machine.
11.00.00
One copy of test report, approved data sheet and operating manual shall be despatched with the meter. 4 copies of these documents shall be submitted to owners engineering department for record.
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CLAUSE NO.
12.00.00
Guaranteed Technical parameter(GTP) The meters shall be supplied as per the GTP enclosed at Annexure-A Annexure-A Sr Description No 1 Type Standard to which the meter conforms: Guarantee Period from the date of first Installation Rated Voltage: Basic Current(Ib): Meter shall display in Primary Quantity as per adopted CT Ratio Maximum Continuous Current : Frequency Range: Power Factor Range Completely type tested as per Indian Standard IS Minimum Starting Current : Accuracy class. : Test Output device Operation indicator Power consumption in voltage and current circuit Limits of error at all Power factor of unity/0.5 at multiples of rated currents. Compliance to IS-14697 for Change in error due to a) Variation in frequency: b) Variation in Temperature c) Variation in Voltage One minute Power frequency withstand Voltage : Should be Compliant to EMC & EMI as per Basic insulation level: Impulse withstand Voltage Current rating of the terminal: THREE PHASE METER Static single Phase ,CT operated meter IS-14697:1999 24 Months 240 Volts(Phase to Neutral) 5A as per CT Secondary CT ratio (50/5),Yes (2Ib) 50Hz +/- 5% 0.5 lag-Unity-0.8 lead 14697 0.1% of Ib 0.5 Class LED LED/LCD As per IS-14697 As per IS-14697
2 3 4 5 6 7 8 9 10 11 12 13 14 15
16 17
As per IS-14697 As per IS-14697 As per IS-14697 As per IS-14697 As per IS-14697 As per IS-14697 As per IS-14697
CHAPTER-III SECTION-E3 CT Operated Static Energy Meter Page 13 of 15
18 18 19 20
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CT OPERATED STATIC ENERGY METER FOR 1 PHASE DT Sr Description No 21 22 External Magnetic Influence Maximum size of cable, which can be connected at terminals: Terminals to be bi-metallic and suitable for Aluminum / copper Cables Terminal Block material THREE PHASE METER
As per IS-14697 16 Sq mm YES
23
24 Resistance to Heat and Fire
25 26 27 28 29
Details of meter case: Degree of protection against dust and water : Details of alpha-numeric LCD display i.No. of digits Tamper protection features (List out)
The material of which the terminal block is made shall be capable of passing the test given in ISO 751(1993) and ISO 75-2(1993) for a temperature of 135C and a pressure of 1.8 Mpa(Method A) The test will be carried out accordinng to IS 11000 (Part2 /Sec1)With the following temperature Terminal Block 960 15C,Terminal cover and Meter case 650 10C,Duration of Application 30 S 1S As per Technical Specification IP-51
30 32 34
Whether test output provided Meter & Terminal Cover sealing Type Test Certificate
35 Programming of TOD & MD Integration Period for 15/30 min in field through CMRI with password facility TOD wise kwh,
7(Height Of Digit Not Less than 10 mm) Voltage failure,Current unbalnce,Curent bypass,Current reversal,Magnetic logging LED Provision of Meter Cover and Terminal cover sealing is given Type Test Certificate is not be more than 03 years old. YES
36 37
YES , kwh
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38 39
Phasewise KW & KVA, Overall PF, MD reset count, frequency, time & date, RTC battery health Parameter shall be available in Data Collection. MD configuration Meter Communication Port
YES
KW - MD1 and KVA- MD2 for 30 /15 minutes ; can be configured. Optical port Necessary software shall be supplied with meter for data downloading With help of CMRI /BCS List Enclosed
41 Software: Necessary software shall be supplied with meter for data downloading With help of CMRI /BCS Display Parameter and sequence of display in Push button and auto scroll mode (Listout)
42
43
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MCCB SCOPE This specification includes manufacturing, design, testing and supply of 3-pole, 50 Hz, AC, LT moulded case circuit breakers (MCCB) suitable for protection of 3phase Distribution Transformers and 1-Pole, 50 Hz, AC, LT moulded case circuit breakers (MCCB) suitable for protection of 1- phase Distribution Transformers for providing in LT Distribution Board.
1.00.00
2.00.00
APPLICABLE STANDARDS The moulded case circuit breakers shall comply with the latest version of IS 13947: Part 1 & 2: 1993 and REC Specification 18/1981(Revised 1983).
3.00.00 3.01.00 3.02.00
TECHNICAL REQUIREMENTS Rated Voltage The rated voltage of the circuit breakers shall be 415V. Current Setting The standard current settings of the circuit breakers for use with the transformers of different ratings shall be as follows: Transformer Rating in KV 10(Single Phase) 16(3 Phase) 25(3Phase) Number of Poles Current Setting (Amps.) 40 25 40
3.03.00
The circuit breakers for transformers protection shall have triple-pole construction so that all the three poles close or trip simultaneously. 3.04.00 Time/Current Characteristic The circuit breakers shall have the following time/current characteristic: Multiple of normal current setting Tripping time 1.05 1.2 1.3 1.4 2.5 4.0 6.0 12.0 More than 2.5 hours More than 10 minutes but less than 2 hours Less than 30 minutes Less than 10 minutes Less than 1 minute Not less than 2 seconds Less than 5 seconds Instantaneous (less than 40 milli-seconds)
Time current characteristic of the circuit breaker shall be tested in accordance with Clause 7.7.2.3(b)(2) of IS: 2516 (Part I & II/Sec.1)-1985 and the test shall be made with all the three phases loaded. For the time/current characteristic, the reference calibration temperature of the breakers shall be 40oC.
RGGVY WORKS STANDARD TECHNICAL SPECIFICATION (REV.- 03) TECHNICAL SPECIFICATION VOL-II (PART-C) CHAPTER-II SECTION-E-4 MCCB Page 1 of 4
CLAUSE NO.
MCCB Rated Short-Circuit Breaking Current The rated short-circuit breaking current of the circuit breakers shall be as follows: Transformer Rating (KVA) 10 16 25 Min. rated short circuit Breaking Current of the Circuit Breaker (KA) 10 10 10
3.05.00 3.05.01
The short circuit breaking capacity shall be based on the short circuit test carried out at power factor not exceeding 0.4 (lagging). For the purpose of this test, the following operating sequence shall be followed. Break-3 minutes interval-make break-3 minutes interval-make break 3.05.02 While the above stipulations regarding the test power factor and the sequence of operation shall be binding, the other procedure for making the short circuit test and the test circuit etc., shall be in accordance with IS: 2516 (Part I & II/Section 1)-1985 or the latest version thereof. GENERAL REQUIREMENTS The metallic portions of the mechanism shall be either inherently resistant to or so treated as to make them resistant to the atmospheric corrosion. The circuit breakers shall have trip-free mechanism. The breakers should clearly indicate on and off positions. Terminals and Wiring A suitable terminal block in the enclosure shall be provided (below the circuit breaker) for termination of incoming and outgoing cables in order to prevent direct pressure on the circuit breaker terminals. The enclosure shall be fully wired up with insulated copper wires suitable for ratings to connect the outgoing and incoming terminals of the circuit .breaker to the terminal block by means of tinned copper lugs. The wires should have adequate clearance from each other and from the enclosure body. Necessary spacers, cleats etc. may be provided for this purpose. Aluminium terminal ends (lugs) of adequate size shall also be provided by the supplier to connect the incoming and outgoing cables to the terminal block to facilitate proper connections of Aluminium cables at the site. The lugs shall conform to IS:8309. The sizes of lugs shall be suitable for various current settings of the circuit breakers. Necessary provision shall be made in the enclosure for a separate neutral link on the same terminal block, to which incoming and outgoing neutral conductors can be connected. Aluminium terminal ends (lugs) of adequate size shall be provided for this purpose. The design of terminal block shall be such that all the incoming and outgoing terminals (including neutral) are in a line.
TECHNICAL SPECIFICATION VOL-II (PART-C) CHAPTER-II SECTION-E-4 MCCB Page 2 of 4
4.00.00 4.01.00
4.03.00 4.03.01
4.03.02
4.03.03
CLAUSE NO.
MCCB The terminals and the terminal screws/nuts in the terminal block shall be of electroplated brass. Roll-bonded aluminium-copper bimetallic washers 1 mm thick (of appropriate size and shape) shall be provided by the supplier on both sides of the aluminium lugs to avoid bimetallic action in the terminations of incoming and outgoing cables in the terminal block.
4.03.04
A suitable insulating shield shall be provided in the enclosure to guard against accidental touching of the live parts while operating the breaker. The bottom plate of the enclosure shall be made detachable to facilitate easy crimping of lugs to the cable ends and for convenience in making connections. The plate shall be provided with two holes suitable for the cable sizes and glands made of tough elastic material shall be provided to ensure proper grip and support to the cables.
4.04.00
Earthing The assembly comprising of the enclosure, framework and the circuit breaker shall be provided with an earthing terminal readily accessible and of adequate size. The earthing terminal shall be clearly marked. One of the fixing bolts of the enclosure shall be used for providing second earthing connection.
5.00.00
TESTS The following type and routine tests shall be carried out on the circuit breaker in accordance with the IS 13947: Part 1 & 2: 1993
5.01.00
Type Tests Type tests shall include the following : a) b) c) d) e) f) g) Verification of temperature rise limits. Verification of dielectric properties. Verification of rated short-circuit making and breaking capacities. Verification of the ability to carry rated short-time with stand current. Verification of mechanical operation and of mechanical and electrical endurances. Verification of overload performance. Verification of operating limits and characteristics of over current opening releases.
5.02.00
Routine Tests Routine tests shall include the following : a) b) Mechanical Operation test Calibration of releases and
TECHNICAL SPECIFICATION VOL-II (PART-C) CHAPTER-II SECTION-E-4 MCCB Page 3 of 4
CLAUSE NO.
MCCB c) Dielectric tests
6.00.00 6.01.00
INSPECTION Mounting, connection and clearance details of MCCB, to be mounted inside the Distribution Transformer LT DB, as described in the specification, shall be coordinated. Detailed drawing showing the layout and arrangement (with internal view) of the DB shall be prepared and submitted to the Owners Engineer for approval before commencement of manufacturing and supply.
CHAPTER-II SECTION-E-4 MCCB
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CLAUSE NO.
LTDB FOR DISTRIBUTION TRANSFORMER SUBSTATION SCOPE This specification includes manufacture, design, testing and supply of LT Distribution Box (LTDB) suitable for Single phase 2 wire and 3 phase 4 wires with neutral solidly grounded system for providing on secondary side of distribution substations.
1.00.00
2.00.00
APPLICABLE STANDARDS The distribution box shall comply with the following Indian Standard Specification . IS:2950 : A.C. Connectors IS: 13947 :1993 (Part I & II)-1985: LT Circuit Breakers (MCCB) IS: 9676/1980: Temperature weather condition.
3.00.00 3.01.00
CONSTRUCTIONAL REQUIREMENTS The distribution box shall be made of MS sheet suitable for outdoor mounting and to match with the capacity of the Distribution Transformer. The Distribution box shall be made out of CRCA sheet which shall have a thickness of not less than 2.5 mm. for door panel and 3 mm for body panel and shall be dust, moisture, vermin and weather proof with degree of protection IP-55 as per IS:13947 suitable for outdoor use. The doors shall be provided with insulated handles and with separate padlocking arrangement. There shall be a partition plate having thickness of 2.5 mm separating the upper and lower compartment. Box shall be mounted on structure at a suitable height. The Mounting arangements shall be as per tender drawing enclosed. The LT phase connections from LT bushing of DT shall terminate at MCCB which shall be provided in lower compartment of the box. The output from MCCB shall be extended to the CT primary ,CT shall be mounted in the lower compartment of the LTDB.CT secondary shall be terminated on disconnecting type TB mounted in upper compartment and further meter shall be connected through TB by using the insulated conductors with proper crimped lugs.TB shall be provided with suitable arrangement for CT secondary shorting. . The neutral from DT shall terminate at energy meter through neutral CT. The primary side of all four CT(3 phase +one neutral)shall be terminated on LT buses in lower compartment in case of 3 phase DB and equivalent arrangement with one phase CT and one neutral CTshall be done in single phase DB.. All these bars shall have cross-holes suitable for 4/6/10/16 sq.mm conductors with screw on the top for fixing of conductors. Four (4) cross-holes per bar shall be made. All LT lines emanating from LT buses shall be provided with porcelain fuses of rating 63 A. Cable entries in to the box shall be from bottom. Suitable no. of holes with cable glands along with IS approved gaskets shall be provided in the lower compartment of the Distribution Box. Neoprene Rubber gasket shall be used in the door to avoid ingress of moisture and other elements in the distribution box. The distribution box shall have epoxy based powder coating with white colour inside the box & smoke
TECHNICAL SPECIFICATION VOL-II (Part-C) CHAPTER-II SECTION-E5 LTDB for Distribution Transformer Substation Page 1 of 4
3.02.00
3.04.00
CLAUSE NO.
LTDB FOR DISTRIBUTION TRANSFORMER SUBSTATION grey shade No-692 for outside as per IS-5. Gland Plate of 3mm thickness shall also be used to facilitate fixing of glands and cable entries at site. A srawing showing a typical arrangement of the distribution box with front view (cover removed) is enclosed.
3.05.00 3.06.00
The final drawing of the DB shall be submitted to the owner by contractor for review and approval before commencement of manufacturing and supply. All parts, doors, movable covers and panels shall be fitted all around with neoprene gaskets. The gaskets shall be provided along a channel on periphery of the doors and covers. The Distribution box shall have neat appearance inside and outside with all equipment mounted flush having no visible welds, with all exterior surfaces even and smooth. The door is to be provided in front with internal hinges. The wiring shall be such that terminals are accessible by use of ordinary tools. Connections shall be provided with adequate clearance to avoid short circuits and risk of fire and ease in connection and disconnection MCCB MCCB shall be used for protecting the distribution transformer. Technical details of the MCCB are described in the technical specification separately.
3.07.00
3.08.00
3.09.00
Energy Meter CT Operated Static energy meter of 0.5 Class shall be used for Single phase DT and 3 phase DT. Energy meter shall be placed in the upper compartment of the box for the measurement of energy.Disconnecting type TB shall be used for connecting CT and Energy Meter,with CT shorting arrangement at TB the TB shall be placed in the upper compartment The technical details of the energy meter are described in the technical specification separately.
3.10.00
CT The current transformer shall be of 0.5 Accuracy class conforming to IS:2705-(Part2): Specification for Current Transformers( Measuring Current Transformers). The CTs should be mounted in the lower compartment of the LTDB housing .Suitable mounting arrngements be provided for the CTs.The CT shall be properly Type tested as per IS :2705 and type test report shall not be more than 5 year old
3.10.00 3.10.01
Bus Bar and Connections Phase and neutral bus bar shall be provided with connectors of electrolytic aluminium with 99.9 percent purity of approved make. The bus bars shall be suitably supported on insulators to stand the mechanical and electric forces on account of short circuit on the system. The bus bar conductors shall be uniform throughout its length and in no case tapered. The size shall be so chosen to limit current density to 1.0 Amps per sq. mm. The
3.10.02
CLAUSE NO.
LTDB FOR DISTRIBUTION TRANSFORMER SUBSTATION neutral bus bar should be of the same size and current carrying capacity as that of phase bus bar.The bus bar shall be of minimum 150 mm length.
3.11.00
Earthing Suitable Earthing arrangement shall be provided for the box and connection shall be extended to the local earthing for safety. The cover provided for the box shall also be earthed from the box by way of flexible copper link of suitable dimension.
4.00.00
TESTS Each type of LT Distribution box shall be completely assembled, wired, adjusted and tested at the factory as per the relevant standards and during manufacture and on completion.
4.01.00
Routine Test The tests shall be carried out in accordance with IS:13947 and 8623 include including but not necessarily limited to the following: (a) (b) (c) Visual Check Verification of Component Rating Other Checks i) ii) iii) iv) (d) (e) (f) (g) (h) (i) (j) Easy Accessibility and Maintenance. Colour Coding provided by coloured tapes. Bus bar dimensions Degree of Protection check by paper.
Dimension check Insulation Resistance Tests Mechanical Operation Tests Bus bar support and clearances Continuity of circuits and Function Painting Overload Release setting of the Circuit Breakers
4.02.00
Type Test All type tests shall be performed in accordance with IS:13947 and 8623.
5.00.0
Rear plate of box shall be provided with suitable fixing arrangement for 1/3 phase Energy meter as per type and make of energy meter.
CLAUSE NO.
LTDB FOR DISTRIBUTION TRANSFORMER SUBSTATION GAURANTEED TECHNICAL PARAMETERS The following gauranteed technical parameters shall be applicable
Description Sr No 1 2 2(i) 2(ii) Degree of Protection CRCA Sheet Thickness Cover and Partition Body Door Shall be provided with Insulated Nylon Handle with Separate Padlocking facility Powder Coating paint CT Ratio CT Accuracy class Type of CT Rated Burden LTDB for SINGLE PHASE METER Type tested For IP-55 as per 12063 LTDB for THREE PHASE METER Type tested For IP-55 as per 12063
6.00.00
Minimum 2.5 mm Minimum 3.0 mm
Minimum 2.5 mm Minimum 3.0 mm
3 4 5 (i) ( ii ) ( iii )
( iv )
CT Type Test
Yes As per IS: 5 shade 692 (Grey) 50/5 0.5 class Ring type / Window Type 5VA CT is Completely type tested As per IS IS 2705Part1 and 2 type test report enclosed
Yes As per IS: 5 shade 692 (Grey) 50/5 0.5 class Ring type / Window Type 5VA CT is Completely type tested As per IS IS 2705Part1 and 2 type test report enclosed
Completely Type tested Completely Type tested as per IS 13947 part 2 as per IS 13947 part 2 type test report enclosed type test report enclosed MCCB Type Test Make of CT and MCCB Shall be NESCL Corporate Quality Assurance (CQA) Approved
CHAPTER-II SECTION-E5 LTDB for Distribution Transformer Substation
Page 4 of 4
CLAUSE NO.
COMMON METER READING INSTRUMENT SCOPE This specification covers design, manufacture, testing before despatch, transportation, supply and delivery to the Owners stores portable hand held Common Meter Reading Instrument (CMRI) for reading (uploading) the data of different make of meters and to have a capability to dump (download) the same to the base computer system. The CMRI shall have memory / space for storing software of at least 3 different makes of electronic meters as specified by purchaser.
1.00.00
2.00.00 2.01.00
CODES AND STANDARDS The CMRI shall conform in all respects to the following standards. i) CBIP Technical Report no. 111 Specification for CMRI. ii) IEC 529 Degree of Protection provided by enclosures iii) IS: 12063 Classification of Degree of Protection provided by enclosures of electrical items. iv) IS 9000 Basic environmental testing procedure for electronic & electrical items. v) IEC 1000 Electromagnetic compatibility vi) IEC 1000-4-2: 1995 Electrostatic discharge immunity test vii) IEC 10004-3: 195 Radiated, radio frequency electromagnetic field immunity test, Magnetic immunity test viii) CISPAR 22 Limits and method of measurement of radio disturbance characteristics of information technology equipment. OPERATING CONDITIONS CMRI shall have IP 67 protection and shall be suitable for continuous operation under following climatic conditions i) ii) iii) iv) v) vi) vii) Maximum Ambient Air Temperature in shade :55oC Minimum Ambient Air Temperature : -10oC Maximum Relative Humidity : 95% (condensing) Minimum Relative Humidity : 10% Height above mean sea level : Up to 2200 meters Average number of monsoon months/annum : 5 months Annual Rainfall in mm : 100mm to 1500mm
3.00.0
4.00.00 4.01.00
GENERAL REQUIREMENTS CMRI shall be tailor-made for downloading all data stored in the memory of static meters of type- 3-phase 4-wire, 3-phase 3 wire HT/LT Tri-vector meters, whole current meters, single phase meter, and faithfully transferring it to the local PC in the BCS (Base Computer System). The offered meter reading device shall be portable, compact and battery powered. Its memory shall be adequate to enabling transfer of data from three makes of meters equipped with suitable communication port and transferring them on to a base
TECHNICAL SPECIFICATION VOLUME-II (PART-C)
CHAPTER-I SECTION-E6 CMRI
Page 1 of 7
CLAUSE NO.
COMMON METER READING INSTRUMENT computer system such as an IBM compatible PC or an external peripheral & vice versa. The offered CMRI shall have capacity compatible to read not less than 30 meters for billing & tamper data but without load survey and minimum 50 meters for billing and tamper data with load survey. The CMRI software for downloading data from meter to CMRI, as also BCS, are propriety to individual meter manufacturer and hence there are to be supplied by the respective meter manufacturers. The CMRI shall be capable of downloading all the available parameters at least for 100 meters in a stretch.
4.02.00
Each device shall be supplied complete with i) A lead with optical head for coupling it to the meter. ii) A lead for plugging it to a personal computer. iii) An internal battery for powering the devices. iv) A case for safely carrying it about. v) A battery charger. vi) A built in function to check the balance memory. The total arrangement shall be such that one (1) operator can carry out the whole operation himself, in about five (5) minutes per meter.
4.03.00
The CMRI shall have a key for starting the data tapping from the coupled meter's 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 the data transfer is over. Data tapping operation shall not erase the data from the meter's memory, or effect the meter operation in any way. The memory of the CMRI shall get automatically cleared when the data has been transferred to the PC only then the CMRI shall accept data from another meter. CMRIs shall also have the necessary provision for meter clock correction. CMRIs should have adequate memory, to host application software, for enabling downloading of meter data of 3 makes of meters.
4.04.0
Software The CMRI shall be supplied with necessary software which would enable a local IBM-Compatible PC to (i) Accept the data from the CMRI and store it in its memory, (ii) Display the collected data on PC's screen, with forward/backward rolling, (iii) Print out the data collected from one or more meters, starting from a certain date and time, as per operator's instructions, (iv) Transmit the collected data through an appropriate communication link to the central computer, starting from a certain date and time, as per operator's instructions. (v) Store the collected data on a floppy disc.
Page 2 of 7
CLAUSE NO.
COMMON METER READING INSTRUMENT 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 the utility in a compatible form to enable its easy loading into the PCs CMRI should be compatible with Low Power Radio module to be provided by the bidder for receiving the data from the meter to the CMRI/Hand Held Unit and ultimately transferring to BCS & vice versa for loading required instructions to the meters. TECHNICAL REQUIREMENT Physical Characteristics Size CMRI should be handy, lightweight and small in size for ease of portability.
4.04.01
5.00.00
6.00.00 6.01.00 6.01.01
6.01.02
Weight Weight of CMRI including batteries shall be approximately less than 1.0 kg.
6.01.03
Enclosure: CMRI casing shall be of electrical insulating material of high thermal stability and mechanical strength. Its degree of protection confirms to IP 67 LEVEL (2) as per IS 12063 / IEC-529.The enclosure should be solvent resistant and shall be provided with a suitable holding Strap for proper gripping.
6.01.03
Ruggedness CMRI is able to withstand harsh field environment without physical damage or loss of data.
6.01.04
Display The display of CMRI is having the following characteristics. a) Easy readability in varying ambient light conditions. b) 4 lines and 20 characters per line on the screen. c) The size of the character shall be 4 mm. d) The contrast and intensity control to get a clear display in varying ambient light. Key Board The keyboard of the CMRI is having the following attributes. a) Long operation life i.e. minimum 100000 operations (typical). b) Feed back for key press acknowledgement to user.
6.01.06
Page 3 of 7
CLAUSE NO.
COMMON METER READING INSTRUMENT c) Legible and non-fading keypad imprints characters/symbols. d) Each English alphabet shall have a separate key. for all alphanumeric
6.01.07
Input / Output ports (I/O Ports) The CMRI shall be having two serial input/output Ports; both the ports shall be serial port RS 232C compatible. Another optional port can be used for convenience of connecting peripherals such as bar-code reader, printer, battery charger, loader charger etc. The offered CMRI shall be able to provide power supply for optical sensor used for meter reading applications. PHYSICAL INTERFACE Interface between meter and CMRI The interface between a meter and CMRI shall consist of 2 parts. Meter optical sensor terminating in to a 9-pin D type male connector with a cable of 500 mm +/- 10 mm. Length. b) The interface between a meter and the offered CMRI shall be with a flexible shielded cable of length 1500mm +/-10mm having 9pin D type female connector with electrical circuit. This cable and optical probes conforming to IEC 1107, PACT & ANSI standards will be supplied by the CMRI manufactures. The two ends of the cable is stress relieved.
7.00.00 7.01.0
7.02.00
Interface between CMRI and Base computer station Suitable flexible shielded cable of sufficient length for communication between CMRI and base computer station shall be provided. This communication shall be serial RS-232C. On the base computer station end of the cable a 9-pin D-type female connector shall be provided. The two ends of the cable are stress relieved. This cable shall also be supplied along with the CMRI. HARDWARE AND SOFTWARE REQUIREMENT Operating system To facilitate use of various meters, specific MRI programs in one CMRI, MS DOS version 5.0 or higher system shall be used. The facility to upgrade the BIOS/OS by a CMRI supplier shall be available without exposing the hardware of the CMRI. The additional program necessary to transfer application programs with serial port shall be provided.
8.00.00 8.01.0
8.02.00
Memory: a) The CMRI shall be having a minimum memory capacity of 5 MB Static RAM (SRAM) with battery backup and upgradeable to 8 MB SRAM. b) BIOS/OS on FLASH memory / EEPROM Memory
Page 4 of 7
CLAUSE NO.
COMMON METER READING INSTRUMENT Communication The CMRI shall be able to communicate for a) Down loading / up loading data from / to the meter b) Uploading / downloading data to / from the Base computer station c) CMRI shall be capable to read bar code information using a bar code scanner from barcodes of ac static / electromechanical electricity meters by using appropriate scanner and bar code soft ware. d) CMRI shall support flexible baud rate ranging from 300 Baud to 19200 (or higher) Baud rates to cater communication needs stated above. Real time clock A real time clock is provided in the CMRI, which have the following features: Power requirement: The clock shall have a minimum of 15 days battery back up. Calendar: The clock shall have 20 years calendar. Time drift: The time drift shall be negligible and shall not exceed 20 seconds per day.
8.03.00
8.04.00
8.05.0
Time Setting Facility: The CMRI shall have the facility to get its time set from Base computer station. Proper security for this is ensured using password
8.06.0
Power supply (Battery) for CMRI The CMRI shall have the following features for its power requirements: a) The CMRI shall be powered by rechargeable battery housed within its enclosure. The average capacity of charged battery shall be sufficient to communicate with meters and base computer station for at least: i) 6 hours while communicating through optical interface of meters and ii) 8 hours without powering Input / Output ports for optical interface. To reduce the equipment down time and inventories, there shall be provision to charge the CMRI battery without being removed from the equipment. A suitable battery charger for charging of CMRI battery shall be provided. There would be a provision for AUTO POWER SAVE, which force the instrument in the power saving mode in case of no activity within 5 minutes. The battery used for data retention in SRAM would have a minimum of 3 years backup capacity. The CMRI would have battery low indication and automatic cutoff to avoid further drain of the battery.
TECHNICAL SPECIFICATION VOLUME-II (PART-C) CHAPTER-I SECTION-E6 CMRI Page 5 of 7
b)
c)
d)
e)
f)
CLAUSE NO.
COMMON METER READING INSTRUMENT COMMUNICATION PROTOCOL AND SOFTWARE Software The following software shall be provided in the offered CMRI. i) ii) Operating system compatible to MS DOS 5.0 or (latest version ver 7.0). Necessary software for loading application programs via a serial port for uploading and down loading between CMRI and Base computer Station (BCS).
9.00.00 9.01.00 9.01.01
9.01.02
i)
Provision for loading the software into the CMRI of the specific makes of the meters, for the purpose of reading and programming of the specific make(s) of static meters, such Software shall be provided by respective meter manufacturers. ii) BCS software accepting data from CMRI, processing generating reports and downloading instruction from BCS to CMRI. Special Requirement The offered CMRI shall have provision for storing the third party software and can also be loaded for special applications such as manual meter reading, data entry through keyboard of CMRI, printing, display of balance memory etc.
9.01.03
9.01.04
The CMRI shall have provision to read the energy registers so that accuracy testing can be done at site with standards calibrating equipments. The CMRI shall have the provision to read the various instantaneous electrical parameters at site like voltages, current, PF, phase angles, power (kW, KVAr, and KVA) frequency etc. The CMRI shall have facility to estimate the memory space available before reading the meter. DATA SECURITY The meter manufacturers are responsible for maintaining the security of the data extracted from the meters using manufacturer specific algorithm in the software up to down loading to BCS.
9.01.05
9.01.06
10.00.0
11.00.00 11.01.0
TESTS Type Test CMRI shall be type tested as per clause 5 of CBIP Technical Report No. 111.
Page 6 of 7
CLAUSE NO.
COMMON METER READING INSTRUMENT
11.02.0
Acceptance Tests For CMRI And PC Software All CMRI after final assembly and before despatch from Bidder's/Manufacturer's works shall be duly tested to verify that they are suitable for supply to the Purchaser. In particular, each and every CMRI shall be subjected to the following acceptance test: (i) (ii) Functional Checks Downloading Meter Data from the Meter(s)
(iii) (iv) (v) (vi) (vii)
Compatibility with PC software Downloading the meter data on PC Functioning of advance and retard time commands. Per meter downloading time verification. Capacity of CMRI for data storage.
Page 7 of 7
CLAUSE NO.
11KV HORN GAP FUSE SCOPE This specification covers design, manufacture, testing at works and supply of Horn Gap Fuses of 11 kV, 50 Hz three / two phase system for installing on distribution substation to protect Distribution Transformer.
1.00.00
2.00.00
APPLICABLE STANDARDS The various Components shall conform to the following specifications: a) b) REC construction standard- F6 High voltage fuses-IS: 9385
3.00.00
Construction Details HG fuse shall be manufactured as per the enclosed drawing All ferrous parts (bolts, nuts, washers, M.S. flats, clamps and M.S. round holding clamps etc. for the insulator & horn gap fuses) shall be hot dip galvanized as per relevant IS.
4.00.00 4.01.00
TESTS Type test The following shall constitute type & routine tests i) Dielectric Test on assembled HG fuse unit as per IS : 9385/80 (Part 2) a) b) c) ii) Lightning impulse: Dry Power frequency Wet power frequency
Temperature Rise Tests at rated current as per IS: 9385/80 (Part 1) a) General Physical Verification b) Dimension verification c) Dry Power frequency
4.02.00
Routine Test
4.03.00
Acceptance Tests: a) Dimensional Verification. b) HV Test. c) Mechanical Operation.
TECHNICAL SPECIFICATION VOL-II, (PART-B)
CHAPTER-II SECTION-E7 11KV HORN GAP FUSE
Page 1 of 2
CLAUSE NO.
11KV HORN GAP FUSE
d) Verification of all components. The supplier/ bidder shall clearly and specifically indicate the name of manufacturer of the pin insulator. Test certificate showing the results of the routine and type tests carried out for insulator as per IS : 731/1971 Shall have to be submitted along with the offer. 5.00.0 GUARANTEED TECHNICAL PARTICULARS The following gauranteed technical parameters shall be applicable. PART-A Sl No Description 1 MAKE 2 3 4 5 6 7 8 9 Particulars
10 11 12
THREE PHASE HORN ITEM GAPE FUSE RATED VOLTAGE 12 kv SYSTEM VOLTAGE 11kV SYSTEM FREQUENCY 50 Hz RATED CURRENT 200A PF WITH STAND VOLTAGE 28 Kv for one minute IMPULSE WITH STAND VOLTAGE 75 Kv GOVERNING SPECIFICATION IS 9385 part-II PIN INSULATOR 540 Kg as minimum MECHANICAL LOAD failing load CREEPAGE DISTANCE 320 mm REFERENCE STANDARD IS 731/1971 COMPLIED Type test reports (all mentioned in relevant clause)
TECHNICAL SPECIFICATION VOL-II, (PART-B)
CHAPTER-II SECTION-E7 11KV HORN GAP FUSE
Page 2 of 2
CLAUSE NO.
11 KV DROP OUT FUSE
1.00.00
SCOPE This specification covers design, manufacture, testing before despatch, packing, transportation and delivery of outdoor, open, drop-out expulsion type Fuse suitable for installation in 50 Hz, 11 KV distribution systems. APPLICATION The distribution fuse cutouts are intended for use in distribution transformers and have no inherent load break capacity. APPLICABLE STANDARD High voltage fuses -IS: 9385 (Part-I to III) REC Specification- 53/1987 RATED VOLTAGE The rated voltage shall be 12 KV. RATED CURRENT The rated current shall be 100 A. RATED LIGHTNING IMPULSE WITHSTAND VOLTAGE VALUES FOR THE FUSE BASE The rated lightning impulse withstand voltages both for positive and negative polarities shall be as given below: a) To earth and between poles 75 KV (Peak) b) Across the isolating distance of fuse base 85 KV (Peak) RATED ONE MINUTE POWER FREQUENCY WITHSTAND VOLTAGE (DRY & WET) VALUES FOR THE FUSE BASE a) b) To earth and between poles Across the isolating distance 28 KV (rms) 32 KV (rms)
2.00.00
3.00.00
4.00.00
5.00.00
6.00.00
7.00.00
8.00.00
TEMPERATURE RISE LIMIT (In Air) a) b) c) Copper contacts silver faced 65oC Terminals 50oC Metal parts acting as springs. The temp. shall not reach such a value that elasticity of the metal is changed.
TECHNICAL SPECIFICATION VOL-II (PART B)
CHAPTER-II SECTION-E8 D. O. FUSE
Page 1 of 9
CLAUSE NO.
11 KV DROP OUT FUSE
9.00.00
RATED BREAKING CAPACITY The rated breaking capacity shall be 8 KA (Asymmetrical). GENERAL REQUIREMENTS/CONSTRUCTIONAL DETAILS The cutouts shall be of single vent type (downward) having a front connected fuse carrier suitable for angle mounting. All ferrous parts shall be hot dip galvanised in accordance with the latest version of IS:2633. Nuts and bolts shall conform to IS:1364. Spring washers shall be electrogalvanised. Typical constructional details of the fuse cutout shall be as shown in Fig. 1. FUSE BASE TOP ASSEMBLY The top current carrying parts shall be made of a highly conductive copper alloy and the contact portion shall be silver plated for corrosion resistance and efficient current flow. The contact shall have a socket cavity for latching and holding firmly the fuse carrier until the fault interruption is completed within the fuse. The top contact shall be actuated by a strong steel spring which keeps it under sufficient pressure to maintain a firm contact with the fuse carrier during all operating conditions. The spring shall also provide flexibility and absorbs most of the stresses when the fuse carrier is pushed into the closing position. The current carrying parts of the assembly shall be protected from water and dust formation by a stainless steel top cover. The top contact assembly shall have a robust galvanised steel hook to align and guide the fuse carrier into the socket latch even when the fuse carrier is closed at an off-centre angle. The top assembly shall have an aluminum alloy terminal connector (refer clause 19). The top assembly shall be robust enough to absorb bulk of the forces during the fuse carrier closing and opening operations and shall not over-stress the spring contact. It shall also prohibit accidental opening of the fuse carrier due to vibrations or impact.
10.00.00 10.01.00
10.02.00
10.03.00 11.00.00 11.01.00
11.02.00
11.03.00
11.04.00
11.05.00
11.06.00
Page 2 of 9
CLAUSE NO.
11 KV DROP OUT FUSE
12.00.00 12.01.00
FUSE BASE BOTTOM ASSEMBLY The conducting parts shall be made of high strength highly conductive copper alloy and the contact portion shall be silver plated for corrosion resistance and shall provide a low resistance current path from the bottom fuse carrier contacts to the bottom terminal connector. The bottom assembly shall have hinge contacts made from highly conductive, anticorrosive copper alloy and shall accommodate and make a firm contact with the fuse carrier bottom assembly. The fuse carrier shall be placed easily in or lifted from The hinges without any maneuvering. In addition, the bottom assembly shall perform the following functions :i) When opened manually or after fault interruption the fuse carrier shall swing through 180o to the vertical and its further travel shall be prevented by the fuse base bottom assembly. The fuse carrier shall be prevented from slipping out of the self locking hinges during all operating conditions and only when the fuse carrier has reached its fully open position can it be removed from the hinge support.
12.02.00
ii)
12.03.00 13.00.00 13.01.00
The assembly shall have an aluminium alloy terminal connector (refer clause 19). FUSE CARRIER TOP ASSEMBLY The fuse carrier top contact shall have a solid replaceable cap made from highly conductive, anti-corrosive copper alloy and the contact portion shall be silver plated to provide a low resistance current path from the Fuse Base Top Contact to the Fuse Link. It shall make a firm contact with the button head of the fuse link and shall provide a protective enclosure to the fuse link to check spreading of arc during fault interruptions. The fuse carrier shall be provided with a cast bronze opening eye (pull ring) suitable for operation with a hook stick from the ground level to pull-out or close-in the fuse carrier by manual operation. FUSE CARRIER BOTTOM ASSEMBLY The fuse carrier bottom assembly shall be made of bronze castings with silver plating at the contact points to efficiently transfer current to fuse base. It shall make smooth contact with the fuse base bottom assembly during closing operation. The bottom assembly shall have a lifting eye for the hook stick for removing or replacing the fuse carrier.
13.02.00
14.00.00 14.01.00
14.02.00
Page 3 of 9
CLAUSE NO.
11 KV DROP OUT FUSE
14.03.00
The bottom assembly shall have a suitable ejector which shall perform the following functions : i) It shall keep the fuse link in the centre of fuse tube and keep it tensioned under all operating conditions. It shall be capable of absorbing the shock when the fuse carrier is pushed into the closed position and shall not allow the fuse link to be damaged. This is specially important when the fuse link is of low-ampere rating. The ejector at the instant of interruption shall retain the fuse carrier in the closed position long enough to ensure that the arc is extinguished within the fuse tube thereby excluding the possibility of arcing and subsequent damage at the contact surfaces. The ejector shall help the fuse link separation after fault interruption, allowing the fuse carrier to drop out and clearing the pigtail of the blown fuse link through the bore of fuse tube.
ii)
iii)
iv)
15.00.00
FUSE BASE (PORCELAIN) The fuse base shall be a bird-proof, single unit porcelain insulator with a creepage distance (to earth) not less than 320mm. The top and bottom assemblies as also the middle clamping hardwares shall be either embedded in the porcelain insulator with sulphur cement or suitably clamped in position. For embedded components, the pull out strength should be such as to result in breaking of the porcelain before pull out occurs in a test. For porcelain insulators, the beam strength shall not be less than 1000 Kg.
16.00.00
FUSE TUBE The fuse tube shall be made of fibre glass coated with ultraviolet inhibitor on the outer surface and having arc quenching bone fibre liner inside. The tube shall have high bursting strength to sustain high pressure of the gases during fault interruption. The inside diameter of the fuse tube shall be 17.5mm. The solid cap of the fuse carrier shall clamp the button head of the fuse link, closing the top end of the fuse tube and allowing only the downward venting during fault interruption.
17.00.0
TESTS TYPE TESTS The cutout shall be subjected to the following type tests : i) Dielectric tests (rated impulse withstand and rated one minute power frequency with stand test voltages)
Page 4 of 9
CLAUSE NO.
11 KV DROP OUT FUSE
ii)
Temperature rise test The above tests shall be carried out in accordance with IS:9385 Part I & II.
For Porcelain Fuse Base only. iii) iv) Pull out test for embedded components of the fuse base Beam strength of porcelain base
Acceptance Tests: Dimensional Verification. HV Test. Mechanical Operation. Temperature Rise Test. Verification of all components. Routine Tests: Verification of dimension Mechanical Operation. HV Test. 18.00.00 18.01.00 MOUNTING ARRANGEMENT Typical constructional details of the mounting arrangement shall be as Fig. 2. shown in
18.02.00
The cutouts shall be provided with a suitable arrangement for mounting these on 75x40mm or 100x50mm channel cross arm in such a way that the centre line of the fuse base is at an angleof 15o to 20o from the vertical and shall provide the necessary clearances from the support. Mounting arrangement shall be made of high strength galvanised steel flat and shall be robust enough to sustain the various stresses encountered during all operating conditions of the cutout. For more details see enclosed figure 2. Strength of the component marked 1 (see figure) shall be determined by clamping the member with the shorter leg at the top to a rigid support by M-10 carriage bolts. A downward force shall be applied along the axis of M-14 carriage bolt parallel to the longer leg and in the direction of longer leg of the member under test. A load of 50 Kg. shall be applied and then removed to take up any slack in the mounting arrangement before the measurement of position is taken, the permanent set measured at the axis of the M-14 carriage bolt shall not exceed 1.6mm when a load of 425 Kg. is applied and removed. The strength of the M-14 bolt shall in no case be less than1900 Kg. and the strength of M-10 bolts not less than 3500 Kg.
18.03.00
Page 5 of 9
CLAUSE NO.
11 KV DROP OUT FUSE
19.00.00
TERMINAL CONNECTIONS The cutout shall be provided with two aluminium alloy (alloy designation 2280 (A11) as per IS:617-1975) terminal connectors at top and bottom of fuse base assemblies to receive aluminium conductors of diameters between 6.3mm to 10.05mm. These terminals shall be easily accessible irrespective of the cutout location with respect to the pole. The terminals shall meet the test requirements of REC Construction Standard E-30.
20.00.00
INSPECTION All tests and inspection shall be made at the place of manufacture unless otherwise especially agreed upon by the manufacturer and the purchaser at the time to purchase. The manufacturer shall extend the inspector representing the purchaser all reasonable facilities without charge, to satisfy him that the material is being furnished in accordance with this specification.
21.00.00
GUARANTEED TECHNICAL PARAMETERS The following gauranteed technical parameters shall be applicable. PART-A Sl. No PARTICULARS 1 Make 2 Type 3 Application 4 5 6 7 8 9 10 11 Rated voltage System voltage Rated current Phase to phase spacing System frequency Maximum ambient temperature Rated breaking capacity Fuse link coordination VALUE Open, drop out expulsion type (single insulator) Protection/isolation of distribution transformers 12 kv 11 kv 100 amp As per ie rules 50 hz. 50c 8 ka(asym.) Will coordinate with existing system, protective equipment 65c (as per rec) 50c (as per rec) Is:9385 (part i to iii) Is:2544/1973
12 Temp. Rise limits: (in air) A) copper contacts B) terminals 13 Applicable standard Insulator (clamp type) 14 Spec:
Page 6 of 9
CLAUSE NO.
11 KV DROP OUT FUSE
15 Rated one minute power frequency withstand voltage (dry & wet) for the fuse base: A) to earth and between poles B) across the isolating distance 16 Rated lighting impulse withstand voltage for the fuse base: A) to earth and between poles B) across the isolating distance 17 Temp. Rise limits: A) copper contacts B) terminals 18 Single unit solid core porcelain isolators: A) creepage B) beam strength C) middle clamping hardware 19 Mounting 20 Specification 21 Beam strength Type test reports (all mentioned in relevant clause)
28kv (rms) {as per rec} 32kv (rms) {as per rec}
75kv (peak) 85kv (peak)
65c 50c
(as per rec) (as per rec)
Minimum 320mm Minimum 1000kg Hot dip galvanized Vertical Is:2544/1973 1000Kg Complied
Make shall be NESCL Corporate Quality Assurance (CQA) approved
Page 7 of 9
CLAUSE NO.
11 KV DROP OUT FUSE
Page 8 of 9
CLAUSE NO.
11 KV DROP OUT FUSE
Page 9 of 9
CLAUSE NO.
LT CABLES SCOPE This specification covers manufacture, design, testing and dispatch of PVC Insulated LT cables for use as Transformer Cable and to connect from Distribution Transformers secondary to distribution box in the distribution system.
1.00.00
2.00.00
APPLICABLE STANDARDS The PVC insulated LT cables shall comply with the latest versions of the following Standards. a) i) Transformer Cables Single-core unarmoured aluminium cables IS : 1554 (Part-I) (PVC Insulated Heavy Duty Electric Cables for working voltages upto and including 1100 V) and REC Spec. No. 26/1983 (Revised 1987)
3.00.00 3.01.00 4.00.00
SIZE AND TYPE The size and type of PVC insulated LT cables for different applications under this project, shall be as in the following table: SHAPE OF CABLE All single core cables of circular shape.
5.00.00 5.01.00 6.00.00
CONDUCTORS Aluminium conductor complying with IS:8130-1976 shall be used. TESTS All the type tests, acceptance tests and routine tests shall be carried out as per the relevant I.S. indicated in clause 3.01.00 above.
7.00.00 7.01.00 7.02.00 8.00.00
PACKING Transformer cables shall be supplied in wooden drums with 250 metres length, as required by the purchaser. The cable reels/drums shall comply with IS:10418 (Specification on Drums for Electric Cables). MARKING The following information shall be marked on the reel/drum carrying transformer cables : a) b) c) Manufacturers name, brand name or trade mark Type of cable and voltage grade Number of cores
TECHNICAL SPECIFICATION VOL-II (PART-B) CHAPTER-II SECTION-E9 LT CABLES PAGE 1 OF 3
RGGVY - WORKS STANDARD TECHNICAL SPECIFICATION (REV.- 03)
CLAUSE NO.
LT CABLES d) e) f) g) h) i) j) Nominal cross-sectional area of conductor Length of cable on reel/drum or coil Direction of rotation of drums (by means of an arrow) Approximate gross weight Country of manufacture Year of manufacture and RGGVY work by NTPC Electric Supply Co. Ltd., NOIDA.
9.00.00
INSPECTION All tests and inspection shall be made at the place of manufacture. The manufacturer shall afford the inspector, representing the purchaser, all necessary facilities (without charge) to satisfy him that the material is being supplied in accordance with the Specification.
9.00.00
Guaranteed Technical parameters The following gauranteed technical parameters shall be applicable. PART-A Sl.No. Particulars 16 sq mm. Aluminium conductor 1 Applicable standard Indian Standard Power conductor Material No. of strands Shape of Conductor Max.DC resistance at 20 deg C(Ohm/KM) Insulation Type Nominal Thickness (mm) Inner Sheath Armouring Outer Sheath Type Minimum thickness (mm) Colour Current rating (Amperes) Cable shall be fire resistant Standard Length Embossing/Marking Size of Drum IS:1554 Pt 1/88,IS8130/84,IS:5831/84,IS:3975/99 EC Grade Aluminium H2 Grade (IS:8130/84) 7 Stranded Circular 1.91 (IS:5831/84) Type A PVC compound 1.0 NA NA PVC Compound Type ST-1 1.24 Grey IS:3961 Pt-II Yes,complies with IS:5831 250 +/- 5% As per IS:1554 As per IS:10418
CHAPTER-II SECTION-E9 LT CABLES PAGE 2 OF 3
4 5 6
7 8 9 10
CLAUSE NO.
LT CABLES Sl.No. Particulars 11 Progressive sequential marking of the length of cable in meter at every meter Type test reports (all mentioned in relevant clause) 16 sq mm. Aluminium conductor Yes
COMPLIED
Make shall be NESCL Corporate Quality Assurance(CQA) Approved
PAGE 3 OF 3
FIELD QUALITY PLAN

PROJECT / UTILITY : CONTRACT No. CONTRACTOR : PACAKAGE: ITEM : SUB SYSTEM : QAP NO. : REV. NO.: DATE : Type of Check
3
ERECTION WORK ISO/AB SWITCH/ DOFUSE
Sr. No.
1 1 1.1 1.2 1.3 1.4 2 2.1 2.2 2.3 2.4 3 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9
CHARACTERISTICES / ITEMS
2 RECEIPT & STORAGE Receiving inspection (Completeness of documents, test certificates, instruction manual etc.) Unloading Visual exmination for damage & defects Proper storage PRE INSTALLATION Availability of instruction manual and drawing, lifting arrangement Availability of all materials Foundation (If required) Vertically of support structure INSTALLATION Rating plate details Check for proper slinging & lifting Check for the tightness of base bolts & other bolted joints by torque wrench. Check level & alignment of the base, housing assembly and flangs. Ensure proper erection of poles, main blade & drive assembly as per approved drgs. Check for the alignment of isolator and verticality of isolator / AB switch / DO Fuse. Check for the clearance between live part to earth. Check for no vibration or rotation of contacts of insulators during isolator operation. (Electrical & Mechanical) Check for the provision of earthing and earth connection. Check operation of the isolator by rotating one of the insulator stack manually and adjust the length of the crossed tandem assembly to ensure proper engagement of contacts during closign. PRE COMMOSSIONING Check for visual damage to any parts including porcelain isolator. Check manual / operation and inter locks. IR Value a. Between each pole to earth. Ground connections Check continuity
Instruments
4
Class
5
Quantum/ Reference Documents & Frequency Acceptance Standard

6 7
Format Of Records
8
Remarks
9
V V V V
B B B B
100% 100% 100% 100%
Delivery Challan & NESCL Specification Instruction Manual Packing list / Instruction Manual Instruction Manual
MRC / Check List / ISO / 03 -
V V V V
B B B B
100% 100% 100% 100%
List of approved drawing / Instruction Manuals Packing list, Approved drawing & Bill Of Material Civil foundation drawing GA/ Structural drawing
V V V V V V V V V
B B B B B B B B B
100% 100% 100% 100% 100% 100% 100% 100% 100%
instruction manual Instruction Manual Instruction Manual Instruction Manual Instruction Manual Instruction Manual As per IS 10118 Instruction Manual Instruction Manual
Site record Site record Site record -
3.10
100%
Instruction Manual
4 4.1 4.2 4.3 4.4 4.5
V V Test V Electrical
Megger Multimeter
B B B B B
100% 100% 100% 100% 100%
Instruction Manual Instruction Manual Instruction Manual Instruction Manual Instruction Manual
TC TC TC TC Site Record
CONTRACTOR'S SIGNATURE
NAME & SIGN OF APPROVING AUTHORITY
Legends : CLASS OF CHECK: A -- CRITICAL -- TO BE WITNESSED BY NESCL SITE AND SURVEILLANCE BY NESCL, CC. B -- MAJOR -- TO BE WITNESSED BY CONTRACTOR AND NESCL SITE C-- MINOR -- TO BE WITNESSED BY CONTRACTOR AND SURVEILLANCE BY NESCL SITE TC : Test Certificate MRC : Material Reciept Certificate V : Visual EIC : Engineer In Charge
Page 1 of 1
Contractor's Name: Sub Contractor/ agency Name & Address:
FIELD QUALITY PLAN-- CONDUCTOR,EARTH WIRE ERECTION (HT &LT)

Item: CONDUCTOR,EARTH WIRE (HT & LT) SYSTEM: CONDUCTOR,EARTH WIRE
SUB-SYSTEM: 1 CONDUCTOR(AAAC,AAC,ACSR) ERECTION SL.NO MAIN CHARACTERISTICS/INSTRUM ACTIVITY& ENTS OPERATION CLASS OF CHECK TYPE OF CHECK QUANTUM OF CHECK REFERENCE DOCUMENT ACCEPTANCE NORMS FORMAT OF RECORD RE MARKS COMPONENETS WHICH ARE INSPECTED AND CLEARED BY NESCL SHALL ONLY BE ACCEPTED ON RECEIPT
RECEIPT AND STORAGE
1) RECEIPT AT STORES
VISUAL CHECK
100%
DELIVERY CHLLAN/MDCC
CORRELATION OF THE LOT RECEIVED WITH THE DELIVERY CHLLAN/MDCC DESCRIPTIONS DRUMS FOUND DAMAGED DURING TRANSIT ARE STACKED SEPARATELY DRUMS ARE STORED ON HARD SURFACE AREA CONDUCTOR SHOULD NOT BE DRAGGED ON THE GROUND SEQUENCE OF RUNNING OUT SHALL BE FROM TOP TO BOTTOM, i.e.. THE TOP CONDUCTOR SHALL RUN OUT FIRST, FOLLOWED BY THE SIDE CONDUCTORS ANY DAMAGES TO THE STRANDS SHALL BE REPAIRED WITH REPAIR SLEEVES COMPRESSION TYPE NOT MORE ONE JOINT PER SUB CONDUCTOR PER SPAN AS PER THE REC SPECIFICATIONS GUARDING SHALL BE PROVIDED AT MAJOR CROSSINGS APPROVED DRAWINGS
STORES REGISTER STORES REGISTER STORES REGISTER
2) VISUAL INSPECTION 3) STORAGE 1) HANDLING OF THE CONDUCTOR
C C C
VISUAL CHECK VISUAL CHECK VISUAL
100% 100% 100% STANDARD PRACTICE NESCL SPECIFICATION
SCRATCHES OR DAMAGES TO THE STRANDS WOULD OCCUR IF NOT HANDLED PROPERLY
2) SEQUENCE OF CONDUCTOR ERECTION
VISUAL
100%
NESCL SPECIFICATION
ERECTION OF CONDUCTOR
3) STRINGING OF THE CONDUCTORS
VISUAL
100%
NESCL SPECIFICATION NESCL SPECIFICATION NESCL SPECIFICATION NESCL SPECIFICATION NESCL SPECIFICATION/ IS 278 NESCL SPECIFICATION/ IS2551/1992 AND REC SPEC 57/1993
4) MID SPAN JOINTING 5) BINDING THE CONDUCTOR TO THE INSULATOR 6) ERECTION AT ROAD CROSSINGS 7) ANTICLIMBLING DEVICES
VISUAL
100%
ALL JOINTS AND SPLICES SHOULD BE 15 METERS AWAY FROM THE POLE
VISUAL
100%
VISUAL
100%
THE GROUND CLEARANCES AT ROAD CROSSINGS SHALL BE AS PER RELAVENT IE RULES
VISUAL
100%
8) DANGER BOARDS
VISUAL
100%
APPROVED DRAWINGS
1) MEASUREMENT OF SAGGING
VISUAL
100%
AS PER SAGTENSION CHARTS/ NESCL SPECIFICATIONS NESCL SPECIFICATION NESCL SPECIFICATION
AS PER IE NORMS
TENSIONING AND SAGGNG OPERATIONS ARE CARRIED IN CALM WEATHER, WHEN RAPID CHANGES IN TEMPERATURE ARE NOT LIKELY TO OCCUR
TENSIONIN G AND SAGGING
CLIPPING
1) CLIPPING THE CONDUCTOR IN POSITION 2) JUMBERING AT SECTION AND ANGLE TOWERS
C C
VISUAL VISUAL
100% 100%
MANUFACTURER'S RECOMMENDATION JUMBERS FORMED TO PARABOLIC SHAPE TO ENSURE MAXIMUM CLEARANCE TO EQUIPMENT COMPONENETS WHICH ARE INSPECTED AND CLEARED BY NESCL SHALL ONLY BE ACCEPTED ON RECEIPT
SUB-SYSTEM:2 ERECTION OF EARTH WIRE RECEIPT AND STORAGE 1) RECEIPT AT STORES C VISUAL CHECK 100% DELIVERY CHLLAN/MDCC CORRELATION OF THE LOT RECEIVED WITH THE DELIVERY CHLLAN/MDCC DESCRIPTIONS THE SURFACE OF EARTH WIRE SHOULD BE FREE FROM FLAWS AND DUST EARTH WIRE SHOULD BE STORED IN DRY AREAS EARTH WIRE SHOULD NOT BE DRAGGED ON THE GROUND SEQUENCE OF RUNNING OUT SHALL BE FROM TOP TO BOTTOM, i.e.. THE TOP EARTH WIRE SHALL RUN OUT FIRST, FOLLOWED BY THE SIDE EARTH WIRES ALL JOINTS SHALL BE COMPRESSION TYPE STORES REGISTER STORES REGISTER STORES REGISTER SCRATCHES OR DAMAGES TO THE SURFACE WOULD OCCUR IF NOT HANDLED PROPERLY CHECK THE CLEARANCE BETWEEN EARTH KNOB AND PIN INSULATORS AND THE COMPONENTS SHALL BE ERECTED AS PER DRAWING AND AS PER SPEC GROUND CLEARANCES SHOULD BE MAINTAINED
2) VISUAL INSPECTION 3) STORAGE
C C C
VISUAL CHECK VISUAL CHECK VISUAL
100% 100% 100% STANDARD PRACTICE NESCL SPECIFICATION
ERECTION OF EARTH WIRE
1) HANDLING OF THE EARTH WIRE
2) ERECTION OF EARTH KNOB
VISUAL
100%
NESCL SPECIFICATION
3) STRINGING OF THE EARTH WIRES
VISUAL
100%
NESCL SPECIFICATION
CLASS OF CHECK: A -- CRITICAL -- TO BE WITNESSED BY NESCL SITE AND SURVEILLANCE BY NESCL, CC. B -- MAJOR -- TO BE WITNESSED BY CONTRACTOR AND NESCL SITE C-- MINOR -- TO BE WITNESSED BY CONTRACTOR AND SURVEILLANCE BY NESCL SITE
NAME/ SIGNATURE OF THE SUB-CONTRACTOR/ ERECTION AGENCY
STANDARD FIELD QUALITY PLAN

Distribution Transformer (Outdoor Type)
QP No.NESCL/FSQP/TRF/001
Rev.: . Date: Page 5 of 5
Reviewed By:
Approved By:
Valid Upto ..
S.No. Activity and Operation 1 2
Characteristics/ instruments 3 l) Testing of oil after completion of filtration.
Class of Check 4
Type of Check 5
Quantum of Check 6
Reference Document 7 Manufacturer's Instruction Manual
Acceptance Norms 8
Format of Records 9 D*
Remarks 10
Test
100%
m) Oil level & leakage in transformer tank, radiators.
Test
100%
Manufacturer's Instruction Manual
n) Wiring and termination of cable from instrument, Bucholz Relay, OTI/WTI, MOG.
Physical
100%
Manufacturer's Instruction Manual & Wiring Details/ Drgs.
o) Tap switch position
Physical
100%
Manufacturer's Instruction Manual & Wiring Details/ Drgs. Manufacturer's Instruction Manual & Wiring Details/ Drgs.
p) Polarity and connection of CTs with leads, otherwise CTs secondary to be shorted. q) IR value between terminal and flange bushing.
Physical
100%
Physical
100%
r) Earthing of Transformer as per drawing and IE rules.
Physical
100%
As per drawing
As per drawing
s) General appearance for paint condition.(Retouching of paint if required.)
Physical
100%
t) Whole assembly for tightness and general appearance.
Physical
100%
LEGEND: RECORDS IDENTIFIED WITH "TICK" SHALL ESSENTIALLY BE INCLUDED IN QA DOCUMENTATION LEGEND TO BE USED: CLASS# A: CRITICAL, B: MAJOR, C: MINOR; A SHALL BE WITNESSED BY NESCL FQA, "B" SHALL BE WITNESSED BY NESCL ERECTION/ CONSTRUCTION DEPARTMENT AND "C" SHALL BE WITNESSED BY ERECTION / SUPPLIER (A&B CHECK SHALL BE NESCL CHP STAGE)
FIELD QUALITY PLAN

PROJECT / UTILITY : CONTRACT No. CONTRACTOR : PACKAGE: ITEM : SUB SYSTEM : QAP NO. : REV. NO.: DATE : Type of Check ERECTION WORK CABLES
Sr. No.
Instruments
1
1
1.1 1.2 1.3 1.4 1.5
2
RECEIPT & STORAGE Receiving inspection (Completeness of documents, test certificates, etc.) Unloading Visual exmination Proper storage End Sealing ( Cable ends are sealed by PVC cap to avoid ingress of moisture ) PRE INSTALLATION Unloading of Drums Check for drum mounting - cable wheel/ jack Check for cable unwinding - cable wheel/ jack Check for proper unrolling - Cable Wheel/ Jack Check for cable end sealing Availability of bricks at site for buried cables
Excavation of trench for U/G cable laying
Quantum/ Class Frequenc y 5 6
Reference Documents & Acceptance Standard
Format Of Records
Remarks
7
Delivery Challan & NESCL Specification Instruction Manual Packing list / Instruction Manual Instruction Manual/ IS: 1255 IS: 1255
8
MRC / Check List / C / 10 Site Record
V V V V V
B B B B B
100% 100% 100% 100% 100%
2 2.1 A B C D 2.2
2.3
V V V V V
V
B B B B C
C
100% 100% 100% 100% 100%

100%
IS: 1255 IS: 1255 IS: 1255 IS: 1255

NESCL Specs./ Standard Practice
Site Record Site Record Site Record Site Record Site Record
Site Record
2.4 2.5 2.6

2.7
2.8 2.9 2.10 2.11
Sand Cushioning for buried cables Ascertaining cable route and length Conformity with cable schedule Insulation resistance checking - Meggar ( 500 V for LT & 1000V for Cables upto 11kV) Proper route maintaining during cable laying identification and dressing of cables Use of trefoil clamps for single core cables Proper verticality of multicore cables
V V V
Electrical
Meggar
C B B
A
100% 100% 100%

100%
Cable Route Cable Schedule

IS: 1255
Site Record Site Record Site Record

Site Record
V V V V
B B B B
100% 100% 100% 100%
Cable Route standard Practice standard Practice standard Practice
Site Record Site Record Site Record Site Record
Page 1 of 3
FIELD QUALITY PLAN

Sr. No. CHARACTERISTICES / ITEMS Type of Check Instruments
1
3 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13 3.14 3.15 3.16 3.17 3.18 3.19 3.20
2
INSTALLATION Removal of wooden planks from cable drum Check cable is not dragged on hard ground Check size of cable & cutting of cable length Check the separation between different types of cables laid nearby. Check the laying of cables as per cable schedule. Check the cable tray are earthed as per the drawing. Check the cable glands, lugs, ferrules, cable tag/ marker are provided as per requirement. Check the cable cable drum/ cable to be laid for any external damage. Check the availability and functionality of the rollers. Check there are no damage / twisting of cables during laying. Check that cables are protected from the sharp bends while laying. Check that the power cables are separated from the control cables. Check the phase matching t both end after each joint. Check cable tags are provided at required intervals/required places and both end as per cable schedule. Check the cables are dressed, clamped and supported properly as per the drawing. Insulation Resistance Check Check whether some extra length ( 1.5 mtr.) is kept in each cable run for future use Check that all wall openings/ pipes/ sleeves are sealed to avoid seepage of water check that buried cables are covered with sand layers and by protective bricks Ensure that the location of underground cable joints are identified.
3
V V V V V V V V V V V V V V V Electrical Physical Physical Physical Physical
4
Meggar -

B B B B B B B B B B B B B B B B B B B B 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100%
Format Of Records
Remarks
7
NESCL Specification/ IS:1255 NESCL Specification/ IS:1255 NESCL Specification/ IS:1255 NESCL Specification/ IS:1255 NESCL Specification/ IS:1255 NESCL Specification/ IS:1255 NESCL Specification/ IS:1255 NESCL Specification/ IS:1255 NESCL Specification/ IS:1255 NESCL Specification/ IS:1255 NESCL Specification/ IS:1255 NESCL Specification/ IS:1255 NESCL Specification/ IS:1255 NESCL Specification/ IS:1255 NESCL Specification/ IS:1255 NESCL Specifications/ Instruction Manual NESCL Specifications/ Instruction Manual NESCL Specifications/ Instruction Manual NESCL Specifications/ Instruction Manual NESCL Specifications/ Instruction Manual
8
Site Record Site Record Site Record Site Record Site Record
Legends : CLASS OF CHECK: A -- CRITICAL -- TO BE WITNESSED BY NESCL SITE AND SURVEILLANCE BY NESCL, CC. B -- MAJOR -- TO BE WITNESSED BY CONTRACTOR AND NESCL SITE C-- MINOR -- TO BE WITNESSED BY CONTRACTOR AND SURVEILLANCE BY NESCL TC : Test Certificate MRC : Material Reciept Certificate V : Verify
SITE
Page 2 of 3
FIELD QUALITY PLAN

Sr. No. CHARACTERISTICES / ITEMS Type of Check Instruments
1
EIC : Engineer In Charge
Format Of Records
Remarks
Page 3 of 3
FIELD QUALITY PLAN - CIVIL

PROJECT / UTILITY : CONTRACT No. CONTRACTOR : PACKAGE: Characteristics / Class of Type of Instruments Check Check Quantum of Check Reference Documents QAP NO. : REV. NO.: DATE :
Sr. No.
1 1.1
ACTIVITY AND OPERATION

DOCUMENTS AND DRAWING Check that the instruction manuals for all equipments have been received. Check that the approved civil foundation plan of equipment are available. CIVIL WORKS FOR EQUIPMENT FOUNDATIONS Earth Work Before excavation Chck the pegs conditions as per line and alignment w.r.t. existing structure
Acceptance Norms
Format Of Records
Remarks
Physical
100%
Bill of Material
Office record
1.2
Physical
100%
Bill of Material
Office record
2 2.1 2.1.1 2.1.1.1
Measure Tape Measure Tape
B B
Visual Visual
100% 100%
As per site EIC
As per site EIC
Office record
2.1.1.2 Checking of pit marking as per drawing. 2.1.2 Excavation work
Foundation plan Foundation plan
2.1.2.1 Checking of pit marking / location 2.1.2.2 Check the dimension of pit at bottom (Lx Bx D) Check the type of soil, if BC soil is 2.1.2.3 confirmed follow the instruction on drawing for stone soling 2.1.2.4 Check the type of soil, if Non BC soil is confirmed follow the drawing. Shuttering
Measure Tape Measure Tape Measure Tape
B B B
Physical Physical Physical/ Hammering crobar Physical/ Hammering crobar
100% 100% 100%
Foundation Plan Foundation Plan Foundation Plan Foundation Plan Foundation Plan Foundation Plan
Site record Site record Site record
Measure Tape
100%
Foundation Plan Foundation Plan
Site record
2.3
Sr. No.

Check the shuttering board which are made to shape with steel tape including cleaning & proper surface preparation . Placment of shuttering boards including supports, tie rod etc. Measurement, line and level with steel tape & water level. Check placement, alignment & embedment of anchor bolts, Check no oil on inserts (For foundation bolts) Check bolt setting with templates. Cement Cement - Received from Supplier
Characteristics / Class of Type of Instruments Check Check

Measure tape B Visual
Quantum of Check
100%
Reference Documents
Acceptance Norms
Format Of Records
Site record
Remarks
2.3.1
2.3.2 2.3.3
Tackiling equipment Steel tape & water level Measure tape
B B
Visual Visual
100% 100%
Foundation Plan Foundation Plan Foundation Plan Foundation Plan
Site record Site record
Required as per site condition
2.3.4
Visual
100%
Site record
2.3.5 2.4 2.4.1
Measure tape
Visual
100%
Site record
Review of TC/ As per IS Review of TC/ As per IS
Visual
One of consignment One of consignment
IS: 11269
Manufacturer's Test Certificate Manufacturer's Test Certificate
Site Record
2.4.2
Setting Time & Compressive strength
Visual
IS: 11269
Site Record
2.5 2.5.1 2.5.2 2.6 2.6.1
Reinforced Steel Visual Examination to ensure free from cracks, surface flaws, imperfect edges and dimensional checks Cutting, Bending, placing of reinforced steel bars & lapping Concreting Mixing of cement (OPC, 53 Grade, ISI mark), sand & coarse aggregate as per ratio 1:4:8/1:2:4/1:5:8/ 1:1.5:3 Check workability of concrete Placing concrete, poking and compacting. Testing of concrete cubes for compression strength. 7 Days / 28 Days.
B Tackling Equipment B
Visual Visual
100% 100%
IS: 1786 & Approved Drawings Approved Drawings
Approved Drawings Approved Drawings
Site Record Site Record
Tackling equipment
Visual
100%
2.6.2
Tackling equipment
Visual
100%
2.6.3
Tackling equipment Compression machine
Visual Third party lab test
100% One set per substation
As per instructions of manufacturer's As per instructions of manufacturer's As per instructions of manufacturer's IS 456, IS 516
As per instructions of manufacturer's As per instructions of manufacturer's As per instructions of manufacturer's IS 456, IS 516
Site record
Site record
Site record
2.6.4
Site record
Sr. No.
2.6.5

Check whether curing period of the foundation is completed. Check the backfilling and compection is completed upto ground level.
Characteristics / Class of Type of Instruments Check Check

C Visual
Quantum of Check
100%
Reference Documents
Acceptance Norms
Format Of Records
Site record
Remarks
Visual check for Visual check for min 7 days min 7 days Foundation Plan Foundation Plan
2.6.6
Tackling equipment
Visual
100%
Site record
2.7 2.7.1 2.7.2 2.7.3 2.7.4 2.8 2.8.1 2.8.2 2.8.3 2.8.4
Masonary work Check the proportion, mixing & placement of mortar. Plumb & alignment Curing Control brick height " In day work" Plastering work Plastering thickness and evenness Mortar mix / proportion Check the placement, thickness of plaster, line & level of plaster Curing Legends :
Tackling equipment Tackling equipment
B B B
Visual Visual Visual Visual
Random Random 100% 100%
Foundation Plan Foundation Plan Foundation Plan Foundation Plan Visual check for Visual check for min 7 days min 7 days Foundation Plan Foundation Plan
Site record
Site record
Measure tape
B Tackling equipment Tackling equipment B B B
Visual Visual Visual Visual
Random Random Random 100%
Visual check
Visual check Site record Site record Site record
Foundation Plan Foundation Plan Foundation Plan Foundation Plan Visual check for Visual check for min 7 days min 7 days
CLASS OF CHECK: A -- CRITICAL -- TO BE WITNESSED BY NESCL SITE AND SURVEILLANCE BY NESCL, CC. B -- MAJOR -- TO BE WITNESSED BY CONTRACTOR AND NESCL SITE C-- MINOR -- TO BE WITNESSED BY CONTRACTOR AND SURVEILLANCE BY NESCL SITE TC : Test Certificate V : Verify W : Witness EIC : Engineer In Charge

CONTRACTOR NOA NO: PACKAGE: SUB-SYSTEM: 1 CONDUCTOR ERECTION SL.NO MAIN CHARACTERISTICS/INSTRUM ACTIVITY& ENTS OPERATION RECEIPT AND STORAGE CLASS OF CHECK TYPE OF CHECK QUANTUM OF CHECK
FIELD QUALITY PLAN-- CONDUCTOR STRINGING

Item: CONDUCTOR STRINGING SYSTEM:
REFERENCE DOCUMENT
ACCEPTANCE NORMS
FORMAT OF RECORD
RE MARKS COMPONENETS WHICH ARE INSPECTED AND CLEARED BY NESCL SHALL ONLY BE ACCEPTED ON RECEIPT
1) RECEIPT AT STORES
VISUAL CHECK
100%
DELIVERY CHLLAN/MDCC STANDARD PRACTICE NESCL SPECIFICATION STANDARD PRACTICE NESCL SPECIFICATION
CORRELATION OF THE LOT RECEIVED WITH THE DELIVERY CHLLAN/MDCC DESCRIPTIONS NESCL SPECIFICATION DRUMS FOUND DAMAGED DURING TRANSIT ARE STACKED SEPARATELY DRUMS ARE STORED ON HARD SURFACE AREA
STORES REGISTER STORES REGISTER STORES REGISTER STORES REGISTER
2.) UNLOADING 2) VISUAL INSPECTION 3) STORAGE 1) ENSURE USE OF CORRECT SIZE OF DISC INSULATOR AND CONDUCTOR
C C C
VISUAL CHECK VISUAL CHECK VISUAL CHECK
100% 100% 100%
PRE INSTALLATI ON
VISUAL CHECK
200%
NESCL SPECIFICATION
SITE REGISTER
Page 1 of 2
1) HANDLING OF THE CONDUCTOR
VISUAL
100%
NESCL SPECIFICATION
CONDUCTOR SHOULD NOT BE DRAGGED ON THE GROUND SEQUENCE OF RUNNING OUT SHALL BE FROM TOP TO BOTTOM, i.e.. THE TOP CONDUCTOR SHALL RUN OUT FIRST, FOLLOWED BY THE SIDE CONDUCTORS ANY DAMAGES TO THE STRANDS SHALL BE REPAIRED WITH REPAIR SLEEVES NESCL SPECIFICATION
SITE REGISTER
SCRATCHES OR DAMAGES TO THE STRANDS WOULD OCCUR IF NOT HANDLED PROPERLY
2) SEQUENCE OF CONDUCTOR ERECTION ERECTION OF CONDUCTOR
VISUAL
100%
NESCL SPECIFICATION
SITE REGISTER
3) STRINGING OF THE CONDUCTORS
VISUAL
100%
NESCL SPECIFICATION NESCL SPECIFICATION AS PER SAGTENSION CHARTS/ NESCL SPECIFICATIONS NESCL SPECIFICATION NESCL SPECIFICATION NESCL SPECIFICATION NESCL SPECIFICATION
SITE REGISTER ALL JOINTS AND SPLICES SHOULD BE 30 METERS AWAY FROM THE POLE TENSIONING AND SAGGNG OPERATIONS ARE CARRIED IN CALM WEATHER, WHEN RAPID CHANGES IN TEMPERATURE ARE NOT LIKELY TO OCCUR
4) MID SPAN JOINTING
VISUAL
100%
SITE REGISTER
5) CHECK THE SAGGING AND TENSION OF CONDUCTOR
VISUAL
100%
AS PER IE NORMS
SITE REGISTER
6) BINDING THE CONDUCTOR TO THE INSULATOR

7) ERECTION AT ROAD CROSSINGS CLIPPING 1) CLIPPING THE CONDUCTOR IN POSITION 2) JUMBERING AT SECTION AND ANGLE TOWERS
VISUAL
100%
AS PER THE REC SPECIFICATIONS GUARDING SHALL BE PROVIDED AT MAJOR CROSSINGS MANUFACTURER'S RECOMMENDATION JUMBERS FORMED TO PARABOLIC SHAPE
SITE REGISTER THE GROUND CLEARANCES AT SITE REGISTER ROAD CROSSINGS SHALL BE AS PER RELAVENT IE RULES SITE REGISTER TO ENSURE MAXIMUM CLEARANCE TO EQUIPMENT
VISUAL
100%
VISUAL
100%
VISUAL
100%
SITE REGISTER
CHECK THE EARTH / GROUND CLEARANC
VISUAL
100%
NESCL SPECIFICATION
NESCL SPECIFICATION
SITE REGISTER
Page 2 of 2
Contractor's Name: Sub Contractor/ agency Name&Address:

Item: DTR STRUCTURE AND COMPONENTS Sub-system: ERECTION TRANSFORMER STRUCTURE
FIELD QUALITY PLAN
SECTION - I : MS GALVANIZED COMPONENTS

S.NO MAIN ACTIVITY& OPERATION CHARACTERISTICS/INSTRUMENTS CLASS OF CHECK TYPE OF CHECK QUANTUM OF CHECK REFERENCE DOCUMENT ACCEPTANCE NORMS FORMAT OF RECORD RE MARKS
RECEIPT AND STORAGE
1) RECEIPT AT STORES 2) VISUAL INSPECTION 3) PROPER STORAGE
C C C
VISUAL VISUAL VISUAL
100% 100% 100%
DELIVERY CHALLAN / MDCC
CORRELATION OF THE LOT RECEIVED WITH THE DELIVERY CHALLAN / MDCC DESCRIPTIONS DAMAGED AND GALVANISATION DEFECTIVE COMPONENTS ARE TO BE STACKED SEPARATELY ALL G.I. COMPONENTS SHOULD BE STACKED ON WOODEN SLEEPERS AND THE STORAGE AREA SHALL BE FREE FROM WATER LOGGING AS PER APPROVED DRAWING AS PER APPROVED DRAWING AS PER APPROVED DRAWING AS PER APPROVED DRAWING APPROVED DRAWING AS PER APPROVED DRAWING
SITE REGISTER STORES REGISTER STORES REGISTER
COMPONENTS WHICH ARE INSPECTED AND CLEARED BY NESCL SHALL ONLY BE ACCEPTED ON RECEIPT
STANDARD PRACTICE
1) CHECK THE ALIGN MENT OF TWO POLES FIXING OF MS COMPONENTS 2) FIX THE TOP CHANNEL 3) FIX THE FISH PLATE 3) FIX THE BELTING ANGLES WITH BELTING ANGLE BACK CLAMP 4) HORIZONTAL ALIGNMENT OF THE BELTING ANGLE WITH POLES 5) FIX THE BRACING ANGLES WITH BRACING ANGLE CLAMP 6) ALIGNMENT OF THE BRACING ANGLE WITH BELTING ANGLES
C C C C C C
VISUAL VISUAL VISUAL VISUAL DIMENSIONAL VISUAL
100% 100% 100% 100% 100% 100%
AS PER NESCL SPECIFICATION AS PER NESCL SPECIFICATION AS PER NESCL SPECIFICATION AS PER NESCL SPECIFICATION APPROVED DRAWING AS PER NESCL SPECIFICATION
SITE REGISTER SITE REGISTER SITE REGISTER SITE REGISTER SITE REGISTER SITE REGISTER
BOTH THE POLES SHOULD BE PARALLEL TO EACH OTHER AND SHOULD BE PLANTED AT SAME DEPTH CHECK THE ALIGNMENT OF THE TOP CHANNEL WITH THE POLE THESE FISH PLATE SHOULD BE PLACED RIGIDLY AND HOLES ARE TO BE CHECKED ANGLES SHOULD BE FIXED FROM SPECIFIED FROM GROUND
DIMENSIONAL
100%
APPROVED DRAWING
APPROVED DRAWING
SITE REGISTER
THE BOLTS AND NUTS SHALL BE TIGHT ENOUGH TO HOLD THE BRACING TO THE POLE THE ANGLE BETWEEN THE TWO BRACING SHOULD BE 900 AND SHOULD BE RIGID ENOUGH TO BEAR THE FORCES AS PER APPROVED DRAWING THE NUMBER OF STAYS ARE TO BE ERECTED
8.1) LOCATION FOR THE GUY SETS 8.2) EXCAVATION OF PIT SIZE 0.5M X 0.5M X 1.6M STAY / GUY ERECTION 8.3)SIZING OF ANCHOR PLATE 8.4)GROUTING OF ANCHOR PLATE ANCHOR ROD WITH EARTH FILLING AND
VISUAL
100%
NESCL Specification GUIDELINES IS:5613 NESCL SPECIFICATION NESCL SPECIFICATION NESCL SPECIFICATION NESCL SPECIFICATION NESCL SPECIFICATION
/REC
NESCL SPECIFICATION
SITE REGISTER
C C C B C
DIMENSIONAL DIMENSIONAL DIMENSIONAL MEASURE EMENT VISUAL
100% 100% 100% 100% 100%
REC CONSTRUCTION STANDARD G-1 REC CONSTRUCTION STANDARD K-1 NESCL SPECIFICATION REC CONSTRUCTION STANDARD G-1 REC CONSTRUCTION STANDARD G-1
SITE REGISTER SITE REGISTER SITE REGISTER SITE REGISTER SITE REGISTER GUY INSULATORS ARE ERECTED AT HEIGHT OF 3050 mm FROM THE GROUND . TURN BUCKLE ARE MOUNTED HALF WAY IN THE WORKING POSITION , THUS GIVING THE Max. MOVEMENT FOR TIGHTENING AND LOOSENING IF GUY WIRE IS FOUND HAZARDOUS IT SHOULD BE PROTECTED WITH ASBESTOS PIPE FILL WITH CONCRETE
8.5)ANGLE BETWEEN STAY WIRE AND POLE 8.6)ERECTION OF GUY INSULATOR
8.7) ERECTION TURNBUCKLE
VISUAL
100%
NESCL SPECIFICATION
REC CONSTRUCTION STANDARD G-1
SITE REGISTER
8.8) ENSURE STRUCTURE
THE
RIGIDNESS
OF
THE
VISUAL
100%
STANDARD PRACTICE
APPROVED DRAWING
SITE REGISTER

FIELD QUALITY PLAN
SECTION - II : FIXING OF INSULATORS

RECEIPT AND STORAGE 1) RECEIPT AT STORES C VISUAL 100% DELIVERY CHALLAN / MDCC CORRELATION OF THE LOT RECEIVED WITH THE DELIVERY CHALLAN / MDCC DESCRIPTIONS THE SURFACE OF THE INSULATOR ARE TO BE THROUGHLY CHECKED AND CLEANED, THE THREADING OF THE INSULATOR IS TO BE CHECKED STANDARD PRACTICE AS PER NESCL SPECIFICATION APPROVED DRAWING AS PER NESCL SPECIFICATION AS PER NESCL SPECIFICATION AS PER APPROVED DRAWING APPROVED DRAWING AS PER APPROVED DRAWING APPROVED DRAWING SITE REGISTER PIN INSULATORS SHALL BE TIGHTENED RIGIDLY TO WITH STAND THE LOAD. FOR CHECKING THE CLEARANCES SUITABLE TEMPLATE/ JIGS ARE TO BE USED DEPENDING ON TYPE OF LOCATION T&C OR B&S ARE TO BE USED AS PER APPROVED DRAWING FOR CHECKING THE CLEARANCES SUITABLE TEMPLATE/ JIGS ARE TO BE USED COMPONENTS WHICH ARE INSPECTED AND CLEARED BY NESCL SHALL ONLY BE ACCEPTED ON RECEIPT MAJOR DAMAGED MATERIAL SHALL BE DISCARDED. SITE REGISTER COMPONENTS WHICH ARE INSPECTED AND CLEARED BY NESCL SHALL ONLY BE ACCEPTED ON RECEIPT
2) VISUAL INSPECTION 3) PROPER STORAGE 1) CHECK THREADING OVER THE PINS AND INSULATORS AND CHECK THE ALIGNMENT OF PIN WITH INSULATOR 2) ASSEMBLING THE GI PIN AND INSULATORS 3) FIX THE PIN INSULATOR OVER THE FISH PLATES 4) CHECK THE CLEARANCES BETWEEN THE INSULATORS 5) NOW FIX THE RESPECTIVE DISC INSULATORS WITH DISC INSULATOR CLAMPS 6) CHECK THE CLEARANCES BETWEEN THE INSULATORS
C C C C C B
VISUAL VISUAL VISUAL VISUAL VISUAL DIMENSIONAL
100% 100% 100% 100% 100% RANDOM
STORES REGISTER STORES REGISTER SITE REGISTER
DAMAGED INSULATORS ARE STACKED SEPARATELY
TO BE
FIXING OF INSULATORS
VISUAL
100%
AS PER NESCL SPECIFICATION
AS PER APPROVED DRAWING
SITE REGISTER
DIMENSIONAL
RANDOM
APPROVED DRAWING
SECTION - III : FIXING OF 11KV HG FUSE

1) RECEIPT AT STORES RECEIPT AND STORAGE 2) VISUAL INSPECTION C C VISUAL VISUAL 100% 100% DELIVERY CHALLAN / MDCC CORRELATION OF THE LOT RECEIVED WITH THE DELIVERY CHALLAN / MDCC DESCRIPTIONS DAMAGED AND DEFECTIVE EQUIPMENT SHALL BE STACKED SEPARATELY STANDARD PRACTICE THE HG FUSE COMPONENTS SHALL BE STORED ON WOODEN PLATFORM OF 300mm DEPTH STORES REGISTER STORES REGISTER
3) PROPER STORAGE
VISUAL
100%
STORES REGISTER
1) RATING PLATE DETAILS FIXING OF HG FUSE SET
VISUAL
100%
STANDARD PRACTICE
NESCL SPEC / APPROVED DRAWINGS
STORES REGISTER
2) CHECK LEVEL & ALIGNMENT OF THE BASE, HOUSING ASSEMBLY & FLANGS
VISUAL
100%
STANDARD PRACTICE
INSTRUCTION MANUAL
SITE REGISTER
3) CHECK FOR THE CLEARANCE BETWEEN LIVE PART TO EARTH
VISUAL
100%
STANDARD PRACTICE
INSTRUCTION MANUAL / APPROVED DRAWING\
SITE REGISTER

FIELD QUALITY PLAN
SECTION - IV : ERECTION AND COMMISSIONING OF LINE SECTIONALIZER / AB SWITCH

RECEIPT AND STORAGE 1) RECEIPT AT STORES 2) VISUAL INSPECTION C C VISUAL VISUAL 100% 100% DELIVERY CHALLAN / MDCC CORRELATION OF THE LOT RECEIVED WITH THE STORES REGISTER DELIVERY CHALLAN / MDCC DESCRIPTIONS DAMAGED AND DEFECTIVE EQUIPMENT SHALL BE STORES REGISTER STACKED SEPARATELY STANDARD PRACTICE THE AB SWITCH COMPONENTS SHALL BE STORED ON STORES REGISTER WOODEN PLATFORM OF 300mm DEPTH COMPONENTS WHICH ARE INSPECTED AND CLEARED BY NESCL SHALL ONLY BE ACCEPTED ON RECEIPT MAJOR DAMAGED MATERIAL SHALL BE DISCARDED.
3) PROPER STORAGE A) INSTALLATION 1) RATING PLATE DETAILS 2) CHECK FOR PROPER SLING AND LIFTING 3) CHECK TIGHTNESS OF BASE BOLTS AND OTHER BOLTED JOINTS BY TORQUE WRENCH
VISUAL
100%
C C
VISUAL VISUAL
100% 100%
STANDARD PRACTICE STANDARD PRACTICE
APPROVED DRAWING INSTRUCTION MANUAL
SITE REGISTER SITE REGISTER
VISUAL
100%
STANDARD PRACTICE
INSTRUCTION MANUAL
SITE REGISTER
FIXING OF LINE SECTIONALIZER/ AB SWITCH
4) CHECK LEVEL & ALIGNMENT OF THE BASE, HOUSING ASSEMBLY & FLANGS 5) ENSURE PROPER ERECTION OF POLES, MAIN B LADE & DRIVE ASSEMBLY AS PER APPROVED DRAWINGS 6) CHECK FOR THE ALIGNMENT VERTICALITY OF SECTIONALIZER AND
VISUAL
100%
STANDARD PRACTICE
INSTRUCTION MANUAL
SITE REGISTER
VISUAL
100%
STANDARD PRACTICE
APPROVED DRAWING
SITE REGISTER
C B
VISUAL VISUAL
100% 100%
STANDARD PRACTICE STANDARD PRACTICE
INSTRUCTION MANUAL / APPROVED DRAWING\ INSTRUCTION MANUAL / APPROVED DRAWING\
7) CHECK FOR THE CLEARANCE BETWEEN LIVE PART TO EARTH 9) CHECK FOR NO VIBRATION OR ROTATION OF CONTACTS INSULATORS DURING ISOLATOR OPERATION 10) CHECK FOR NO VIBRATION OR ROTATION OF CONTACTS OF INSULAOTRS DURING ISOLATOR OPERATION 11) CHECK FOR THE PROVISION EARTHING AND EARTH CONNECTION OF
VISUAL
100%
STANDARD PRACTICE
INSTRUCTION MANUAL
SITE REGISTER
VISUAL
100%
STANDARD PRACTICE
INSTRUCTION MANUAL
SITE REGISTER
VISUAL
100%
STANDARD PRACTICE
APPROVED DRAWING
SITE REGISTER
12) CHECK OPERATION OF THE ISOLATOR BY ROTATING ONE OF THE INSULATOR STACK MANUALLY AND ADJUST THE LENGTH OF THE CROSSED TANDEM ASSEMBLY TO ENSURE PROPER ENGAGEMENT OF CONTACTS DURING CLOSING. PRE COMMISSIONING 1) CHECK FOR VISUAL DAMAGE TO ANY PARTS INCLUDING PORCELAIN ISOLATOR 2) CHECK MANUAL / OPERTION AND INTER LOCKS 3) IR VALUE BETWEEN EARTH TO POLE 4) GROUND CONNECTIONS 5) CHECK CONTINUITY
VISUAL
100%
STANDARD PRACTICE
INSTRUCTION MANUAL / APPROVED DRAWING\
SITE REGISTER
ENSURE THE ENTIRE STRUCTURE SHOULD BE RIGID AND CHECK THE RIGIDNESS BY OERATING THE AB SWITCHES
C B B C B
VISUAL VISUAL CHECK VISUAL CHECK VISUAL CHECK VISUAL CHECK
100% 100% 100% 100% 100%
STANDARD PRACTICE STANDARD PRACTICE STANDARD PRACTICE STANDARD PRACTICE STANDARD PRACTICE
INSTRUCTION MANUAL / APPROVED DRAWING\ INSTRUCTION MANUAL / APPROVED DRAWING\ INSTRUCTION MANUAL / APPROVED DRAWING\ INSTRUCTION MANUAL / APPROVED DRAWING\ INSTRUCTION MANUAL / APPROVED DRAWING\
SITE REGISTER SITE REGISTER SITE REGISTER SITE REGISTER SITE REGISTER
10

FIELD QUALITY PLAN
SECTION - V : ERECTION & COMMISSIONING OF DTRS

RECEIPT AND STORAGE 1) RECEIPT AT STORES C VISUAL 100% DELIVERY CHALLAN / MDCC CORRELATION OF THE LOT RECEIVED WITH THE DELIVERY CHALLAN / MDCC DESCRIPTIONS DAMAGED COMPONENTS SHALL BE STAGED SEPARATELY THE TRANSFORMERS AND THE ACCESSORIES SHALL BE STACKED ON DRY LEVELLED AND RAISED PLATFORM. ALL PIPE WORK CONSERVATORS, RADIATORS SHOULD BE STORED WITH THEIR BLANKING PLATES IN POSITION HEATERS IN THE MARSHELLING BOX SHOULD BE KEPT ENERZIZED TO AVOID CONDENSATION AS PER APPROVED DRAWING STORES REGISTER TRANSFORMERS AND ACCESSORIES INCLUDING LAs WHICH ARE INSPECTED AND CLEARED BY NESCL SHALL ONLY BE ACCEPTED ON RECEIPT MAJOR DAMAGED MATERIAL SHALL BE DISCARDED.
2) VISUAL INSPECTION
VISUAL
100%
APPROVED DRAWING
STORES REGISTER
11
3) PROPER STORAGE
VISUAL
100%
STANDARD PRACTICE
STORES REGISTER
ERECTION OF TRANSFORMERS
1) ENSURE THE REGIDNESS OF THE STRUCTURE OVER WHICH TRANFORMER IS TO BE ERECTED 2) LIFTING OF THE TRANFORMERS
VISUAL
100%
STANDARD PRACTICE
SITE REGISTER
VISUAL
100%
12
3) ENSURE PROPOER SITTING OF THE TRANSFORMER OVER THE STRUCTURE 4) HV / LV POSITION 5) OTHER BUSHINGS, ERECTED ACCESSORIES CONNECTORS LIKE ETC. LAs, ARE
C C C
VISUAL VISUAL VISUAL
100% 100% 100%
VERTICALITY OF THE TRANFORMERS SHALL BE AS PER MANUFACTURER MAINTAINED INSTRUCTION MANUAL HV / LV ORIENTATION OF THE TRANFORMER SHALL BE CHECKED THERE SHOULD NOT BE ANY MOVEMENT OF THE STANDARD PRACTICE TRANFORMER AND FIXED TRANSFORMER AND FIXED RIGIDLY TO THE STRUCTURE AS PER MANUFACTURER AS PER NESCL SPEC / APPROVED DRAWING INSTRUCTION MANUAL AS PER MANUFACTURER AS PER NESCL SPEC / APPROVED DRAWING INSTRUCTION MANUAL
SITE REGISTER THE BOLTS AND NUTS SHALL BE TIGHT ENOUGH TO HOLD THE TRANSFORMER WITHOUT ANY SHAKE AIR CLEARANCE SHOULD BE AS PER APPROVED DRAWING AIR CLEARANCES SHOULD BE AS PER APPROVED DRAWING A 5 KV MEGGER PREFERABLY MOTOR OPERATED SHOULD BE USED FOR MEASURING HIGHER VALUES. BUSHINGS ARE THROUGHLY CLEANED BEFORE TAKING IR VALUES. IR VALUES BETWEEN WINDINGS AND BETWEEN WINDINGS TO EARTH ARE CHECKED WHILE CHECKING THESE VALUES NO EXTERNAL LINES LIGHTNING ARRESTERS SHOULD BE IN CIRCUIT
SITE REGISTER SITE REGISTER SITE REGISTER
1) INSULATION RESISTANCE PRE COMMISSIONING CHECKS
TEST
100%
AS PER INSTRUCTION MANUAL
NESCL SPECIFICATION
SITE REGISTER
2) OIL DIEELECTRIC STRENTH TEST 3) GENERAL CHECKS a) ALL OIL VALVES ARE IN CORRECT POSITION, CLOSED OR OPENED AS REQUIRED b) ALL AIR POCKETS ARE CLEARED c) THERMOMETER POCKETS ARE FILLED WITH OIL d) OIL IS AT CORRECT LEVEL IN THE TRANFORMERS e) EARTHING CONNECTIONS ARE DONE f) ARCING HORN GAPS ON BUSHINGS ARE PROPERLY ADJUSTED
TEST
100%
13
IS : 335 SAMPLES FROM TOP AND BOTTOM OF TRANFORMER ARE TESTED
SITE REGISTER
C C C B C C
VISUAL TEST TEST TEST TEST TEST
100% 100% 100% 100% 100% 100%
AS PER INSTRUCTION MANUAL AS PER INSTRUCTION MANUAL AS PER INSTRUCTION MANUAL AS PER INSTRUCTION MANUAL AS PER INSTRUCTION MANUAL AS PER INSTRUCTION MANUAL
SITE REGISTER SITE REGISTER SITE REGISTER SITE REGISTER SITE REGISTER SITE REGISTER ABNORMILITIES IF NOTICED SHOULD BE CORRECTED AFTER FEW HOURS OF ENERZISATION AT NO LOAD THE TRANFORMER SHALL BE SWITCHED OFF. TRANSFORMERS
ENERZISATI ON
14
CHARGING THE TRANSFORMER
VISUAL
100%
NO ABNORMILITY SUCH AS VIBRATION OF THE PARTS, HUM NOISE SHOULD BE ABSORBED
SITE REGISTER

FIELD QUALITY PLAN
SECTION - VI : EARTHING OF DTR STATION

IDENTIFICA TION OF THE EARTH PITS AND EARTHING EQUIPMENT 15 1) IDENTIFY THE LOCATION WHERE THE EARTHING IS TO BE DONE 2) IDENTIFY THE TRANSFORMER NEUTRAL TERMINAL, LA TERMINAL AND OTHER ACCESSORIES A A VISUAL VISUAL 100% 100% AS PER APPROVED DRAWING AND REFERE REC CONSTRUCTION STANDARDS F5 NESCL SPECIFICATION AS PER APPROVED DRAWING AND REFERE REC CONSTRUCTION STANDARDS F10 NESCL SPECIFICATION SITE REGISTER SITE REGISTER
PIPE TYPE EARTHING INSTALLATION OF DP STRUCTURE
1) EXCAVATION OF PIT SIZE
VISUAL
100%
AS PER APPROVED DRAWING AND REFERE REC CONSTRUCTION STANDARDS J2 NESCL SPECIFICATION
SITE REGISTER
16
2) INSTALL 40 DIA GI PIPE WITH 12 DIA HOLES IN THE PIT 3) FILL THE PIT WITH ALTERNATE LAYERS OF 300 mm CHAR COAL AND SALT 4) CONNECTIONS BETWEEN THE PIPE AND POLE WITH 8mm SWG WIRE 5) CONNECT THE EQUIPMENT TO BE EARTHED AND THE PIPE EARTHE TERMINALS WITH GI WIRE
VISUAL
100%
AS PER APPROVED DRAWING AND REFERE REC CONSTRUCTION STANDARDS J2 NESCL SPECIFICATION AS PER APPROVED DRAWING AND REFERE REC CONSTRUCTION STANDARDS J2 NESCL SPECIFICATION AS PER APPROVED DRAWING AND REFERE REC CONSTRUCTION STANDARDS J2 NESCL SPECIFICATION AS PER APPROVED DRAWING AND THERE SHOULD NOT BE ANY LOOSE CONNECTIONS NESCL SPECIFICATION
SITE REGISTER THE ORDINARY SOILS WHERE PIPE COULD HARMOURED IN TREATMENT OF THE PIT WITH CHARCOAL AND SALT IS NOT NECESSARY
VISUAL
100%
SITE REGISTER
C C
VISUAL VISUAL
100% 100%
17
TESTING OF EARTH RESISTIVITY
TESTING OF EARTHING
TEST
100%
STANDARD PRACTICE
INSTRUCTION MANUAL
SITE REGISTER
SECTION - VII : ERECTION OF DANGER BOARDS AND ANTICLIMBING DEVICES

1) FIXING OF DANGER BOARDS AND ANTI CLIMBING DEVICES 18 2) ERECTION OF BARBED WIRE C VISUAL 100% INSTRUCTION MANUAL NESCL SPECIFICATION AND APPROVED DRAWINGS SITE REGISTER C VISUAL 100% INSTRUCTION MANUAL NESCL SPECIFICATION AND APPROVED DRAWINGS AND REC SPECIFICATION NO 57 SITE REGISTER THE LANGUAGE OF LETTERINGS SHALL CONFIRM TO RULE NO 35 OF IE RULES 1956 AND SHALL BE IN HINDHI OR ENGLISH AND IN LOCAL LANGUAGE WIH T THE SIGN OF SKULL AND BONES

FIELD QUALITY PLAN
SECTION - VIII : ERECTION AND COMMISSIONING OF LT DISTRIBUTION BOXES

1) RECEIPT AT STORES 2) VISUAL INSPECTION C C VISUAL VISUAL 100% 100% DELIVERY CHALLAN / MDCC APPROVED DRAWING CORRELATION OF THE LOT RECEIVED WITH THE DELIVERY CHALLAN / MDCC DESCRIPTIONS DAMAGED COMPONENTS SEPARATELY SHALL BE STAGED STORES REGISTER STORES REGISTER COMPONENTS WHICH ARE INSPECTED AND CLEARED BY NESCL SHALL ONLY BE ACCEPTED ON RECEIPT MAJOR DAMAGED MATERIAL SHALL BE DISCARDED.
19
3) PROPER STORAGE
VISUAL
100%
STANDARD PRACTICE
THE TRANSFORMERS AND THE ACCESSORIES SHALL BE STACKED ON DRY LEVELLED AND RAISED PLATFORM. ALL PIPE WORK CONSERVATORS, RADIATORS SHOULD BE STORED WITH THEIR BLANKING PLATES IN POSITION HEATERS IN THE MARSHELLING BOX SHOULD BE KEPT ENERZIZED TO AVOID CONDENSATION AS PER APPRROVED SPECIFICATION AS PER APPRROVED SPECIFICATION DRAWINGS AND NESCL
INSTALLATION
STORES REGISTER
4) ERECTION OF LT DISTRIBUTION BOXES
VISUAL
100%
STANDARD PRACTICE
SITE REGISTER COVER OF THE BOX IS ALSO TO BE EARTHED BY WAY OF FLEXIBLE COPER LINK OF SUITABLE DIMENSION
5) EARTHING OF LTDB
VISUAL
100%
STANDARD PRACTICE
DRAWINGS
AND
NESCL
SITE REGISTER
CLASS OF CHECK: A -- CRITICAL -- TO BE WITNESSED BY NESCL SITE AND SURVEILLANCE BY NESCL, CC. B -- MAJOR -- TO BE WITNESSED BY CONTRACTOR AND NESCL SITE C-- MINOR -- TO BE WITNESSED BY CONTRACTOR AND SURVEILLANCE BY NESCL
SITE
FIELD QUALITY PLAN--ERECTION OF 11KV POLE ACCESSORIES

Item: ERECTION OF 11KV POLE ACCESSORIES Sub-system: G.I COMPONENTS, INSULATORS ,HARDWARE FITTINGS, DANGER BOARDS, ANTI CLIMBING DEVICES, GUARDING FQP No: REV.No: DATE: PAGE:
MS GALVANIZED COMPONENTS
MAIN SL.NO ACTIVITY& OPERATION CHARACTERISTICS/ INSTRUMENTS CLASS OF CHECK TYPE OF CHECK QUANTUM OF CHECK REFERENCE DOCUMENT ACCEPTANCE NORMS FORMAT OF RECORD RE MARKS COMPONENTS WHICH ARE INSPECTED AND CLEARED BY NESCL SHALL ONLY BE ACCEPTED ON RECEIPT
1) RECEIPT AT STORES RECEIPT AND STORAGE
VISUAL CHECK
100%
CHP DOCUMENT
CORRELATION OF THE LOT RECEIVED WITH THE CHP DESCRIPTIONS DAMAGED AND GALVANIZATION DEFECTIVE COMPONENTS ARE TO BE STACKED SEPARATELY ALL G.I. COMPONENTS SHOULD BE STACKED ON WOODEN SLEEPERS AND THE STORAGE AREA SHALL BE FREE FROM WATER LOGGING
STORES REGISTER
VISUAL CHECK
100%
STORES REGISTER
3) PROPER STORAGE
VISUAL CHECK
100%
STANDARD PRACTICE
STORES REGISTER
1) V- CROSS ARM WITH CROSS ARM BACK CLAMP FIXING OF MS COMPONENTS
VISUAL CHECK
100%
SITE REGISTER
CROSS ARMS ARE TO BE FIXED AT THE MARKINGS PROVIDED ON THE POLES
2) HORIZONTAL ALIGNMENT OF CROSS ARMS WITH POLE 3) TOP CLEAT WITH BACK CLAMP 4) VERTICAL ALIGNMENT OF TOP CLEAT WITH POLE 5) TIGHTENING MS COMPONENTS WITH NUTS, BOLTS AND WASHERS
WATER LEVEL
100%
APPROVED DRAWING AS PER NESCL SPECIFICATION APPROVED DRAWING APPROVED DRAWING
APPROVED DRAWING TOP CLEATS ARE TO BE FIXED AT THE MARKINGS PROVIDED ON THE TOP OIF THE POLE
VISUAL CHECK
100%
SITE REGISTER
WATER LEVEL
100%
APPROVED DRAWING
ERECTION CHECK
100%
THE COMPONENTS SHOULD BE FIXED RIGID ENOUGH TO WITH SITE REGISTER STAND ALL THE FORCES
SL.NO
MAIN ACTIVITY& OPERATION
CHARACTERISTICS/ INSTRUMENTS
CLASS OF CHECK
TYPE OF CHECK
QUANTUM OF CHECK
REFERENCE DOCUMENT
ACCEPTANCE NORMS
FORMAT OF RECORD
RE MARKS
INSULATORS WITH PINS

RECEIPT AND STORAGE 1) RECEIPT AT STORES C VISUAL CHECK 100% CHP DOCUMENT CORRELATION OF THE LOT RECEIVED WITH THE CHP DESCRIPTIONS THE SURFACE OF THE INSULATORS ARE TO BE THOROUGHLY CHECKED AND CLEANED, THREADING OF THE INSULATOR THIMBLE TO BE CHECKED STANDARD PRACTICE SITE REGISTER COMPONENTS WHICH ARE INSPECTED AND CLEARED BY NESCL SHALL ONLY BE ACCEPTED ON RECEIPT
VISUAL CHECK
100%
STORES REGISTER
DAMAGED INSULAOTRS ARE TO BE STACKED SEPARATELY
3) PROPER STORAGE 1) CHECK THREADING OVER THE PINS AND INSULATOR THIMBLES AND CHECK THE ALIGNMENT OF PIN WITH INSULATOR 2) ASSEMBLING THE GI PIN AND INSULATORS
VISUAL CHECK
100%
STORES REGISTER
VISUAL CHECK
100%
SITE REGISTER AT GROUND LEVEL THIS PREASSEMBLY CHECK IS DONE FOR PROPER ASSEMBLY
VISUAL
100%
APPROVED DRAWING
APPROVED DRAWING ON ALL THE POLES IN THE STRAIGHT LINE PIN INSULATORS SHALL BE USED. DISC INSULATORS ARE USED AT DEAD END AND ANGLED LOCATIONS FOR CHECKING THE CLEARANCES SUITABLE TEMPLATE/ JIGS ARE TO BE USED
3) FIXING THE PIN INSULATOR TO THE CROSSARMS AND POLE TOP BRACKET
VISUAL CHECK
100%
SITE REGISTER
4) CHECK THE CLEARANCES BETWEEN THE INSULATORS
DIMENSIONAL
RANDOM
APPROVED DRAWING
SL.NO
CLASS OF CHECK
TYPE OF CHECK
QUANTUM OF CHECK
REFERENCE DOCUMENT
ACCEPTANCE NORMS
FORMAT OF RECORD
RE MARKS
FIELD QUALITY PLAN

PROJECT / UTILITY : CONTRACT No. CONTRACTOR : PACAKAGE: ITEM : SUB SYSTEM : QAP NO. : REV. NO.: DATE : Type of Check
3
ERECTION WORK ISO/AB SWITCH/ DOFUSE
Sr. No.
1 1 1.1 1.2 1.3 1.4 2 2.1 2.2 2.3 2.4 3 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8
2 RECEIPT & STORAGE Receiving inspection (Completeness of documents, test certificates, instruction manual etc.) Unloading Visual exmination for damage & defects Proper storage PRE INSTALLATION Availability of instruction manual and drawing, lifting arrangement Availability of all materials Foundation (If required) Vertically of support structure INSTALLATION Rating plate details Check for proper slinging & lifting Check for the tightness of base bolts & other bolted joints by torque wrench. Check level & alignment of the base, housing assembly and flangs. Ensure proper erection of poles, main blade & drive assembly as per approved drgs. Check for the alignment of isolator and verticality of isolator / AB switch / DO Fuse. Check for the clearance between live part to earth. Check for no vibration or rotation of contacts of insulators during isolator operation. (Electrical & Mechanical)
Instruments
4
Class
5

6 7
Format Of Records
8
V V V V
B B B B
100% 100% 100% 100%
MRC / Check List / ISO / 03 -
V V V V
B B B B
100% 100% 100% 100%
V V V V V V V V
B B B B B B B B
100% 100% 100% 100% 100% 100% 100% 100%
instruction manual Instruction Manual Instruction Manual Instruction Manual Instruction Manual Instruction Manual As per IS 10118 Instruction Manual
Site record Site record Site record -
Page 1 of 4
FIELD QUALITY PLAN

Sr. No.
3.9
Check for the provision of earthing and earth connection.
Type of Check
V
Instruments
-
Class
B

100% Instruction Manual
Format Of Records
-
Check operation of the isolator by rotating one of the insulator stack manually and adjust the length of the 3.10 crossed tandem assembly to ensure proper engagement of contacts during closign.
100%
Instruction Manual
4
4.1 4.2 4.3 4.4 4.5
PRE COMMOSSIONING Check for visual damage to any parts including porcelain isolator. Check manual / operation and inter locks. IR Value a. Between each pole to earth. Ground connections Check continuity
V V Test V Electrical
Megger Multimeter
B B B B B
100% 100% 100% 100% 100%
Instruction Manual Instruction Manual Instruction Manual Instruction Manual Instruction Manual
TC TC TC TC Site Record
Legends : CLASS OF CHECK: A -- CRITICAL -- TO BE WITNESSED BY NESCL SITE AND SURVEILLANCE BY NESCL, CC. B -- MAJOR -- TO BE WITNESSED BY CONTRACTOR AND NESCL SITE C-- MINOR -- TO BE WITNESSED BY CONTRACTOR AND SURVEILLANCE BY NESCL SITE TC : Test Certificate MRC : Material Reciept Certificate V : Visual Page 2 of 4 EIC : Engineer In Charge
FIELD QUALITY PLAN
CTION WORK AB SWITCH/ DOFUSE
Remarks
9
Page 3 of 4
FIELD QUALITY PLAN

Remarks
SIGN OF APPROVING AUTHORITY
Page 4 of 4
FIELD QUALITY PLAN

PROJECT / UTILITY : CONTRACT No. CONTRACTOR : PACKAGE: ITEM : SUB SYSTEM : QAP NO. : REV. NO.: DATE : Type of Check
3
ERECTION WORK Lighning Arrestor
Sr. No.
1 1
1.1 1.2 1.3 1.4
2 RECEIPT & STORAGE Receiving inspection (Completeness of documents, test certificates, instruction manual etc.) Unloading Visual exmination for damage & defects Proper storage PRE INSTALLATION Availability of instruction manual and drawing, lifting arrangement
Availability of all materials Vertically of support structure
Instruments
4
Class
5
Quantum/ Reference Documents Format Of Frequency & Acceptance Standard Records

6 7 8
V V V V
B B B B
100% 100% 100% 100%
Delivery Challan & NESCL Specification Instruction Manual Packing list / Instruction Instruction Manual
MRC / Check List / LA / 04 -
2
2.1 2.2 2.3
V V V
B B B
100% 100% 100%
List of approved drawing / Instruction Manuals Packing list, Approved drawing & Bill Of Material GA/ Structural drawing
3 3.1
3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9
INSTALLATION Rating plate details Check cleanliness of surfaces of the arrester and check Megger value. Check base of the surge arrestor. Check the tightness of equipment base with structure. Ensure that the explosion vent of the LA is away from adjacent critical equipment.
Check earthing provision and connection tightness. Check clearance between live part to earth part. Check overall alignment of LA. Mounting height of LA
V Test V V V V V V Measure
Meggar -
B B B B B B B B B
100% 100% 100% 100% 100% 100% 100% 100% 100%
instruction manual Instruction manual Instruction manual Instruction manual Instruction manual Instruction manual Instruction manual Instruction manual Instruction manual
Site record Site record
Page 1 of 4
FIELD QUALITY PLAN

Sr. No.
4 4.1 4.2 4.3 4.4
PRE COMMISSIONING IR Value test Check for resistance of ground connection. Earth continuity test Final Document review
Type of Check
Test Test Test V
Instruments
Class
Quantum/ Reference Documents Format Of Frequency & Acceptance Standard Records

100% 100% 100% 100% Instruction manual Instruction manual Instruction manual instruction manual / final document list TC TC TC TC
Meggar Earth Megger -
A B B B
Legends :
CLASS OF CHECK: A -- CRITICAL -- TO BE WITNESSED BY NESCL SITE AND SURVEILLANCE BY NESCL, CC. B -- MAJOR -- TO BE WITNESSED BY CONTRACTOR AND NESCL SITE C-- MINOR -- TO BE WITNESSED BY CONTRACTOR AND SURVEILLANCE BY NESCL SITE TC : Test Certificate MRC : Material Reciept Certificate V : Visual EIC : Engineer In Charge
Page 2 of 4
FIELD QUALITY PLAN
RECTION WORK ghning Arrestor
Remarks
9
Page 3 of 4
FIELD QUALITY PLAN

Remarks
OF APPROVING AUTHORITY
Page 4 of 4
FIELD QUALITY PLAN-- PSCC POLES(11KV& LT), POLE EARTHING AND GUY ERECTION
Item: PSCC Poles(11KV& LT) Sub-system: POLE ERECTION ,EARTHING, GUY ERECTION
CLASS OF CHECK TYPE OF CHECK QUANTUM OF CHECK REFERENCE DOCUMENT ACCEPTANCE NORMS
QP No: REV.No: DATE: PAGE:

FORMAT OF RECORD RE MARKS
SL.NO
MAIN ACTIVITY& CHARACTERISTICS/INSTRUMENTS OPERATION
VISUAL
100%
SUPPLIER TC
CORRELATION OF THE LOT RECEIVED WITH THE TC BROKEN, DAMAGED POLES SHALL BE STACKED SEPARATELY
SUPPLIER TC
POLES WHICH ARE INSPECTED AND CLEARED BY NESCL SHALL ONLY BE ACCEPTED ON RECEIPT
VISUAL
100%
SITE REGISTER
3) PROPER STORAGE
VISUAL
100%
NESCL SPECIFICATION
1)POLES SHALL BE STACKED IN SUCH A MANNER THAT BROAD SIDE IS VERTICAL. 2)EACH TIER IN THE STACK IS SITE REGISTER SUPPORTED ON WOODEN SLEEPERS LOCATED AT 1.2Mtr APART, WOODEN SUPPORTS ALIGNED IN VERTICAL LINE.
1)POLES SHALL BE TRANSPORTED WITH BROAD FACES PLACED VERTICALLY 2)SUPPORTS ARE LOCATED AT 1.2Mtr APART THROUGH OUT THE LENGTH OF THE POLE 1)ENSURE APPROVED DRAWINGS FOR INSTALLATION OF THE POLES ARE AVAILABLE AT WORK PLACE 2)ENSURE ALL CONSTRUCTION SITE REGISTER MATERIAL LIKE BOULDERS, SAND , CEMENT , STONE CHIPS ARE ALSO AVAILABLE AT WORK PLACE ENSURE THE POLE COORDINATES ARE AVAILABLE IN THE SURVEY MAPS. SITE REGISTER
TRANSPORTATIO N OF POLES
TRANSPORTATION
VISUAL
100%
NESCL SPECIFICATION
PRE INSTALLATION
AVAILABILITY OF APPROVED DRAWINGS ALL CONSTRUCTIONAL MATERIAL.
VISUAL
100%
NESCL SPECIFICATION
AVAILABILITY OF ROUTE SURVEY MAP AT WORK PLACE
VISUAL
100%
ROUTE SURVEY REPORT
Page 1
4.INSALATION OF POLES
4.1.1) MANUAL EXCAVATION / CONTROLLED BLASTING EXCAVATION OF PIT NESCL SPECIFICATION PIT LONGITUDINAL AXIS SHOULD BE IN THE DIRECTION OF THE LINE CONTROLLED BLASTING IS PERMITTED IN CASE OF HARD OR ROCKY SOILS (IN CASE OF INHABITED LOCATION DRILLING/CHIPPING TO BE RESORTED TO) IN HARD ROCK LOCATIONS ONE Mtr. DEEP HOLE AND Dia OF 1.2 TIMES THE BOTTOM DIMENSION OF THE POLE. IN CASE OF BLACK COTTON & WET SOILS PLANTING DEPTH INCREASED BY 0.2 Mtr EQUIVALENT SIZE STONE PLATE CAN ALSO BE USED WHERE EVER FOUND ECONOMICAL
VISUAL
100%
SITE REGISTER
4.1
4.1.2 )SIZE OF PIT
DIMENSIO NAL
100%
NESCL SPECIFICATION
0.6M X 1.2M (OR) 0.6Dia X 1.5M Depth
SITE REGISTER
4.1.3) PLANTING DEPTH IN GROUND BASE FOUNDAT ION
DIMENSIO NAL
100%
NESCL SPECIFICATION TECHNICAL SPECIFICATION / REC CONSTRUCTION STANDARD K-1
1.5M TOP OF THE PRE-CAST SLAB
SITE REGISTER
4.2
BASE CONCRETE OF M-15 GRADE SIZE 0.45M X 0.45M X 0.075M
MEASURE MENT
100%
NESCL SPECIFICATION
SITE REGISTER
4.3.1) POLE ERECTION
VISUAL
100%
NESCL SPECIFICATION
1)POLES SHALL BE LIFTED TO THE PIT WITH THE HELP OF WOODEN SUPPORTS 2)THE POLE SHALL BE KEPT IN VERTICAL POSITION WITH THE HELP 25mm MANILA ROPES. NESCL SPECIFICATION SITE REGISTER TEMPORARY ANCHORS SHALL BE REMOVED ONLY AFTER THE POLE IS SET IN THE FOUNDATION AFTER COMPACTING THE SOIL.
4.3.2) ALIGNMENT & VERTICALITY IN THE BOTH DIRECTIONS POLE ERECTION
SPIRIT LEVEL
100%
NESCL SPECIFICATION
4.3.3) BACK FILLING WITH BRICK BATS AND COMPACTED IN LAYERS
VISUAL
100%
NESCL SPECIFICATION
NESCL SPECIFICATION
SITE REGISTER
4.3
4.3.4) CONCRETING OF FOUNDATIONS (1:2:4) AT CERTAIN POLE LOCATION
MEASURE EMENT
100%
NESCL SPECIFICATION
0.3 Cb.mm OF CONCRETE PER POLE
AT ALL TAPPING POINTS, DEAD END POLES, AT DT LOCATIONS, AT ALL POINTS AS PER REC CONSTRUCTION DRAWING No:A10 AT 1Km OF LAST JAMA SITE REGISTER FILLED STRUCTURE, BOTH SIDE POLES OF NALLA CROSSINGS, ROAD CROSSING, RAILWAY CROSSINGS, AT DP , 4P STRUCTURE AND WITH RAIL POLES. ALL 11KV POLES & LT POLES SHALL BE EARTHED WITH COIL TYPE EARTHING EXCEPT AT LOCATIONS REFERRED AT 5.2
EARTHING OF POLE
5.1) COIL TYPE EARTHING
VISUAL
100%
NESCL SPECIFICATION
REC CONSTRUCTION STANDARD J-1
SITE REGISTER
5.2) PIPE/ ROD TYPE EARTHING
VISUAL
100%
NESCL SPECIFICATION
REC CONSTRUCTION STANDARD J-2
AT BOTH SIDES OF RAILWAY SITE REGISTER ,ROAD, DRAIN, TELECOM, RIVER CROSSINGS
Page 2
6.1) EXCAVATION OF PIT SIZE (DIA600 X 1500 mm) COIL TYPE EARTHING INSTALLATION 6.2)INSTALEARTHING SPIRAL 6.3) FILL THE PIT WITH ALTERNATE LAYERS OF 300mm WITH CHARCOAL AND SALT UPTO 1.2 Mtr.OF DEPTH FROM BOTTOM OF THE PIT. 6.4) CONNECTION BETWEEN THE SPIRAL WIRE AND POLE EARTH WIRE 7.1) EXCAVATION OF PIT SIZE BY 0.6M Dia X 2.7M DEPTH 7.2) INSTALL 40 Dia GI PIPE WITH 12 Dia HOLES IN THE PIT.
C C
VISUAL/DI MENSION VISUAL
100% 100%
NESCL SPECIFICATION
REF: REC CONSTRUCTION STANDARD -J-1
SITE REGISTER ENSURE THE SPIRAL WIRE IS 4mm GI WIRE
VISUAL
100%
VISUAL
100% NESCL SPECIFICATION REF: REC CONSTRUCTION STANDARD- J-2
C C
VISUAL VISUAL
100% 100%
SITE REGISTER
PIPE TYPE EARTHING INSTALLATION
7.3) FILL THE PIT WITH ALTERNATE LAYERS OF 300mm CHAR COAL AND SALT.
7.4) CONNECTION BETWEEN THE PIPE AND POLE WITH 8mm SWG WIRE
VISUAL
100%
VISUAL
100% THE GUY SETS ARE ERECTED AT ANGLE LOCATIONS , DEAD END LOCATIONS , T - Off POINTS , STEEP GRADIENT LOCATIONS, DOUBLE POLE STRUCTURES.
8.1) LOCATION FOR THE GUY SETS
VISUAL
100%
NESCL Specification /REC GUIDELINES IS:5613
NESCL SPECIFICATION
8.2) EXCAVATION OF PIT SIZE 0.5M X 0.5M X 1.6M STAY / GUY ERECTION 8.3)SIZING OF ANCHOR PLATE 8.4)GROUTING OF ANCHOR PLATE AND ANCHOR ROD WITH EARTH FILLING 8.5)ANGLE BETWEEN STAY WIRE AND POLE 8.6)ERECTION OF GUY INSULATOR
C C
DIMENSIO NAL DIMENSIO NAL DIMENSIO NAL
100% 100%
NESCL SPECIFICATION NESCL SPECIFICATION NESCL SPECIFICATION NESCL SPECIFICATION NESCL SPECIFICATION
REC CONSTRUCTION STANDARD G-1 REC CONSTRUCTION STANDARD K-1 NESCL SPECIFICATION IF GUY WIRE IS FOUND HAZARDOUS IT SHOULD BE PROTECTED WITH ASBESTOS PIPE FILL WITH CONCRETE
100%
MEASURE EMENT
VISUAL
100%
REC CONSTRUCTION STANDARD G-1 REC CONSTRUCTION STANDARD G-1 GUY INSULATORS ARE ERECTED AT HEIGHT OF 3050 mm FROM THE GROUND . TURN BUCKLE ARE MOUNTED HALF WAY IN THE WORKING POSITION , THUS GIVING THE Max. MOVEMENT FOR TIGHTENING AND LOOSENING
100%
8.7) ERECTION TURNBUCKLE
VISUAL
100%
NESCL SPECIFICATION
REC CONSTRUCTION STANDARD G-1
Page 3
Page 4
FIELD QUALITY PLAN

PROJECT / UTILITY : CONTRACT No. CONTRACTOR : PACKAGE: Sr. No.
1 1.1 1.2 1.3
ITEM : ERECTION WORK SUB SYSTEM : Safe Dismantling QAP NO. : REV. NO.: DATE : Instruments Class Type of Check Quantum/ Frequency Reference Documents Acceptance Standard Format Of Records Remarks

Safe Dismanteling of existing non operational equipments. Request/ formalities for shut down Disconnection of jumpers after taking shut down. Dismanteling of equipment from plinth.
Spanners Handeling equipment
C A B
Physical Physical
100% 100% 100%
PO PO
As per EIC As per EIC
Site Register Site Register
CONTRACTOR'S SIGNATURE Legends : CLASS OF CHECK: A -- CRITICAL -- TO BE WITNESSED BY NESCL SITE AND SURVEILLANCE BY NESCL, CC. B -- MAJOR -- TO BE WITNESSED BY CONTRACTOR AND NESCL SITE C-- MINOR -- TO BE WITNESSED BY CONTRACTOR AND SURVEILLANCE BY NESCL SITE TC : Test Certificate MIR : Material Inspection report MRC : Material Reciept Certificate V : Visual W : Witness EIC : Engineer In Charge

Item: ERECTION OF BPL CONNECTION Sub-system:
FIELD QUALITY PLAN
SECTION 1 : BOUGHT OUT ITEMS OF BPL CONNECTION

SL.NO MAIN ACTIVITY& OPERATION RECEIPT AND STORAGE CHARACTERISTICS/INSTRUMENTS 1) RECEIPT AT STORES 2) VISUAL INSPECTION 3) PROPER STORAGE CLASS OF CHECK C C C TYPE OF CHECK VISUAL CHECK VISUAL CHECK VISUAL CHECK QUANTUM OF CHECK 100% 100% 100% REFERENCE DOCUMENT ACCEPTANCE NORMS FORMAT OF RECORD STORES REGISTER STORES REGISTER STORES REGISTER THE METER BOARD SHALL BE OF TEAK WOOD QUALITY OR HARD WOOD RE MARKS
APPROVED BOM AND APPROVED MAKE OF THE ITEM APPROVED DRAWING DAMAGED AND DEFECTIVE COMPONENTS ARE TO BE REPLACED WITH GOOD ONE STANDARD PRACTICE STANDARD PRACTICE
SECTION : 2 FIXING OF BOARDS AND ACCESSORIES

FIXING OF BOARDS AND ACCESSORIES 1) IDENTIFYING AND MARKING THE POSITIONS WHERE THE COMPONENTS ARE TO BE ERECTED C VISUAL CHECK 100% AS PER NESCL SPECIFICATION AS PER NESCL SPECIFICATION AS PER NESCL SPECIFICATION AS PER NESCL SPECIFICATION AS PER APPROVED DRAWING SITE REGISTER CLEARANCE SHALL BE MAINTAINED AS PER APPROVED DRAWING AND AS PER SPECIFICATION THE SURFACE OF ALL SITE REGISTER SUPPORTS SHOULD BE CLEANED . SITE REGISTER SITE REGISTER
2) FIXING THE SERVICE SUPPORTS AND GUYS 3) FIXING OF THE WOODEN BOARDS ( METER BOARD AND SWITCH BOARD ) 4) FIXING OF ALL OTHER ACCESSORIES
C C C
VISUAL CHECK DIMENSIONAL VISUAL CHECK
100% 100% 100%
AS PER APPROVED DRAWING AS PER APPROVED DRAWING AS PER APPROVED DRAWING
SECTION : 3 STRINGING OF SERVICE CABLE

1) HANDLING OF THE CABLE STRINGING OF SERVICE CABLE C VISUAL CHECK 100% NESCL SPECIFICATION CABLE SHOULD NOT BE DRAGGED ON THE GROUND CABLE SURFACE SHALL BE SITE REGISTER FREE FROM FAULTS, FLAWS e.t.c
2) SEQUENCE OF CABLE ERECTION
VISUAL CHECK
100%
3) FIX THE G.I WIRE OF SERVICE CABLE TO CLAMPS 4) CHECK THE TIGHTNESS OF SERVICE CABLE WITH CLAMPS 5) CHECK THE GROUND CLEARANCES AFTER ERECTION OF THE SERVICE CABLE
C C C
VISUAL CHECK VISUAL CHECK VISUAL CHECK
100% 100% 100%
SEQUENCE OF RUNNING OUT SHALL BE FROM TOP TO BOTTOM, i.e.. THE TOP CABLE NESCL SPECIFICATION SHALL RUN OUT FIRST, FOLLOWED BY THE SIDE CABLES NESCL SPECIFICATION / NESCL SPECIFICATION / AS AS PER APPROVED PER APPROVED DRAWING DRAWING AS PER THE STANDARD NESCL SPECIFICATION PRACTICE AS PER THE REC SPECIFICATIONS AS PER IE RULES
SITE REGISTER
SITE REGISTER SITE REGISTER THE MINIMUM GROUND SITE REGISTER CLEARANCES SHOULD BE MAINTAINED
SECTION : 4 EARTHING ARRANGEMENT

EARTHING ARRANGE MENT 1) LOCAL EARTHING OF BPL HOUSE HOLD 2) EARTHING OF GI SUPPORT WIRE C C VISUAL CHECK VISUAL CHECK 100% 100% 4 STANDARD PRACTICE / IS 3043 STANDARD PRACTICE / IS 3043 IS 3043 IS 3043 SITE REGISTER SITE REGISTER
SECTION : 5 CHARGING OF BPL CONNECTION

CHARGING OF BPL CONNECTION 1) CHECK THE CONTINUITY OF CONNECTION C C 2) CONNECTION OF SERVICE LINE TO THE POLE 3) CHARGING OF SERVICE CONNECTION C VISUAL CHECK 100% STANDARD PRACTICE STANDARD PRACTICE TEST VISUAL CHECK 100% 100% STANDARD PRACTICE STANDARD PRACTICE STANDARD PRACTICE STANDARD PRACTICE SITE REGISTER TAKE LINE CLEAR ON POLE SITE REGISTER FROM WHICH SERVICE LINE TO BE TAPPED SITE REGISTER CHECK FOR ANY ABNORMALITIES AT THE BOARD
FIELD QUALITY PLAN - STEEL STRUCTURE

PROJECT / UTILITY : CONTRACT No. CONTRACTOR : PACKAGE: ITEM : SUB SYSTEM : QAP NO. : REV. NO.: DATE : Type of Instrume Check nts 3 4 Quantum/ Frequency 6 Reference Documents & Acceptance Standard 7
ERECTION WORK STEEL STRUCTURE
Sr. No. 1
1 1.1 1.2 1.3 1.4 2 2.1 2.2
CHARACTERISTICES / ITEMS 2
RECEIPT & STORAGE Receiving inspection of structure & hardware. Unloading Visual exmination for damages & defects Proper storage PRE INSTALLATION Check material for completeness Verification for necessary identification mark on each structure ERECTION STRUCTURE ERECTION Check for assembly and orientation of sructure as per approved drawing. Check that all joints have been properly made with proper size of bolts and nuts, cover plates and filler washer. Verify all bolts and nuts have been properly tightened. Check that step bolts have been fixed and tighten Check for the alignment of the structure. Check for any beding / sagging of beams / columns. Check earthing of structures
Class 5
Format Of Records 8
MRC / Check List / SS /102 -
Remarks 9
V V V V
B B B B
100% 100% 100% 100%
V V
B B
100% 100%
Packing list/App. Drg./BOM Packing list/App. Drg./BOM
1 1.1 1.2 1.3 1.4 1.5 1.6 1.7
V V V V V V V
B B B B B B B
Random 100% 100% 100% 100% 100% 100%
NESCL Specification/Appd drawing NESCL Specification/Appd drawing NESCL Specification NESCL Specification NESCL Specification/Appd drawing NESCL Specification NESCL Specification
CONTRACTOR'S SIGNATURE Legends : CLASS OF CHECK: A -- CRITICAL -- TO BE WITNESSED BY NESCL SITE AND SURVEILLANCE BY NESCL, CC. B -- MAJOR -- TO BE WITNESSED BY CONTRACTOR AND NESCL SITE C-- MINOR -- TO BE WITNESSED BY CONTRACTOR AND SURVEILLANCE BY NESCL SITE MRC : Material Reciept Certificate Page 1 of 1
FIELD QUALITY PLAN - STEEL STRUCTURE

V : Visual
Page 2 of 2
FIELD QUALITY PLAN
PROJECT / UTILITY : CONTRACT No. CONTRACTOR : PACKAGE:
ITEM : SUB SYSTEM : QAP NO. : REV. NO.: DATE : Type of Check 3 Quantum/ Frequency 6 Reference Documents & Acceptance Standard 7
ERECTION WORK Vacuum Circuit Breaker
Sr. No. 1
1 1.1 1.2 1.3 1.4 2 2.1 2.2 2.3 2.4 3 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 4 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10
CHARACTERISTICS / ITEMS 2
RECEIPT & STORAGE Receiving inspection (Completeness of documents, test certificates, instruction manual etc.) Unloading Visual exmination for damage and defects Proper storage PRE INSTALLATION Availability of instruction manual and drawing, lifting arrangement Availability of all materials VCB foundation VCB Support structure ( Level & Verticality ) INSTALLATION Before erection check adequacy of lifting device. Ensure that breaker are erected with proper handling equipment, check slings, dereck/tripod & rope . Ensure erection has been done as per approved drawing and manual. Check for Individual pole and CB alignment. Check for the tightness of pole base bolt with structure. Check for the checknut tightness of tie rod. (if applicable) Check for cable termination, ferrules and cable tags are provided (with proper lugs and glands) Lubricate all the moving parts of the CB. Earthing of support structure & VCB frame. PRE-COMMISSIONING Check correct installation of circuit breaker & operating mechanism as per instruction manual. Insulation resistance of each pole Insulation resistance of control circuits, motor etc. Resistance of closing & tripping coils. Minimum pick up volts of coils Contact resistance Breaker closing & tripping time Functional checking of all accessories. Functional checking of control circuits, tripping through protective relays and auto reclose operation. Final document review
Instruments 4
Class 5
Format Of Records 8
Remarks 9
V V V V
B B B B
100% 100% 100% 100%
MRC / Check List / VCB / 01 -
V V V V
B B B B
100% 100% 100% 100%
List of Approved drawing/ Instruction Manual Packing list ,Approved drawing & Bill of Material Civil foundation drawing GA/ Structural drawing
V V V V V V V V V
B B B B B B B B B
100% 100% 100% 100% 100% 100% 100% 100% 100%
instruction manual instruction manual GA / equipment detail drawing instruction manual instruction manual instruction manual instruction manual instruction manual instruction manual
V Test Test Test Test Test V Test Test V
Megger Megger Multimeter Multimeter Multimeter Multimeter Multimeter -
B A A A A A A B B B
100% 100% 100% 100% 100% 100% 100% 100% 100% 100%
instruction manual instruction manual instruction manual instruction manual instruction manual instruction manual instruction manual instruction manual instruction manual instruction manual/final document list
TC TC TC TC TC TC TC TC TC
Page 1 of 1
FIELD QUALITY PLAN - PAINTING

PROJECT / UTILITY : CONTRACT No. CONTRACTOR : PACAKAGE: ITEM : SUB SYSTEM : QAP NO. : REV. NO.: DATE : ERECTION WORK PAINTING
Sr. No. 1
1 1.1 1.2 2 2.1 2.2 2.3 2.4 2.5
RECEIPT & STORAGE Recveiving inspection Proper storage PAINTING De rusting from structutres & other rusted part of the equipment Red oxide zinc chromate paint on steel structures Two Coats Synthetic enamel paint - Two Coats or more coats Aluminimum Paint - Two Coats or more coats Final document review
Type of Check 3
Instruments 4
Class 5
Quantum/ Reference Documents & Format Of Frequenc Acceptance Standard Records y 6 7

Delivery Challan & NESCL Specification Delivery Challan & NESCL Specification
Remarks 9
8
MRC / Check List / P / 13 Site Records
V V
C C
100% 100%
V V V V -
Wire Brush, emery paper Paint brush Paint brush Paint brush -
B B B B B
100% 100% 100% 100% 100%
As per EIC As per EIC / IS 2074 As per EIC / IS 2932 As per EIC / IS 2339 Final document list
Site Records Site Records Site Records Site Records
CONTRACTOR'S SIGNATURE Legends : CLASS OF CHECK: A -- CRITICAL -- TO BE WITNESSED BY NESCL SITE AND SURVEILLANCE BY NESCL, CC. B -- MAJOR -- TO BE WITNESSED BY CONTRACTOR AND NESCL SITE C-- MINOR -- TO BE WITNESSED BY CONTRACTOR AND SURVEILLANCE BY NESCL TC : Test Certificate MRC : Material Reciept Certificate V : VISUAL
Page 1 of 1
FIELD QUALITY PLAN--ERECTION OF 11KV POLE ACCESSORIES

Item: ERECTION OF 11KV POLE ACCESSORIES Sub-system: G.I COMPONENTS, INSULATORS ,HARDWARE FITTINGS, DANGER BOARDS, ANTI CLIMBING DEVICES, GUARDING FQP No: REV.No: DATE: PAGE:
MS GALVANIZED COMPONENTS
MAIN SL.NO ACTIVITY& OPERATION CHARACTERISTICS/ INSTRUMENTS CLASS OF CHECK TYPE OF CHECK QUANTUM OF CHECK REFERENCE DOCUMENT ACCEPTANCE NORMS FORMAT OF RECORD RE MARKS COMPONENTS WHICH ARE INSPECTED AND CLEARED BY NESCL SHALL ONLY BE ACCEPTED ON RECEIPT
VISUAL CHECK
100%
CHP DOCUMENT
CORRELATION OF THE LOT RECEIVED WITH THE CHP DESCRIPTIONS
STORES REGISTER
VISUAL CHECK
100%
DAMAGED AND GALVANIZATION DEFECTIVE COMPONENTS ARE TO BE STACKED SEPARATELY ALL G.I. COMPONENTS SHOULD BE STACKED ON WOODEN SLEEPERS AND THE STORAGE AREA SHALL BE FREE FROM WATER LOGGING
STORES REGISTER
3) PROPER STORAGE
VISUAL CHECK
100%
STANDARD PRACTICE
STORES REGISTER
1) V- CROSS ARM WITH CROSS ARM BACK CLAMP FIXING OF MS COMPONENTS
VISUAL CHECK
100%
SITE REGISTER
CROSS ARMS ARE TO BE FIXED AT THE MARKINGS PROVIDED ON THE POLES
2) HORIZONTAL ALIGNMENT OF CROSS ARMS WITH POLE 3) TOP CLEAT WITH BACK CLAMP 4) VERTICAL ALIGNMENT OF TOP CLEAT WITH POLE 5) TIGHTENING MS COMPONENTS WITH NUTS, BOLTS AND WASHERS
WATER LEVEL
100%
APPROVED DRAWING
APPROVED DRAWING
VISUAL CHECK
100%
SITE REGISTER
TOP CLEATS ARE TO BE FIXED AT THE MARKINGS PROVIDED ON THE TOP OIF THE POLE
WATER LEVEL
100%
APPROVED DRAWING
APPROVED DRAWING
ERECTION CHECK
100%
THE COMPONENTS SHOULD BE APPROVED DRAWING FIXED RIGID ENOUGH TO WITH STAND ALL THE FORCES
SITE REGISTER
SL.NO
CLASS OF CHECK
TYPE OF CHECK
QUANTUM OF CHECK
REFERENCE DOCUMENT
ACCEPTANCE NORMS
FORMAT OF RECORD
RE MARKS
INSULATORS WITH PINS

RECEIPT AND STORAGE 1) RECEIPT AT STORES C VISUAL CHECK 100% CHP DOCUMENT CORRELATION OF THE LOT RECEIVED WITH THE CHP DESCRIPTIONS SITE REGISTER COMPONENTS WHICH ARE INSPECTED AND CLEARED BY NESCL SHALL ONLY BE ACCEPTED ON RECEIPT
VISUAL CHECK
100%
THE SURFACE OF THE INSULATORS ARE TO BE THOROUGHLY CHECKED AND CLEANED, THREADING OF THE INSULATOR THIMBLE TO BE CHECKED STANDARD PRACTICE
STORES REGISTER
DAMAGED INSULAOTRS ARE TO BE STACKED SEPARATELY
3) PROPER STORAGE 1) CHECK THREADING OVER THE PINS AND INSULATOR THIMBLES AND CHECK THE ALIGNMENT OF PIN WITH INSULATOR 2) ASSEMBLING THE GI PIN AND INSULATORS
VISUAL CHECK
100%
STORES REGISTER
VISUAL CHECK
100%
SITE REGISTER AT GROUND LEVEL THIS PREASSEMBLY CHECK IS DONE FOR PROPER ASSEMBLY
VISUAL
100%
APPROVED DRAWING
APPROVED DRAWING ON ALL THE POLES IN THE STRAIGHT LINE PIN INSULATORS SHALL BE USED. DISC INSULATORS ARE USED AT DEAD END AND ANGLED LOCATIONS FOR CHECKING THE CLEARANCES SUITABLE TEMPLATE/ JIGS ARE TO BE USED
3) FIXING THE PIN INSULATOR TO THE CROSSARMS AND POLE TOP BRACKET
VISUAL CHECK
100%
SITE REGISTER
4) CHECK THE CLEARANCES BETWEEN THE INSULATORS
DIMENSIONAL
RANDOM
APPROVED DRAWING
PROJECT / UTILITY : CONTRACT No. CONTRACTOR : PACAKAGE: Sr. No.

1 1 1.1 1.2 1.3 1.4 2 2.1 2.2 2.3 3 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8
ITEM : SUB SYSTEM : QAP NO. : REV. NO.: DATE : Type of Check
3
ERECTION WORK DC SYSTEM
2 RECEIPT & STORAGE Receiving inspection (Completeness of documents, test certificates, instruction manual etc.) Unloading Visual exmination for damage & defects Proper storage PRE INSTALLATION Availability of instruction manual and drawing, lifting arrangement Availability of all materials Completion of civil / ventilation requirement of battery room. INSTALLATION - BATTERY Rating plate details Check availability of safety devices, water and first aid box. Check installation of batteries and rack as per approved layout. Check the specific gravity of the electrolyte prior to pouring in the cells. Check for availability of electrolyte level up to required level and there is no leakage. Check alignment and level of each cell Check for tightness inter cell connection and application of grease. Check for provision of earthing and tightness of earthing connection. Ensure cell are not earth any where.
Instruments
4
Class
5
Quantum/ Frequency
6

7
Format Of Records
8
Remarks
9
V V V V
B B B B
100% 100% 100% 100%
MRC / Check List / DC / 06 -
V V V
B B B
100% 100% 100%
List of approved drawing / Instruction Manuals Packing list, Approved drawing & Bill Of Material Control room detail
V V V
B B B
100% 100% 100%
instruction manual BOM / NESCL Specifcation Instruction Manual
Site record -
V V V V
B B B B
100% 100% 100% 100%
Instruction Manual Instruction Manual Instruction Manual Instruction Manual
3.9 3.10 3.11 3.12 4 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13 4.14 4.15 4.16
Check all cell no. are properly fixed and are visible. The cabling from Battery Charger to first, last and tap cells is completed. Check all the cells are connected in correct polarity. Painting of battery stand INSTALLATION - BATTERY CHARGER Rating plate details The quantity, ratings, type and make of the devices are as per the BOM as given in approved drawings. No physical damages are there in any devices of the panels and replacement of damaged parts. connection to the earthing grid are tightened properly. Fuses provided are of rating as shown in the approved drawings. Check that the labeling of devices is as per the approved drawings. Check the wiring is completed as per the approved drawings. External cabling and termination with glands is completed as per the Cable schedule. Cable tags, ferrules for cores are provided as per cable schedule. Dressing and clamping of cables is done properly. Check the phases sequence of the Mains supply to the battery charger. Check functioning of all relays/meters/selector switches etc. All alarms & annunciations, indications are functioning properly. Check the Float & Boost charger operation, set the o/p voltage (if reqd). Check the current limiting feature of charger & set the current limit (if reqd). IR Value check
V V V V
B B B B
100% 100% 100% 100%
Instruction Manual Instruction Manual Instruction Manual Instruction Manual
V V V V V V V V V V V V V V V Measure
B B B B B B B B B B B B B B B A
100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100%
instruction manual Instruction Manual Instruction Manual Instruction Manual Instruction Manual Instruction Manual Instruction Manual Instruction Manual Instruction Manual Instruction Manual Instruction Manual Instruction Manual Instruction Manual Instruction Manual Instruction Manual Instruction Manual
Site record -
5 5.1 5.2 5.3
PRE-COMMISSIONING Check that all the assembly activities are completed. The cabling from Battery Charger to first, last and tap cells is completed. Check the polarity of the DC connection from Battery charger to Battery. Check that the charging & discharging cycle is completed as per guidelines of manufacturer to prove battery AH capacity at 10 hr discharge rate. Recharge Final document review
V V Test
Multimeter
B B B
100% 100% 100%
Instruction Manual Instruction Manual Instruction Manual
TC TC Site Record
5.4 5.5 5.6
V Electrical V
A B B
100% 100% 100%
Instruction Manual/IS 1651 Instruction Manual Approved panel drawing / Final document list
TC Site record TC
CONTRACTOR'S SIGNATURE Legends : CLASS OF CHECK: A -- CRITICAL -- TO BE WITNESSED BY NESCL SITE AND SURVEILLANCE BY NESCL, CC. B -- MAJOR -- TO BE WITNESSED BY CONTRACTOR AND NESCL SITE C-- MINOR -- TO BE WITNESSED BY CONTRACTOR AND SURVEILLANCE BY NESCL SITE TC : Test Certificate MRC : Material Reciept Certificate V : Visual EIC : Engineer In Charge
FIELD QUALITY PLAN
PROJECT / UTILITY : CONTRACT No. CONTRACTOR : PACAKAGE:
ITEM : SUB SYSTEM : QAP NO. : REV. NO.: DATE : Type of Check 3 Quantum/ Reference Documents & Frequency Acceptance Standard 6 7
ERECTION WORK CT/ PT
Sr. No. 1
1 1.1 1.2 1.3 1.4 2 2.1 2.2 2.3 2.4 3 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13 3.14 4 4.1
RECEIPT & STORAGE Receiving inspection (Completeness of documents, test certificates, instruction manual etc.) Unloading Visual exmination for damage & defects Proper storage PRE INSTALLATION Availability of instruction manual and drawing, lifting arrangement Availability of all materials CT foundation Vertically of support structure INSTALLATION Rating plate details Check that the C.T. have been installed in proper polarity (P1 & P2 position) Check for the tightness of equipment base bolts with Check overall alignment of C.T. Check for the primary ratio connected as per requirement. Earthing of support structure & CT frame. Check provision of earthing and tightness of earthing connection. Check for the tightness of clamps/ connectors. Check for secondary termination tightness and crimping of leads. Check the cable tags and ferrules are provided Ensure that unused secondary core are correctly shorted. R,Y,B identification Check for oil leackages Check verticality of equipment on support structure PRE COMMISSIONING Measure IR value using meggar a. Primary to secondary cores and earth with 2.5 kV. b. Between secondary cores. c. Between secondary to earth.
Instruments 4
Class 5
Format Of Remarks Records 8

MRC / Check List / CT / 02 -
V V V V
B B B B
100% 100% 100% 100%
V V V V
B B B B
100% 100% 100% 100%
V V V V V V V V V V V V V V
B B B B B B B B B B B B B B
100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100%
instruction manual As per EIC/SLD instruction manual instruction manual Rating plate instruction manual instruction manual instruction manual instruction manual Cable schedule instruction manual instruction manual / No leackages instruction manual
Site record Site record Site record
Megger Test Test Test Test Test Test Multimeter/Dry cell Primary injection kit -
100%
instruction manual
TC
4.2 4.3 4.4 4.5
Check polarity. Check for CT ratio by primary Injection method. Magnetising curve Final document review
A A B B
100% 100% 100% 100%
instruction manual / SLD instruction manual instruction manual instruction manual/final document list
TC TC TC TC
Page 1 of 1
FIELD QUALITY PLAN
PROJECT / UTILITY : CONTRACT No. CONTRACTOR : PACAKAGE: . Sr. No.

1 1 1.1 1.2 1.3 1.4 2 2.1 2.2 2.3 3 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13 3.14 4 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9
3
ERECTION WORK Control & Relay Panel
2 RECEIPT & STORAGE Receiving inspection (Completeness of documents, test certificates, instruction manual etc.) Unloading Visual exmination for damage & defects Proper storage PRE INSTALLATION Availability of instruction manual and drawing, lifting arrangement Availability of all materials Panel inatallation space INSTALLATION Rating plate details Verticality & levelling of panels on support stuctures. Check earth bus connection Check the floor leveling where the panels are to be installed. Check the physical conditon of the panels after opening the packing and verify the material as per BOM. Ensure the panels are lifted using proper slings/ tackles. Check the panels are levelled, aligned and erected properly. Removal of top and side blanking plates. Inter panel wiring is comleted as per drawing. Check the tightness of inter panel nuts and bolts, Main bus, earth bus connection etc. Checked for broken glass, switch handle, lamp cover etc. Glanding of external cables Blanking of unused cable entry locks Proper sealing & locking arrangement of panel door PRE COMMISSIONING Circuit diagram check Auxiliary power supply test Functional & operation test of fittings on the panels. Relay settings as per recommendation Scheme check IR Value check Secondary injection test for relays Check minimum pick up & drop out voltage of all coils & auxiliary contacts Final document review
Instruments
4
Class
5
Quantum/ Frequency
6

7
Format Of Records
8
Remarks
9
V V V V
B B B B
100% 100% 100% 100%
MRC / Check List / CRP / 05 Site record Site record -
V V V
B B B
100% 100% 100%
List of approved drawing / Instruction Manuals Packing list, Approved drawing & Bill Of Material Control room detail
Site record Site record -
V Measure V V V V V V V V V V V V
B B B B B B B B B B B B B B
100% 100% 200% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100%
instruction manual instruction manual instruction manual As per site conditionss NESCL Specification Erection manual As per site conditionss Approved panel drawing Approved panel drawing Approved panel drawing Approved panel drawing Approved panel drawing Approved panel drawing Approved panel drawing
Site record Site record Site record Site record -
V Test V V V Electrical Electrical Electrical V
Multimeter Megger Injection kit Voltmeter -
B B B B B A A A B
100% 100% 100% 100% 100% 100% 100% 100% 100%
Approved panel drawing Approved panel drawing Approved panel drawing Approved panel drawing Approved panel drawing Instruction manual Instruction manual Instruction manual Approved panel drawing / Final document list
TC TC TC TC TC site record site record site record TC
CONTRACTOR'S SIGNATURE Legends : CLASS OF CHECK: A -- CRITICAL -- TO BE WITNESSED BY NESCL SITE AND SURVEILLANCE BY NESCL, CC. B -- MAJOR -- TO BE WITNESSED BY CONTRACTOR AND NESCL SITE C-- MINOR -- TO BE WITNESSED BY CONTRACTOR AND SURVEILLANCE BY NESCL SITE TC : Test Certificate MRC : Material Reciept Certificate V : Visual EIC : Engineer In Charge
Page 1 of 1
FIELD QUALITY PLAN

PROJECT / UTILITY : CONTRACT No. CONTRACTOR : PACKAGE: Sr. No.
1 1 1.1 1.2 1.3 1.4 2 2.1 2.2 2.3 2.4 3 3.1 3.2 3.3 3.4 3.5 4 4.1 4.2
3
ERECTION WORK LIGHTING
2 RECEIPT & STORAGE Receiving inspection (Completeness of documents, test certificates, etc.) Unloading Visual exmination for defect and damages Proper storage PRE INSTALLATION Availability of Catalouge / Leaflet Availability of all materials Readiness of lighting pole Check verticality of lighting poles & level of foundations INSTALLATION Proper angle/height fixing for lighting fixture to get desired lux level. Check for connection of light fitting and control accessories. Check for proper painting of lighting supporting structures and lighting pole. Check for mechanical protection of lighting cable. Check for proper identification of switches/ modules on LDB for different lighting area. COMMISSIONING Lighting adequacy Final document review
Instruments
4
Class
5
Quantum/ Frequency
6

7
Format Of Records
8
Remarks
9
V V V V
B B B B
100% 100% 100% 100%
MRC / Check List / L / 09 -
V V V V
B B B B
100% 100% 100% 100% 100%
List of catalogues & Leaflets Packing list, Approved Drawings & Bill of Material NESCL Specification NESCL Specification
Site Record
V V V V V
B B B B B
100% 100% 100% 100% 100%
NESCL Specification NESCL Specification NESCL Specification NESCL Specification NESCL Specification
V V
B B
100% 100%
NESCL Specification Final document list
CONTRACTOR'S SIGNATURE Legends : CLASS OF CHECK: A -- CRITICAL -- TO BE WITNESSED BY NESCL SITE AND SURVEILLANCE BY NESCL, CC. B -- MAJOR -- TO BE WITNESSED BY CONTRACTOR AND NESCL SITE C-- MINOR -- TO BE WITNESSED BY CONTRACTOR AND SURVEILLANCE BY NESCL SITE TC : Test Certificate V : Visual MRC : Material Reciept Certificate
Page 1 of 1
MANUFACTURERS NAME & ADDRESS
MANUFACTURING QUALITY PLAN

ITEM: THREE PHASE CT OPERATED STATIC ENERGY METER
TYPE OF CHECK
PROJECT/ UTILITY: PACKAGE : CONTRACT NO. : MAIN-SUPPLIER :
QP NO.: REV.NO.: DATE:
SL. NO
COMPONENTS
CHARACTERISTICS
CLASS
QUANTUM OF CHECK
REFERENCE DOCUMENT
ACCEPTANCE NORMS
FORMAT OF RECORD M
AGENCY
REMARKS C N
PCB
3 Visual Check for the following: Legend Marking Masking
P Single Sampling Level II of IS 2500 (PartI) (AQL=0.65) Major Visual / Electrical 2 from each lot 2 from each lot 100% AS per Specification Sheet for the component ----do-------do---BBT OK As Per Specification Sheet for the component AS per Specification Sheet for the component
** 10. V
11.
Dimension Electrical Testing Bare Board Testing
IQC Documents
P P V
V V V
V V V
Review of records of the at the time of Final Inspection
Shunts
Visual Check for Damages and twisting & Tinning of wires Major Resistance Value Dimensions
Visual / Electrical
Single Sampling Level II of IS 2500 (PartI) (AQL=0.65) ----do---10% of Sample Qty.
I.Q.C. Deptt. of ----do-------do---IQC Documents P V V Review of records of the at the time of Final Inspection
----do-------do----
Visual check for Damages, Twisting, Tinning of wire, Epoxy coating & Shielding CTs Electrical Tests: Inductance Resistance Output Voltage Dimensions Major Visual / Electrical
Single Sampling Level II of IS 2500 (PartI) (AQL=0.65) ----do----
AS per Specification Sheet for the component ----do----
I.Q.C. Deptt. of ----do---IQC Documents P V V Review of records of the at the time of Final Inspection
10% of Sample Qty
----do----
----do----
Page 1 of 9

L. O
COMPONENTS
CHARACTERISTICS
CLASS
TYPE OF CHECK
QUANTUM OF CHECK
REFERENCE DOCUMENT
ACCEPTANCE NORMS
FORMAT OF RECORD M
AGENCY REMARKS C ** 10. N 11.
3 Visual Check for Damage Colour
6 Single Sampling Level II of IS 2500 (PartI) (AQL=0.65)
7 As per Specification Sheet for the component ----do----
8 I.Q.C. Deptt. of ----do----
LED
Electrical Test: Forward Voltage Drop Reverse Voltage Drop Dimensions Visual Damage Coding Package Resistance value Tolerance Dimension
Major
Visual / Electrical
----do----
IQC Documents
10% of Sample Qty Single Sampling Level II of IS 2500 (PartI) (AQL=0.65) Major Visual / Electrical ----do---10% of Sample Qty
----do---As per Specification Sheet for the component
----do----
I.Q.C. Deptt. of IQC Documents P V V Review of records of the at the time of Final Inspection
Resistance
----do-------do----
----do-------do----
Page 2 of 9

L. O
COMPONENTS
CHARACTERISTICS
CLASS
TYPE OF CHECK
QUANTUM OF CHECK
REFERENCE DOCUMENT
ACCEPTANCE NORMS
FORMAT OF RECORD M
2 Visual Damage Package
7 As per Specification Sheet for the component ----do-------do---As per Specification Sheet for the component
8 I.Q.C. Deptt. of ----do-------do---I.Q.C. Deptt. of
Capacitor
Capacitance value Tolerance Dimension Visual Check for Damage Package Marking Diode Electrical Test: Forward Voltage Drop Reverse Voltage Drop Dimensions Visual Check for Damage Package Marking Zener Diode Electrical Test: Forward Voltage Drop Reverse Voltage Drop Zener Voltage Dimensions
Major
Visual / Electrical
----do---10% of Sample Qty Single Sampling Level II of IS 2500 (PartI) (AQL=0.65)
IQC Documents
Major
Visual / Electrical ---do---10% of Sample Qty Single Sampling Level II of IS 2500 (PartI) (AQL=0.65) ----do-------do---As per Specification Sheet for the component As per Specification Sheet for the component ----do-------do----
IQC Documents
Major ---do-------do----
IQC Documents
10% of Sample Qty
----do----
Page 3 of 9

TYPE OF CHECK
L. O
COMPONENTS
CHARACTERISTICS
CLASS
QUANTUM OF CHECK
REFERENCE DOCUMENT
ACCEPTANCE NORMS
FORMAT OF RECORD M
3 Visual Check for Damage Package Marking Electrical Test: Functional Dimensions Visual Check for Damage Marking Electrical Test: Functional Dimensions Visual Check for Damage Package
7 As per Specification Sheet for the component
ICs
Major
Visual / Electrical
---do---10% of Sample Qty Single Sampling Level II of IS 2500 (PartI) (AQL=0.65)
----do-------do---As per Specification Sheet for the component ----do-------do---As per Specification Sheet for the component
As per Specification Sheet for the component
IQC Documents
MOV
Major
Visual / Electrical
IQC Documents
Crystal Electrical Test: Functional Dimensions
Major
Visual / Electrical ---do---10% of Sample Qty ----do-------do----
IQC Documents
Page 4 of 9

L. O
COMPONENTS
CHARACTERISTICS
CLASS
TYPE OF CHECK
QUANTUM OF CHECK
REFERENCE DOCUMENT
ACCEPTANCE NORMS
FORMAT OF RECORD M
3 Visual Check for Damage No. of Digits Mounting Holes
6 Single Sampling Level II of IS 2500 (Part-I) (AQL=0.65) ---do----
Stepper Motor Counter
Electrical Test: HV Test Resistance Functional Boiling Water Test Dimensions
Major
Visual / Electrical
----do----
IQC Documents
2 from each Lot 10% of Sample Qty
----do-------do----
Page 5 of 9

L. O
OPERATIONS
CHARACTERISTICS
CLASS
TYPE OF CHECK
QUANTUM OF CHECK
REFERENCE DOCUMENT
ACCEPTANCE NORMS
FORMAT OF RECORD
AGENCY
REMARKS
PCB Inspection
Soldering Solder bridging or dry solder Components Mounting Polarity of components Functional Testing
Major
Visual
100% check and again 5 nos. randomly selected daily by Q.C.
Functionally OK
QC Documents
Counter & PCB Assembly
Counter alignment
Major
Visual
100% check and 5 nos. randomly selected daily by Q.C.
Reference Sample & Alignment should be proper
As per Specification Sheet for the component As per Specification Sheet for the component As per Specification Sheet for the component As per Specification Sheet for the component
QC Documents
Review of records of the at the time of Final Inspection Review of records of the at the time of Final Inspection
Assembled Base connection
Tightness of Connections Major Terminal Block Gasket Name Plate Marking Serial Number punching and control Name Plate position Cover fitment with base Visual
100% check and 5 nos. randomly selected daily by Q.C. 100% check and 5 nos. randomly selected daily by Q.C. 100% check and 5 nos. randomly selected daily by Q.C.
Reference Sample & Work Instructions
QC Documents
Name Plate
Major
Visual
As per NTPC Specification Reference Sample & Work Instructions
QC Documents
Cover Fixing
Major
Visual
QC Documents
Page 6 of 9

TYPE OF CHECK
L. O
CHARACTERISTICS OPERATIONS
CLASS
QUANTUM OF CHECK
REFERENCE DOCUMENT
ACCEPTANCE NORMS
FORMAT OF RECORD M
AGENCY REMARKS C ** 10. N 11. Review of records of the at the time of Final Inspection Review of records of the at the time of Final Inspection Review of records of the at the time of Final Inspection
2 Meter Calibration
3 Meter is calibrated by solder shorting in phase as well as neutral element
8 As per Specification Sheet for the component As per Specification Sheet for the component As per Specification Sheet for the component
Major
Electrical
100% check
Specified Standard
QC Documents
Temper Test
As per the requirements of specification
Major
Electrical
10 Nos. samples selected daily by Q.C.
As per NTPC Specification
QC Documents
Packing
Sealing Functional Testing of Meter
Major
Visual
Should be proper as per customer requirement
QC Documents
Page 7 of 9

L. O
OPERATIONS
CHARACTERISTICS
CLASS
TYPE OF CHECK
QUANTUM OF CHECK
REFERENCE DOCUMENT
ACCEPTANCE NORMS
FORMAT OF RECORD M
AGENCY REMARKS C ** 10. N 11. Review of Records of at the time of Final Inspection - do - do - do - do - do -
2 Routine Test
A.C. High Voltage Test Insulation Test Test on limits of Errors Test of Starting condition Test of no load condition Meter Constant Acceptance Test A. C. High Voltage Test Insulation Test Test on limits of Errors Test of Starting condition Test of no load condition Meter Constant
Critical Critical Critical Critical Critical Critical Critical Critical Critical Critical Critical Critical
Electrical Electrical Electrical Electrical Electrical Electrical Electrical Electrical Electrical Electrical Electrical Electrical
100% on each Meter 100% on each Meter 100% on each Meter 100% on each Meter 100% on each Meter 100% on each Meter As per IS : 14697 As per IS : 14697 As per IS : 14697 As per IS : 14697 As per IS : 14697 As per IS : 14697
IS : 14697 IS : 14697 IS : 14697 IS : 14697 IS : 14697 IS : 14697 IS : 14697 IS : 14697 IS : 14697 IS : 14697 IS : 14697 IS : 14697
QC Documents QC Documents QC Documents QC Documents QC Documents QC Documents Inspection Report Inspection Report Inspection Report Inspection Report Inspection Report Inspection Report
P P P P P P P P P P P P
V V V V V V w w w w w w
Page 8 of 9

L. O
OPERATIONS
CHARACTERISTICS
CLASS
TYPE OF CHECK
QUANTUM OF CHECK
REFERENCE DOCUMENT
ACCEPTANCE NORMS
FORMAT OF RECORD M
AGENCY REMARKS C ** 10. P P P P w w w w w w w w Type Test clearance from NESCL Engineering department To be done after Vibration Test N 11.
3 Test of repeatability of meter Test of Power Consumption Test on limits of Errors Anti-Tamper Tests
4 Critical Critical Critical Critical
5 Electrical Electrical Electrical Electrical
6 As per IS : 14697 As per IS : 14697 As per IS : 14697 As per NESCL Tech. Specs.
7 IS : 14697 IS : 14697 IS : 14697 IS : 14697
8 IS : 14697 IS : 14697 IS : 14697 IS : 14697
9 Inspection Report Inspection Report Inspection Report Inspection Report
Type Tests
All Type Tests as per IS : 14697
Critical
Electrical / Mech
As per IS : 14697
IS : 14697
IS : 14697
Inspection Report
end:
Manufacturer Contractor NTPC Electric Supply Company Ltd. C : Incoming Quality Control Perform Verify Witness
Page 9 of 9

ITEM: SINGLE PHASE WHOLE CURRENT ENERGY METER
TYPE OF CHECK
SL. NO
COMPONENTS
CHARACTERISTICS
CLASS
QUANTUM OF CHECK
REFERENCE DOCUMENT
ACCEPTANCE NORMS
FORMAT OF RECORD M
AGENCY REMARKS C ** 10. V N 11. V
PCB
3 Visual Check for the following: Legend Marking Masking Dimension Electrical Testing Bare Board Testing Visual Check for Damages and twisting & Tinning of wires
7 AS per Specification Sheet for the component ----do-------do---BBT OK As Per Specification Sheet for the component ----do-------do---AS per Specification Sheet for the component ----do----
9 P
Major
Visual / Electrical
2 from each lot 2 from each lot 100% Single Sampling Level II of IS 2500 (PartI) (AQL=0.65) ----do---10% of Sample Qty. Single Sampling Level II of IS 2500 (PartI) (AQL=0.65)
AS per Specification Sheet for the component
IQC Documents
P P V
V V V
V V V
I.Q.C. Deptt. of ----do-------do---I.Q.C. Deptt. of ----do---IQC Documents P V V Review of records of the at the time of Final Inspection IQC Documents P V V Review of records of the at the time of Final Inspection
Shunts
Major Resistance Value Dimensions Visual check for Damages, Twisting, Tinning of wire, Epoxy coating & Shielding
Visual / Electrical
CTs Electrical Tests: Inductance Resistance Output Voltage Dimensions
Major
Visual / Electrical
----do----
10% of Sample Qty
----do----
----do----
Page 1 of 9

SL. NO
COMPONENTS
CHARACTERISTICS
CLASS
TYPE OF CHECK
QUANTUM OF CHECK
REFERENCE DOCUMENT
ACCEPTANCE NORMS
FORMAT OF RECORD M
3 Visual Check for Damage Colour
7 As per Specification Sheet for the component ----do----
8 I.Q.C. Deptt. of ----do----
LED
Electrical Test: Forward Voltage Drop Reverse Voltage Drop Dimensions Visual Damage Coding Package Resistance value Tolerance Dimension
Major
Visual / Electrical
----do----
IQC Documents
10% of Sample Qty Single Sampling Level II of IS 2500 (PartI) (AQL=0.65) Major Visual / Electrical ----do---10% of Sample Qty
----do---As per Specification Sheet for the component
----do----
I.Q.C. Deptt. of IQC Documents P V V Review of records of the at the time of Final Inspection
Resistance
----do-------do----
----do-------do----
Page 2 of 9

SL. NO
COMPONENTS
CHARACTERISTICS
CLASS
TYPE OF CHECK
QUANTUM OF CHECK
REFERENCE DOCUMENT
ACCEPTANCE NORMS
FORMAT OF RECORD M
2 Visual Damage Package
7 As per Specification Sheet for the component ----do-------do---As per Specification Sheet for the component
8 I.Q.C. Deptt. of ----do-------do---I.Q.C. Deptt. of
Capacitor
Capacitance value Tolerance Dimension Visual Check for Damage Package Marking 7 Diode Electrical Test: Forward Voltage Drop Reverse Voltage Drop Dimensions Visual Check for Damage Package Marking 8 Zener Diode Electrical Test: Forward Voltage Drop Reverse Voltage Drop Zener Voltage Dimensions
Major
Visual / Electrical
----do---10% of Sample Qty Single Sampling Level II of IS 2500 (PartI) (AQL=0.65)
IQC Documents
Major
Visual / Electrical ---do---10% of Sample Qty Single Sampling Level II of IS 2500 (PartI) (AQL=0.65) ----do-------do---As per Specification Sheet for the component As per Specification Sheet for the component ----do-------do----
IQC Documents
Major ---do-------do----
IQC Documents
10% of Sample Qty
----do----
Page 3 of 9

TYPE OF CHECK
SL. NO
COMPONENTS
CHARACTERISTICS
CLASS
QUANTUM OF CHECK
REFERENCE DOCUMENT
ACCEPTANCE NORMS
FORMAT OF RECORD M
3 Visual Check for Damage Package Marking Electrical Test: Functional Dimensions Visual Check for Damage Marking Electrical Test: Functional Dimensions Visual Check for Damage Package
ICs
Major
Visual / Electrical
----do-------do---As per Specification Sheet for the component ----do-------do---As per Specification Sheet for the component
IQC Documents
10
MOV
Major
Visual / Electrical
IQC Documents
11
Crystal Electrical Test: Functional Dimensions
Major
Visual / Electrical ---do---10% of Sample Qty ----do-------do----
IQC Documents
Page 4 of 9

SL. NO
COMPONENTS
CHARACTERISTICS
CLASS
TYPE OF CHECK
QUANTUM OF CHECK
REFERENCE DOCUMENT
ACCEPTANCE NORMS
FORMAT OF RECORD M
3 Visual Check for Damage No. of Digits Mounting Holes
6 Single Sampling Level II of IS 2500 (Part-I) (AQL=0.65) ---do----
12
Stepper Motor Counter
Electrical Test: HV Test Resistance Functional Boiling Water Test Dimensions
Major
Visual / Electrical
----do----
IQC Documents
2 from each Lot 10% of Sample Qty
----do-------do----
Page 5 of 9

SL. NO
OPERATIONS
CHARACTERISTICS
CLASS
TYPE OF CHECK
QUANTUM OF CHECK
REFERENCE DOCUMENT
ACCEPTANCE NORMS
FORMAT OF RECORD
AGENCY
REMARKS
1.
PCB Inspection
Soldering Solder bridging or dry solder Components Mounting Polarity of components Functional Testing
Major
Visual
100% check and again 5 nos. randomly selected daily by Q.C.
Functionally OK
QC Documents
2.
Counter & PCB Assembly
Counter alignment
Major
Visual
Reference Sample & Alignment should be proper
As per Specification Sheet for the component As per Specification Sheet for the component As per Specification Sheet for the component As per Specification Sheet for the component
QC Documents
Review of records of the at the time of Final Inspection Review of records of the at the time of Final Inspection
3.
Assembled Base connection
Tightness of Connections Major Terminal Block Gasket Name Plate Marking Serial Number punching and control Name Plate position Cover fitment with base Visual
100% check and 5 nos. randomly selected daily by Q.C. 100% check and 5 nos. randomly selected daily by Q.C. 100% check and 5 nos. randomly selected daily by Q.C.
Reference Sample & Work Instructions
QC Documents
4.
Name Plate
Major
Visual
As per NTPC Specification Reference Sample & Work Instructions
QC Documents
Cover Fixing
Major
Visual
QC Documents
Page 6 of 9

TYPE OF CHECK
SL. NO
CHARACTERISTICS OPERATIONS
CLASS
QUANTUM OF CHECK
REFERENCE DOCUMENT
ACCEPTANCE NORMS
FORMAT OF RECORD M
AGENCY REMARKS C ** 10. N 11. Review of records of the at the time of Final Inspection Review of records of the at the time of Final Inspection Review of records of the at the time of Final Inspection
2 Meter Calibration
6.
3 Meter is calibrated by solder shorting in phase as well as neutral element
8 As per Specification Sheet for the component As per Specification Sheet for the component As per Specification Sheet for the component
Major
Electrical
100% check
Specified Standard
QC Documents
Temper Test
As per the requirements of specification
Major
Electrical
10 Nos. samples selected daily by Q.C.
As per NTPC Specification
QC Documents
Packing
Sealing Functional Testing of Meter
Major
Visual
Should be proper as per customer requirement
QC Documents
Page 7 of 9

SL. NO
OPERATIONS
CHARACTERISTICS
CLASS
TYPE OF CHECK
QUANTUM OF CHECK
REFERENCE DOCUMENT
ACCEPTANCE NORMS
FORMAT OF RECORD M
AGENCY REMARKS C ** 10. N 11. Review of Records of at the time of Final Inspection - do - do - do - do - do -
1 1
2 Routine Test
A.C. High Voltage Test Insulation Test Test on limits of Errors Test of Starting condition Test of no load condition Meter Constant 2. Acceptance Test A. C. High Voltage Test Insulation Test Test on limits of Errors Test of Starting condition Test of no load condition Meter Constant
Critical Critical Critical Critical Critical Critical Critical Critical Critical Critical Critical Critical
Electrical Electrical Electrical Electrical Electrical Electrical Electrical Electrical Electrical Electrical Electrical Electrical
100% on each Meter 100% on each Meter 100% on each Meter 100% on each Meter 100% on each Meter 100% on each Meter As per NESCL Tech. Specs./ IS: 13779 As per NESCL Tech. Specs./ IS: 13779 As per NESCL Tech. Specs./ IS: 13779 As per NESCL Tech. Specs./ IS: 13779 As per NESCL Tech. Specs./ IS: 13779 As per NESCL Tech. Specs./ IS: 13779
QC Documents QC Documents QC Documents QC Documents QC Documents QC Documents Inspection Report Inspection Report Inspection Report Inspection Report Inspection Report Inspection Report
The offered quantity of meters shall be divided into sub-lots of 4000 meters each and sampling plan for each sub-lot of 4000 meters shall be as per IS: 13779
Page 8 of 9

SL. NO
OPERATIONS
CHARACTERISTICS
CLASS
TYPE OF CHECK
QUANTUM OF CHECK
REFERENCE DOCUMENT
ACCEPTANCE NORMS
FORMAT OF RECORD M
AGENCY REMARKS C ** 10. P P P P w w w w w w w w Type Test clearance from NESCL Engineering department To be done after Vibration Test N 11.
3 Test of repeatability of meter Test of Power Consumption Test on limits of Errors Anti-Tamper Tests
4 Critical Critical Critical Critical
5 Electrical Electrical Electrical Electrical
6 As per NESCL Tech. Specs./ IS: 13779 As per NESCL Tech. Specs./ IS: 13779 As per NESCL Tech. Specs./ IS: 13779 As per NESCL Tech. Specs.
7 As per IS 13779:99 As per IS 13779:99 IS : 13779 IS : 13779
8 IS 13779:99 IS 13779:99 IS : 13779 IS : 13779
9 Inspection Report Inspection Report Inspection Report Inspection Report
3.
Type Tests
All Type Tests as per IS 13779
Critical
Electrical / Mech
As per IS 13779:99
As per IS 13779:99
IS 13779:99
Inspection Report
Legend: M : Manufacturer C : Contractor N : NTPC Electric Supply Company Ltd. IQC : Incoming Quality Control P : Perform V : Verify W : Witness
Page 9 of 9
MANUFACTURE'S NAME & ADDRESS:

ITEM: All Aluminum Conductor (AAC) QP NO: REV.NO: DATE: No of pages:5
PROJECT/UTILITY: PACKAGE: CONTRACT NO: MAIN-CONTRACTOR: Format of Records 9 M
SUB-SYSTEM:
Sl.No Component & operation Characteristics
Class
Type of Check
Quantum of Check
Reference Document
Acceptance Norms
Agency
Remarks
1 1.1
5 6 SECTION-I : RAW MATERIAL
10 C N
11
1.1.1
a) Chemical Analysis
Major
Test
One sample per heat of 4MT
IS - 398 - Part I 1996
NESCL SPEC
QC RECORD V
Review of Mfg test certificate at the time of final inspection. In absence of Mfg TCs and proper correlation, one sample per lot of V 1000 MT or part there of shall be tested at 3rd party lab and TCs from lab shall be reviewed at the time of final inspection V V V V Review of supplier TCs at the time of final inspection. DO DO DO
1.1.2 1.1.3 1.1.4 1.1.5 AL wire ROD
a) Diameter of Al Wire Rod b) Breaking Load/ Tensile Test c) Conductivity d) Elongation
Major Major Major Major
Dimensional Test Test Test
One sample from each coil One sample from each coil One sample from each coil One sample from each coil
IS - 5484 & NESCL SPEC IS- 5484 & NESCL SPEC IS- 5484 & NESCL SPEC IS- 5484 & NESCL SPEC IS- 5484 & NESCL SPEC
IS - 5484 & NESCL SPEC IS - 5484 & NESCL SPEC IS - 5484 & NESCL SPEC IS - 5484 & NESCL SPEC
QC RECORD P QC RECORD P QC RECORD P QC RECORD P
V V V V
1.1.6
e) Cleanliness & surface smoothness
Major
Visual
100% on each coil
The wire rod shall be smooth & free from pipes, laps, cracks, kinks, twists, scams and other injurious defects QC RECORD P with in the limits of good commercial practices.
Review of supplier TCs at the time of final inspection.

PROJECT/UTILITY: PACKAGE: CONTRACT NO: MAIN-CONTRACTOR:
2.1 2.1.1 Intermediate Draswing a)INTERMEDATE DRAWING & SOLUTIONISING OF DRAWN BATCH a) Diameter of drawn Aluminium wire b) Tensile Test c) Resitivity d) AL wire Ageing process time and temperature control process a) Surface finish & winding (Visual check) b) Diameter of AL Wire c) Breaking Load/ Tensile Test d) Resistance d) Wrapping Test e) Elongation f) Micro Structure g) Density h) Coefficient of linear expansion i) Constant Masstemperature Coefficient ( ) j) Final Modulus of elasticity Major
SUB-SYSTEM: SECTION - II : INPROCESS INSPECTION Visual
Solutionising Temp : 510 +/- 30 deg C Soaking time : 60 +/- 10 Minutes QC RECORD P Continuous Temp record by graph One Sample from each spool One Sample from each spool One Sample from each spool IS 398 (P-I) & NESCL SPEC Plant Standards Plant Standards IS 398 (P-I) & NESCL SPEC IS 398 (P-I) & NESCL SPEC IS 398 (P-I) & NESCL SPEC QC RECORD P QC RECORD P QC RECORD P
This Process is suitable for M or O temper wire rod materials Review of records at the time of final inspection DO DO
2.1.2 2.1.3 2.1.4
Major Major Major
Dimensional Test Test
V V V
V V V
2.1.5
Major
Visual
for each batch
Plant Stadards
Plant Stadards The wire shall smooth, uniform and free from all imperfection such as spills, splits, scale IS 398 (P-I) & NESCL SPEC IS 398 (P-I) & NESCL SPEC IS 398 (P-I) & NESCL SPEC IEC 104 & NESCL SPEC IS 398 (P-I) & NESCL SPEC Fine Grains IS 398 (P-I) & NESCL SPEC IS 398 (P-I) & NESCL SPEC IS 398 (P-I) & NESCL SPEC
QC RECORD P
DO
AL drawn wire (Before Ageing)
2.1.6 2.1.7 2.1.8 2.1.9 2.1.10 2.1.11 2.1.12 2.1.13 2.1.14 2.1.15
Major Major Major Major Major Major Major Major Major Major
Visual Dimensional Test Test Test Test Test Test Test Test
100% on each spool One Sample each Spool One Sample each Spool One Sample each Spool One Sample each Spool One Sample each Spool One Sample per 40 MT or Part there of One Sample each Spool One Sample each Spool One Sample each Spool
IS 398 (P-I) & NESCL SPEC IS 398 (P-I) & NESCL SPEC IS 398 (P-I) & NESCL SPEC IS 398 (P-I) & NESCL SPEC IEC 104 & NESCL SPEC IS 398 (P-I) & NESCL SPEC IS 398 (P-I) & NESCL SPEC IS 398 (P-I) & NESCL SPEC IS 398 (P-I) & NESCL SPEC IS 398 (P-I) & NESCL SPEC IS 398 (P-I) & NESCL SPEC
QC RECORD P QC RECORD P QC RECORD P QC RECORD P QC RECORD P QC RECORD P QC RECORD V QC RECORD P QC RECORD P QC RECORD P
V V V V V V V V V V
V V V V V V V V V V
DO DO DO DO DO DO Review of records ( Test is conducted at any approved third party lab) Review of supplier TCs at the time of final inspection. DO DO
2.1.16
Major
Test
One Sample each Spool
IS 398 (P-I) & NESCL SPEC
QC RECORD P
DO

QP NO: REV.NO: DATE: SUB-SYSTEM: No of pages:5 SECTION - III : FINAL CONDUCTOR STRADING ITEM: All Aluminum Conductor (AAC)
3.1 3.1.1 a) Lay Ratio/ direction of the Lay and Compactness Major
Visual
Each length at the beginning
QC RECORD P
DO
3.1.2
b) Smoothness/ Surface finish
Major
Visual
3.1.3
c) Joints
Major
Visual
3.1.4 4.1
d) Surface cleanliness
Major
Visual
4.1.1
Type Test of finished conductor
CRITCAL
INSPECTION
5.1 ROUTINE TEST 5.1.1 a) Check for Joints b) Surface Condition of the strand and stranded conductor c) All Acceptance test d) Check the drums Major Visual
The finished conductor shall be smooth, compact, uniform & free from all imperfection including kinks (protrusion of wire) iwre cross cover, IS 398 (P-I) & NESCL over looseness ( wire being 100% SPEC dislocated by finger/ hand pressure and or unusual bangle noise on tapping material inclusion or black spot (on account of reaction with trapped rain water) dirt, grease etc. There shall be no Joints. Medium IS 398 (P-I) & NESCL grade Kraft/ Crepe/ Polythene paper 100% shall be used in between the layers of SPEC conductors After reeling the conducotr the exposed surface of the outer most 100% AS PER NESCL layer of conductor shall be wrapped with waterproof thick bituminised paper/ polythene paper to preserve SECTION - IV : TYPE TEST ON FINAL CONDUCTOR AS APPLICABLE AS PER NESCL CONTRACT All the type tests to be carried out as AGREEMENT, AS PER NESCL SPEC per NESCL Specification by NESCL MINUTES OF THE Engineering Department. MEETING AS APPLICABLE SECTION - V : FINAL INPECTION & TESTING IS 398 (P-I) & NESCL 100% on each drum No Joints are allowed SPEC 100% on each drum 20% on each drum and part there of AS PER NESCL SPEC IS 398 (P-I) & NESCL SPEC IS 398 (P-I) & NESCL SPEC AS PER NESCL SPEC The wire shall smooth, uniform and free from all imperfection such as spills, splits, scale AS PER NESCL SPEC AS PER NESCL SPEC
QC RECORD P
DO
QC RECORD P
Review of records of the contractor at the time of final inspection. The contractor shall furnish an under taking to this effect at the time of final inspection Review of records of the contractor at the time of final inspection.
QC RECORD P
QC RECORD W W W
Approved Type Test reports or waiver by Engg Dept to be shown at time of final inspection
QC RECORD P
Review of records of the contractor Contractor to ensure that there is no surface defects on AL. strands of complete conductor as NESCL requirement Review of records of the contractor at the time of final inspection. Review of records of the contractor at the time of final inspection.
5.1.2
Major
Visual
QC RECORD P
5.1.3 5.1.4
Major Major
Test/ Dimensional Visual/ Dimesional
QC RECORD P QC RECORD P
V V
V V

ITEM: All Aluminum Conductor (AAC) QP NO: REV.NO: DATE: No of pages:5 IS 398 (P-I) & NESCL SPEC IS 398 (P-I) & NESCL SPEC IS 398 (P-I) & NESCL SPEC IS 398 (P-I) & NESCL SPEC IEC 104 & NESCL SPEC Plant Standards IS - 1778 - 1980 & NESCL SPEC IS - 1778 - 1980 & NESCL SPEC
SUB-SYSTEM: 5.1.5 5.1.6 5.1.7 5.1.8 5.1.9 5.1.11 7.1 7.1.1 a) Dimensions b) Barrel batten strength test c) Chemical test on packing paper, corrugated kraft paper & adhesive CRITCAL ACCEPTANCE TEST a) Lay Ratio/ direction of the Lay b) Diameter c) Breaking Load/ Tensile Test d) Resistance d) Wrapping Test f) Micro Structure CRITCAL CRITCAL CRITCAL CRITCAL CRITCAL CRITCAL Visual/ Dimesional One Sample for Every 10 Drums One Sample for Every 10 Dimensional Drums One Sample for Every 10 Test Drums One Sample for Every 10 Test Drums One Sample for Every 10 Test Drums One Sample for Every 10 Test Drums SECTION - VII : WOODEN DRUMS One Sample for Every 10 Dimensional Drums Test One Sample for Every 10 Drums
IS 398 (P-I) & NESCL SPEC IS 398 (P-I) & NESCL SPEC IS 398 (P-I) & NESCL SPEC IS 398 (P-I) & NESCL SPEC IS 398 (P-I) & NESCL SPEC Fine Grains All Dimensions shall correlate with approved drawing
QC RECORD P W W QC RECORD P W W QC RECORD P W W QC RECORD P W W QC RECORD P W W QC RECORD P W W QC RECORD QC RECORD P W W
7.1.2
CRITCAL
Minmum Barrel Strength to be mutully agreed between contractor and QC RECORD P W W customer as per techincal Spec Chloride - 0.05 %Max Sulphate - 0.25%Max Copper - 0.01%Max pH - 5.5 to 7.5 (Aq Extract) Review of results at the time of final inspection
7.1.3
Major
Visual
One Sample for Every 10 Drums
QC RECORD P
7.1.4
d) check of wooden drums
Major
Visual
100%
IS - 1778 - 1980 & NESCL SPEC
The inner cheek of the flange and drum barrel surface shall be secured with carboard or double corrogated or thick bitumised water proof bamboo paper by means of suitable adhesive material. After reeling the conductor QC RECORD P the exposed surface of the outer layer of the conductor shall be wrapped with water proof thick bituminsed papar/ polythene paper to preserve the conductor from dirt and demaged during transport and handling
care shall be taken while handling the drums by lifters Medium grade kraft/ crepe/polythene paper shall be used between the layers of the conductors

PROJECT/UTILITY: PACKAGE: CONTRACT NO: MAIN-CONTRACTOR: QC RECORD P V V
8.1 8.1.1 a)Application of water proof paper b) Space between outermost layer and inner surface of lagging c) Proper Packing d) Contract/ Award Letter No. e) Name and Consignee Address f) MFG Name and Address g) Drum No. Check for identification and packing h) Size & code of conductor i) Length of conductor J) Gross weight of drum K) Tare weight of drum L) Net weight M) Arrow marking for unwinding N) Sealing the two outter ends with heat shrinkable sleeves
SUB-SYSTEM: SECTION - VIII :PACKING & MARKING Visual
8.1.2
Dimensional
QC RECORD P
8.1.3 8.1.4 8.1.5 8.1.6 8.1.7 8.1.8 8.1.9 8.1.1 0 8.1.1 1 8.1.1 2 8.1.1 3 8.1.1 4 8.1.1 5 8.1.1 6 8.1.1 7
QC RECORD P QC RECORD P QC RECORD P QC RECORD P QC RECORD P QC RECORD P QC RECORD P QC RECORD P Major 100% NESCL SPEC NESCL SPEC QC RECORD P QC RECORD P Visual QC RECORD P
V V V V V V V V V V V
V V V V V V V V V V V VERIFICATION OF THE INTERNAL DOCUMENTS DURING FINAL INSPECTION
QC RECORD P
o) Lead sealing with QC RECORD P V V plier at both ens p) Marking of QC RECORD P V V CHP/MCHP q) Position of QC RECORD P V V conductor r) Tack welding on 8.1.1 the Nuts on the barrel QC RECORD P V V 8 & hube plate s) Barrel Diameter at three locations & 8.1.1 arrow marking at the QC RECORD P V V 9 location of measurement t) Project Name Major Visual 100% NESCL SPEC RGGVY by NESCL QC RECORD P V V 8.1.20 Marking *-All type tests to be carried out as per NESCL specification, Contract Agreement and as per minutes of the meeting between NESCL and VEL Approval of type tests by Engineering department of NESCL or waival thereof to be shown at the time final inspection to enable NESCL issue MDCC. - Record identified'' "tick mark" shall be essentially included by supplier in QA Documentations. LEGEND : M - MANUFACTURER C - CONTRACTOR N - CUSTOMER P - PERFOM V - VERIFICATION W - WITNESSING QC - QUALITY CONTROL
SIGNATURE OF THE CONTRACTOR
1
MANUFACTURERS NAME AND ADDRESS :

ITEM :11 KV A B SWITCH
QP NO.: REV. NO.: Date:
PROJECT/ UTILITY: PACKAGE: CONTRACT NO.: MAIN-SUPPLIER:

AGENCY REMARKS
NO
COMPONENT & OPERATIONS
CHARACTERISTICS
CLASS
TYPE OF CHECK
QUANTUM OF CHECK
REFERENCE DOCUMENT
ACCEPTANCE NORMS
FORMAT OF RECORDS
CTIION: 1 RAW MATERIAL

IS-191 IS-191 Part-IV, IS-1897 IS-191 Part-II IS-1897 IS-191 Part-IV, IS-1897 IS-191 Part-II IS-1897 Review of Manufacturer QC RECORD P V V ----DO--QC RECORD P V V
Visual Examination
Major
PH
Part-IV, IS-1897 IS-191
Review Of Records At The Time Of Final Inspection
Dimension
Major
PH
Part-II IS-1897
Tensile Strength
COPPER FLATS
Major
ME
IS-1608
IS-1608
IS-1608
SUPPLIER TC
TC/Reputed lab TC at the time of final inspection
IS-191
IS-191 Part-IV IS-1897 IS-191 Part-IV IS-1897 IS-191 Part-IV IS-1897 IS-5082 IS-3965
IS-191 Part-IV IS-1897 IS-191 Part-IV IS-1897 IS-191 Part-IV IS-1897 IS-5082 IS-3965 QC RECORD QC RECORD P P V V V V Review Of Records At The Time Of Final Inspection ---DO--Review of Manufacturer SUPPLIER TC V V V ---DO--SUPPLIER TC V V V ---DO--SUPPLIER TC V V V ---DO---
Chemical Composition
Major
CH
Part-IV IS-1897 IS-191
Bend Test
Major
ME
Resistivity /Conductivity
Major
Part-IV IS-1897
Visual Examination Dimension
Major Major
PH PH
IS-5082 IS-3965
Tensile Strength
ALUMINIUM FLATS
Major
ME
SUPPLIER TC IS-1608 IS-5082 IS-5082 IS-5082 IS-1608 IS-5082 IS-5082 IS-5082 IS-1608 IS-5082 IS-5082 IS-5082 SUPPLIER TC SUPPLIER TC SUPPLIER TC
Bend Test Resistivity /Conductivity Chemical Composition
Major Major
ME E CH
V V V
V V V
V V V
---DO-----DO-----DO---
Major
2
NO COMPONENT & OPERATIONS 2. CHARACTERISTICS CLASS TYPE OF CHECK 5. QUANTUM OF CHECK 6. REFERENCE DOCUMENT 7. ACCEPTANCE NORMS 8. FORMAT OF AGENCY RECORDS M C 9.
QC RECORD
REMARKS N 11. Review Of
3.
4. Major
10. P V V
Visual Examination
PH
IS-2062
IS-2062
IS-2062
Records At The Time Of Final Inspection
IS-808, Dimension Major PH IS-1730, IS-1732, IS-3954 MILD STEEL SECTIONS Tensile Strength Major ME IS-1608
IS-808, IS-1730, IS-1732, IS-3954
IS-808, IS-1730, IS-1732, IS-3954 Review of Manufacturer

SUPPLIER TC QC RECORD
---DO---
IS-1608
IS-1608
Major
CH
IS-2062
IS-2062
IS-2062
SUPPLIER TC
---DO--Review Of
Bend Test
Major
ME
IS-2062
IS-2062
IS-2062
QC RECORD
Visual Examination
Major
PH
100% 10 Nos.
PLANT STANDARD PLANT STANDARD PLANT
PLANT STANDARD PLANT STANDARD PLANT STANDARD PLANT STANDARD
QC RECORD
---DO---
Dimension CONTACT SPRINGS Functional check
Major
PH
QC RECORD
per lot --DO--
---DO---
Major
PH
QC RECORD
STANDARD PLANT
---DO---
Fitment/Springs
Major
PH
--DO--
QC RECORD
STANDARD
---DO---
3
NO COMPONENT & OPERATIONS 2. CHARACTERISTICS CLASS TYPE OF CHECK 5. QUANTUM OF CHECK 6. REFERENCE DOCUMENT 7. ACCEPTANCE NORMS 8. FORMAT OF RECORDS AGENCY REMARKS M 10. P V V C N 11. Review Of Visual Examination Major PH IS-1367-III IS-1367-III IS-1367-III
QC RECORD
3.
4.
9.
Dimension
Major
PH
IS-1363
IS-1363
IS-1363
QC RECORD
---DO--Review of Manufacturer
FASTNERS
Wedge Test
Major
ME
IS-1367-III
IS-1367-III
IS-1367-III
SUPPLIER TC
Hardness
Major
ME
IS-1367-III
IS-1367-III
IS-1367-III
SUPPLIER TC
---DO---
Galvanizing
Major
Major
CH
IS-1367-XIII
IS-1367-XIII
IS-1367-XIII
SUPPLIER TC
---DO--Review Of Records
Visual
PH
IS-2486- II
IS-2486- II
IS-2486- II
QC RECORD
At The Time Of Final Inspection
GI PINS
Dimension
Major
PH
IS-2486- II
IS-2486- II
IS-2486- II
QC RECORD
Galvanization Checks
Major
CH
IS-4759
IS-4759
IS-4759
SUPPLIER TC
TC /Reputed lab TC at the time of final inspection
4
COMPONENT & OPERATIONS 2. CHARACTERISTICS CLASS TYPE OF CHECK 5. QUANTUM OF CHECK 6. REFERENCE DOCUMENT 7. IS-2544 Visual Major PH 100% IS-5350 IS-731 IS-2544 Dimension Major PH IS-5350 IS-731 Major IS-2544 IS-731 IS-2544 IS-731 IS-2544 IS-731 IS-2544 IS-731 IS-2544 IS-731 IS-2544 Galvanizing test Major CH IS-4759 IS-731 AL. ALLOY ZINC Chemical Composition Chemical Composition Major Major CH CH IS-617 IS-209 IS-13229 IS-2544 IS-731 IS-2544 IS-731 IS-2544 IS-731 IS-2544 IS-731 IS-2544 IS-731 IS-2544 IS-4759 IS-731 SI-617 IS-209 IS-13229 IS-2544 IS-731 IS-2544 IS-731 IS-2544 IS-731 IS-2544 IS-731 IS-2544 IS-731 IS-2544 IS-4759 IS-731 IS-617 IS-209, IS-4759
SUPPLIER TC SUPPLIER TC SUPPLIER TC SUPPLIER TC SUPPLIER TC
NO
ACCEPTANCE NORMS 8. IS-2544 IS-5350 Is-731
FORMAT OF RECORDS 9.
AGENCY M C 10. N
REMARKS
3.
4.
11. NGK Birla/ WSI/ Jayshree
QC RECORD
Makes only. Review Of Records At The Time Of Final Inspection
Approved Drgs.
Approved Drgs.
QC RECORD
---DO---
Review of Manufacturer
SUPPLIER TC
High Voltage Test
INSULATOR
Temperature Cycle
Major
SUPPLIER TC
-----DO----
Mechanical Strength/Failing load Test
Major
ME
-----DO----
Puncture Test
Major
-----DO----
Porosity Test
Major
PH
-----DO----
-----DO----
V V
V V
V V
---DO-----DO---
SUPPLIER TC
5
COMPONENT & OPERATIONS 2. CHARACTERISTICS CLASS TYPE OF CHECK 5. QUANTUM OF CHECK 6. REFERENCE DOCUMENT 7. ACCEPTANCE NORMS 8. FORMAT OF RECORDS 9.
QC RECORD
AGENCY M 10. P V V C N
NO
REMARKS
3.
4. Major
11. Review Of Records
Visual
PH
IS-1239
IS-1239
IS-1239
Dimension
Major
PH
IS-1239
Approved Drgs
IS-1239
QC RECORD
-----DO---Review of Manufacturer
Chemical Analysis
Major
CH
IS-1239
IS-1239
IS-1239
SUPPLIER TC
GI TUBES
Tensile Strength
Major
ME
IS-1239
IS-1239
IS-1239
SUPPLIER TC
-----DO----
Elongation
Major
ME
IS-1239
IS-1239
IS-1239
SUPPLIER TC
-----DO----
Bend Test
Major
ME
IS-1239
IS-1239
IS-1239
QC RECORD
Review Of Records At The Time Of Final Inspection Review of Manufacturer
Galvanizing
Major
CH
IS-1239
IS-1239
IS-1239
SUPPLIER TC
6
NO COMPONENT & OPERATIONS 2. CHARACTERISTICS CLASS TYPE OF CHECK 5. QUANTUM OF CHECK 6. REFERENCE DOCUMENT 7. ACCEPTANCE NORMS 8. FORMAT OF RECORDS 9. AGENCY REMARKS M 10. C N 11.
3.
4.
CTIION: 2 INPROCESS INSPECTION

Review Of Records
Visual Examination
Major
PH
100%
-FQP
-FQP
QC RECORD
WELDED/FABRICATED M.S. COMPONENT Dimension Major PH
Min. five sample per lot
-FQP
-FQP
QC RECORD
----DO---
Fitment/Assembly
Major
PH
One sample per lot 100% Min. five sample per lot One sample per lot
-FQP
-FQP
QC RECORD
----DO---
Visual Examination FABRICATION OF COPPER CONTACTS Fitment /Assembly Dimension
Major Major
PH PH PH
-FQP -FQP
-FQP -FQP
QC RECORD
P P P
V V V
V V V
----DO-----DO------DO---
QC RECORD
Major
-FQP
-FQP
QC RECORD
Visual Examination
Major
PH
100% One sample
IS-4759
IS-4759
QC RECORD
----DO---
Appearance HOT DIP GALVANIZING Uniformity Mass of zinc
Major
PH
of each component per lot
IS-2629
IS-2629
QC RECORD
----DO---
Major Major
CH CH
-----DO-------DO----
IS-2633 IS-6745
IS-2633 IS-6745
QC RECORD
P P
V V
V V
----DO------DO---
QC RECORD
7
NO COMPONENT & OPERATIONS 2. CHARACTERISTICS CLASS TYPE OF CHECK 5. QUANTUM OF CHECK 6. REFERENCE DOCUMENT 7. ACCEPTANCE NORMS 8. FORMAT OF RECORDS 9. AGENCY M 3. 4. Major Visual Examination PH 100% IS-5561 IS-5561
QC RECORD
C 10.
Dimension
Major
PH
One sample perApprove lot d drags.
Approved Drgs.
QC RECORD
-----DO---Review of type test
Major Tensile TERMINALS CONNECTOR ME Type test IS-5561 IS-5561 TYPE TEST REPORT W V V
from CPRI/NABL approved lab on similar connector.
Resistance
Major
Type test
IS-5561
IS-5561
TYPE TEST REPORT
V -----DO----
Temperature Rise
Major
Type test
IS-5561
IS-5561
TYPE TEST REPORT
-----DO----
-----DO---Short Time Current test Major E Type test IS-5561 IS-5561 TYPE TEST REPORT W V V Review Of Visual Examination Major PH 100% IS-3203 IS-6012 IS-3203 IS-6012 SV W V V Inspection Records At The Time of Final Inspection One sample Thickness of plating Major PH of each components per lot IS-3203 IS-6012 IS-3203 IS-6012 SV W V V ---DO---
ELECTROPLATING
8
NO COMPONENT & OPERATIONS 2. CHARACTERISTICS CLASS TYPE OF CHECK 5. PH QUANTUM OF CHECK 6. 100% REFERENCE DOCUMENT 7. -FQP Approved/Floor Drgs. Approved/Floor Drgs. ACCEPTANCE NORMS 8. -FQP Approved/Floor Drgs. Approved/Floor Drgs. FORMAT OF AGENCY RECORDS M C 9. QC RECORD P 10. V
V REMARKS
N
3. Visual Examination
4. Major
Dimension ASSEMBLIES/SUBASSEMBLIES Verification of components
Major
PH
10%
QC RECORD P
---DO---
Major
PH
10% Min. one
QC RECORD P
---DO---
Functional check
Major
PH
sample per lot
-FQP
-FQP
QC RECORD P
---DO--V
PACKING
Visual
Major
PH
100%
Packing list Approved Drgs.
QC RECORD P
Verification of packing List at the time of final inspection & review
9
COMPONENT & OPERATIONS 2. CHARACTERISTICS CLASS TYPE OF CHECK 4. 5. QUANTUM OF CHECK 6. REFERENCE DOCUMENT 7. ACCEPTANCE NORMS 8. FORMAT OF RECORDS 9. AGENCY REMARKS M 10. C N 11.
L. NO
3.
ECTIION: 3 PRODUCT TESTING
TYPE TEST GO AB SWITCH
All type tests as per relevant IS & Technical Specifications 1) Power Frequency Voltage Dry Test
IS-9920, Major TTR Prototype NESCL Technical specification
IS-9920, NESCL Technical specification IS-9920, NESCL Technical specification Approved Drgs
TYPE TEST REPORT
Type Test Clearance from W W W NESCL Engineering Department
ROUTINE TEST-GO AB SWITCH
2)Measurement of Resistance of main circuit 3)Operating Test
Major
Routine Checks
IS-9920, NESCL 100% Technical specification Approved Drgs
Review Of Routine test QC RECORD P V V reports during final Inspection
Visual Examination
Major
Physical
100%
IS-9920/9921, Part-I-IV
IS-9920/9921, Part-I-IV
Test Report
Dimension ACCEPTANCE TESTSGOAB SWITCH Verification of component Operational check Measurement of Resistance on main circuits Power Frequency withstand voltage test
Physical Approved Drgs. Physical Physical Electrical Sample as per IS: 2500 IS-9920, Part-I-IV IS-9920, Part-I-IV Approved Drgs.
P P Test Report P P
W W W W
W W W W
Major
Electrical
10
SECTIION: 5 REMARKS
The MQP should be read in conjunction with NESCL specification and shall deem to include additional tests if any required as per contract. In case of any contradiction between the manufacturers manufacturer FQP & NESCL FQP, this MQP and NESCL specification following precedence shall be followed: a) NESCL specification b) This Manufacturing Quality Plan c) Manufacturers FQP. It is the responsibility of the manufacturer to ensure that this document is readily available at their works as well as at the works of their sub vendors in order to avoid any delay at the time of inspection. In case of any tests being carried out at third party lab, such lab/facility should be NABL accredited / accepted by NESCL. The raw material/bought out items should be procured from reputed sources. The manufacturer shall maintain the proper co-relation of test certificates from raw material stage to finished product stage and the records should be available during inspection by NESCL. Any material rejected during power grid inspection shall be disposed off with the approval of NESCL. For destructive disposal NESCL may depute its representative for witnessing. In case the material is to be returned to sub-vendor, all such items shall be indelibly marked (to prevent mixing) at the works of the manufacturer and offered to NESCL Inspector for verification of marking. Insulators shall be procured from M/S Birla NGK (JSI)/ India pottery only. LEGEND M: MANUFACTURER/SUB-SUPPLIER C: SUPPLIER/ NOMINATED INSPECTION AGENCY (SUBJECT TO PRIOR APPROVAL OF NESCL), N: NESCL P: PERFORM W: WITNESS AND V: VERIFICATION. AS APPROPRIATE, ,PH:PHYSICAL, E:ELECTRICAL ME:MECHANICAL,CH:CHEMICAL CHP: NESCL SHALL IDENTIFIED IN COLUM N
DOC. NO.: REV CAT..
ANUFACTURER
MAINSUPPLIER
UB-SUPPLIER SIGNATURE
FOR NESCL USE REVIEWED BY APPROVED BY APPROVAL SEAL
10
STANDARD MANUFACTURING QUALITY PLAN

ITEM :ACSR CONDUCTOR Size : QP NO: REV.NO: DATE: Reference Document 7 Acceptance Norms 8 PROJECT/UTILITY: PACKAGE: CONTRACT NO: MAIN-CONTRACTOR: Format of Records D 9 SUPPLIER TC / THIRD PARTY TC SUPPLIER TC / QC RECORD DO DO DO
Sl.No 1
Component & operation 2
SUB-SYSTEM: Class Type of Check Quantum of Check 4 5 6 SECTION: 1 RAW MATERIALS INSPECTION ONE SAMPLE 1.CHEMICAL MINOR CHEMICAL FROM 4 MT OR PART THEREOF ONE SAMPLE 2. DIAMETER OF ALUMINIUM ROD MINOR MEASUREMENT FROM EACH COIL 3.BREAKING LOAD / TENSILE MINOR MECHANICAL DO TEST Characteristics 3 4.RESISTIVITY TEST MINOR MINOR ELECTRICAL MECHANICAL DO DO
Agency * 10 M C N P P P P P V V V V V V V V V V
Remarks 11
IS 4026-1976 IS 5484-1978 DO DO DO
IS 4026-1976 IS 5484-1978 DO DO DO
ALUMINIUM WIRE ROD 5.ELONGATION TEST THE WIRE ROD SHALL BE SMOOOTH & FREE FROM PIPES, LAPS CRACKS, QC RECORD KINKS, TWISTS, SEAMS & OTHER INJURIOUS DEFECTS WITHIN THE LIMITS OF GOOD COMMERCIAL PRACTICE IS 398 (Pt-II) 1996 DO DO DO DO DO IS 4826-1979 IS 2633-1972 IS 4826-1979 IS 2633-1972 & GTP SUPPLIER TC SUPPLIER TC / QC RECORD DO DO DO DO DO DO
6.CLEANLINESS & SURFACE SMOOTHNESS
MINOR
VISUAL
100% ON EACH COIL
DO
1. CHEMICAL ANALYSIS 2.DIAMETER GALVANISED STEEL WIRE 3.BREAKING LOAD / TENSILE TEST 4.ELONGATION TEST 5. TORSION TEST 6. WRAPPING TEST 7. PREECE TEST 8. WEIGHT OF ZINC COATING
MINOR CRITICAL CRITICAL CRITICAL CRITICAL MAJOR MAJOR MAJOR
CHEMICAL MEASUREMENT MECHANICAL MECHANICAL MECHANICAL MECHANICAL CHEMICAL CHEMICAL
THREE SAMPLES PER HEAT ONE SAMPLE FROM EACH COIL DO DO DO DO DO DO
IS 398 (Pt-II) 1996 DO DO DO DO DO IS 4826-1979 IS 2633-1972 IS 4826-1979 IS 2633-1972 & GTP
P P P P P P P P
V V V V V V V V
V V V V V V V V
GALVANISED STEEL WIRE
Page 1 of 4

ITEM :ACSR CONDUCTOR Size : QP NO: REV.NO: DATE: Reference Document 7 Acceptance Norms 8 PROJECT/UTILITY: PACKAGE: CONTRACT NO: MAIN-CONTRACTOR: Format of Records D 9
Sl.No 1
Characteristics 3
SUB-SYSTEM: Class Type of Check Quantum of Check 4 5 6 SECTION: 2 IN PROCESS INSPECTION
Agency * 10 M C N
Remarks 11
1. SURFACE FINISH & WINDING
MAJOR
VISUAL
100% ON EACH SPOOL
IS 398(Pt-II) 1996
THE WIRE SHALL BE SMOOTH & FREE FROM ALL IMPERFECTIONS SUCH AS SPIKES SPITES SCALE INCLUSIONS, DIE MARKS, SCRATCHES, FILLINGS, BLOW HOLES ETC. IS 398(Pt-II) 1996 IS 398(Pt-II) 1996 IS 398(Pt-II) 1996 THE WIRE SHALL NOT CRACK OR BREAK IS 398 (Pt-II)-1996
QC RECORD
ALUMINIUM DRAWN WIRE 2. DIA OF DRAWN WIRE 3. BREAKING LOAD / TENSILE TEST 4. RESISTANCE TEST 5.WRAPPING TEST CRITICAL CRITICAL MAJOR MAJOR MAJOR MEASUREMENT MECHANICAL ELECTRICAL MECHANICAL MEASUREMENT
ONE SAMPLE FROM EACH COIL ONE SAMPLE FROM EACH SPOOL DO DO ONE SAMPLE FROM EACH SPOOL
DO DO DO DO IS 398 (Pt-II)-1996
DO DO DO DO DO
P P P P P
V V V V V
V V V V V
STEEL STRANDING
1. LAY RATIO / DIRECTION & COMPACTNESS 1. LAY RATIO / DIRECTION & COMPACTNESS a).INNER ALUMINIUM LAYER
MINOR
MEASUREMENT
CONDUCTOR STRANDING
b).OUTER ALUMINIUM LAYER
MINOR
MEASUREMENT
ONE SAMPLE FROM EACH SPOOL ONE SAMPLE FROM EACH SPOOL
IS 398 (Pt-II)-1996
IS 398 (Pt-II)-1996
DO
IS 398 (Pt-II)-1996
IS 398 (Pt-II)-1996
DO
2) SMOOTHNESS / SURFACE SCRATCHES 3) JOINTS
MINOR
VISUAL
100%
DO
THERE SHALL BE LOSENESS OVER LAPPING OF DO STRANDS, CHIPPING OF ALUMINIUM ETC.

NO JOINTS DO
MAJOR
VISUAL
100%
DO
Page 2 of 4

ITEM :ACSR CONDUCTOR Size : QP NO: REV.NO: DATE: Acceptance Norms 8 PROJECT/UTILITY: PACKAGE: CONTRACT NO: MAIN-CONTRACTOR: Format of Records D 9
Sl.No 1
Characteristics 3
ACCEPTANCE TEST ON FINISHED CONDUCTOR
LAY RATIO
SUB-SYSTEM: Class Type of Check Quantum of Check Reference Document 4 5 6 7 SECTION: 3 FINAL INSPECTION & TESTING ONE SAMPLE MINOR MEASUREMENT FROM EACH 10 IS 398 (Pt-II)-1996 DRUMS
Agency * 10 M C N
Remarks 11
IS 398 (Pt-II)-1996
QC RECORD
1.DIAMETER 2.BREAKING LOAD / TENSILE TEST 3.RESISTANCE 4.WRAPPING TEST
MAJOR
DO
DO
DO
DO
DO
MAJOR MAJOR MAJOR
MECHANICAL ELECTRICAL MECHANICAL
DO DO DO
DO DO DO
DO DO THE WIRE SHALL NOT CRACK OR BREAK
DO DO DO
P P P
W W W
W W W
ACCEPTANCE TEST ON ALUMINIUM TEST ON ALUMINIUM WIRE OF FINISHED CONDUCTOR
5.SURFACE FINISH
MAJOR
VISUAL
DO
DO
THERE SHALL BE NO SPILL & SPLITS, SLAG, INCLUSION, DO DIEMARK, SCRATCHES, FITTINGS BLOW HOLES.
IS 398 (Pt-II)-1996 DO DO DO DO THE WIRE SHALL NOT BREAK OR FLAKE DO QC RECORD DO DO DO
6.DUCTILITY TEST 1. DIAMETER 2.BREAKING LOAD / TENSILE TEST 3.ELONGATION 4.TORSION TEST(EITHER TEST OF 3 OR 4)
MAJOR MAJOR MAJOR MAJOR MINOR
MECHANICAL MEASUREMENT MECHANICAL DO DO
DO ONE SAMPLE FROM EACH 10 DRUMS OR PART DO DO DO
DO IS 398 (Pt-II) 1996 DO DO DO
P P P P P
W W W W W
W W W W W EITHER ELONGATION OR TORSION TEST TO BE DONE
ACCEPTANCE TEST OF GALVANISED STEEL WIRE OF FINISHED 5.WRAPPING TEST
MINOR
DO
DO
DO IS 4826-1979 IS 2633-1972 IS 4826-1979 IS 2633-1972 DO
DO
6.PREECE TEST 7.WEIGHT OF ZINC COATING 8.ADHESION TEST
MINOR MINOR MINOR
CHEMICAL CHEMICAL MECHANICAL
DO DO DO
IS 4826-1979 IS 2633-1972 IS 4826-1979 IS 2633-1972
DO DO
P P P
W W W
W W W
NO CRACKING ON SURFACE DO
Page 3 of 4

ITEM :ACSR CONDUCTOR Size : SUB-SYSTEM: Type of Check 5 QP NO: REV.NO: DATE: Reference Document 7 Acceptance Norms 8 PROJECT/UTILITY: PACKAGE: CONTRACT NO: MAIN-CONTRACTOR: Format of Records D 9
Sl.No 1
Characteristics 3 CHECH FOR JOINTS SURFACE LENGTH MEASUREMENT OF FINISHED AND LENGTH FINISHED CONDUCTOR MEASUREMENT
Class 4
Quantum of Check 6
Agency * 10
Remarks 11
MAJOR
VISUAL/ MECHANICAL
DO
IS : 398 (Pt-II) - 1996
NO SCALE ON THE SURFACE DO
5 6
SEALING AT BOTH ENDS BY THE INSPECTING AUTHORITY WOODEN DRUMS DIMENSIONS MAJOR MEASUREMENT DO IS : 1778 - 1980 AS DETAILED IN THE SPECIFICATION DO VISUAL CHECKING AT THE CONTRACTOR PRIMISES DO DO DO DO DO DO DO P W
P W
1. PROPER PACKING PACKING & DESPATCH 2. MANUFACTURER NAME CHECK FOR IDENTIFICATION 3. SIZE & CODE & PACKING 4. GROSS WEIGHT 5. TARE WEIGHT 6. NETT WEIGHT 7. LENGTH OF CONDUCTOR 8. PAINTING
MAJOR
VISUAL
100% AS PER P.O.. & GTP
AS PER P.O.. & GTP
MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR
VISUAL VISUAL VISUAL VISUAL VISUAL VISUAL VISUAL
100% 100% 100% 100% 100% 100% 100%
AS PER P.O.. & GTP AS PER P.O.. & GTP AS PER P.O.. & GTP AS PER P.O.. & GTP AS PER P.O.. & GTP AS PER P.O.. & GTP AS PER P.O.. & GTP
AS PER P.O.. & GTP AS PER P.O.. & GTP AS PER P.O.. & GTP AS PER P.O.. & GTP AS PER P.O.. & GTP AS PER P.O.. & GTP AS PER P.O.. & GTP
P P P P P P P
V V V V V V V
NOTE: A) Proper co-relation of test certificate from raw materials to finished conductor for all thr drums shall be maintaind. B) The manufacturer will carry over the acceptance test on aluminium & steel strands on 10% of the drum offered for inspection and will submit the records at the time of inspection.You will witness acceptance test on 10% of the drums offered. C) All Aluminium & galvanised steel wire strands are required to be tested for each sample drawn for acceptance test. D) Aluminium wire Rods :- The Contractor shall obtain the following test certificates from the supplier of Aluminum Wire Rod for rewiew by you : i) Chemical coposition of Aluminium wire Rod ii) All the test results of the tests carried out by the sub-vendor on the finished Aluminium Wire Rod E) Galvanised steel wire : - The Contractor shall obtain the following test certificate from their Sub- Vendor for revies by you: i) Chemical composition of Steel Wire Rod. ii) Purity of Zinc iii) All the test result of the test carried our by the Sub- Vendor on the finished Steel Wire F) The conductor ends shall be properly sealed and secured with the help of nails on then side of one the flanges G) The following test facility / calibration certificate shall be at suppliers works : i) Calibration of various testing machine
P= V= W=
Performed By Verified By Witness of test
M= Manufacturer N= Customer (NESCL) C = Contactor SIGNATURE OF THE CONTRACTOR
Page 4 of 4
SIGNATURE OF THE MANUFACTURER

Item : : Name of the Contractor Name of the Sub- contractor Name of the Package LOA No LOA Date Sl.No CROSS ARMS FOR 11 & 33 KV LINES : : : : : Characteristics Class Type of Check Quantum of Check Reference Document Acceptance Norms MQP NO: Format of Records M C 1.1 PHYSICAL RAW MATERIAL (MS PROPERTIES SECTIONS, ANGLES, CHANNELS, FLATS, 1.2 CHEMICAL RODS, SHEETS ETC.) PROPERTIES MAJOR DOCUMENT VERIFICATION DOCUMENT VERIFICATION 100% NESCL Specification & IS 2062 NESCL Specification & IS 2062 IS 2062 GRADE-A Supplier TC V V N V SOURCING FROM NESCL APPROVED SUPPLIERS ONLY THE SAMPLE SHALL BE TESTED AT THIRD PARTY LAB OR MFG'S OWN LAB AS DESIRED BY NESCL THE MANUFACTURING PROCESS CHART RELEVANT TO THE MACHINE SHALL BE DISPLAYED AT THE RESPECTIVE WORK AREAS Agency Remarks
Component & operation
MAJOR
100%
IS 2062 GRADE-A
Supplier TC
2.1 DRILLING
MAJOR
VISUAL/ MEASURE MENT VISUAL/ MEASURE MENT VISUAL/ MEASURE MENT VISUAL/ MEASURE MENT
100%
PLANT STANDARD
AS PER APPROVED FABRICATION DRAWINGS AS PER APPROVED FABRICATION DRAWINGS AS PER APPROVED FABRICATION DRAWINGS AS PER APPROVED FABRICATION DRAWINGS
QC Record
2.2 CUTTING 2.3 BENDING 2.4 ARC WELDING 2.4.1 SELECTION OF ELECTRODE SIZE & CURRENT RANGE MANUFACTURING PROCESSES
MAJOR MAJOR MAJOR
100% 100% 100%
PLANT STANDARD PLANT STANDARD AS PER WELDING PROCESS SPECIFICATION PLANT STANDARD
QC Record QC Record QC Record
P P P
V V V
V V V QUALIFIED AND EXPERIENCED WELDERS SHALL BE ENGAGED NESCL APPROVED WELDING ELETRODES SHALL BE USED. CHART RELEVANT TO THE WELDING PROCESS SHALL BE DISPLAYED
MAJOR
VISUAL
100%
PLANT STANDARD
QC Record
2.4.2 PROCESS OF WELDING
MAJOR
VISUAL
100%
WELDING SHOULD BE FREE FROM DEFECTS SUCH AS BLOW HOLES, BURN THROUGH, INCLUSIONS, LACK OF FUSION, INCOMPLETE PENETRATION, CRACKING Etc PROPER EDGE PLANT STANDARD PREPARATION, CORRECT WELD CURRENT RANGE SUITABLE TRAVEL OF THE ELECTRODE, REMOVING THE SLAG FROM PREVIOUS RUNS BY BUFFING E.T.C SHOULD BE ADHERED TO FOR GOOD WELDING PLANT STANDARD NO VISIBLE CRACKS, BLOW HOLES ALLOWED ON THE WELDMENTS
QC Record
THE PROBABLE CAUSES FOR THE WELD DEFECTS SHALL BE DISPLAYED IN THE WELDING AREA AND THE WELDERS AND HELPERS SHOULD BE REGULARLY TRAINED IN WELDING
2.4.3 POST WELD INSPECTION 3 GALVANISATION
MAJOR
DP TEST
RANDOM
QC Record
SEPARATE QUALITY PLAN IS TO BE SUBMITTED FOR GALVANISATION PROCESS COVERING ALL SEVEN TANK PROCESSES AS PER IS: 2629
3.1 DIMENSIONAL CHECKS 1 CLEANED SURFACES OF THE COMPONENTS 2 SMOOTH WELDMENT SURFACES 3. DIMENSIONS OF THE COMPONENTS AS PER DRAWINGS CHECKED WITH USE OF JIGS AND FIXTURES NO DYE PENETRATION
3.1.1 DIMENSIONAL CHECKS
CRITICAL
VISUAL AND DIMENSIONAL
RANDOM
NESCL SPECIFICATION AND PLANT STANDARD
INSPECTION REPORT
3.1.2 CHECK FOR CRITICAL WELDING (DPI TEST) 3.2 MECHANICAL PROPERTIES 3.2.1 ULTIMATE TENSILE STRENGTH CRITICAL (UTS) 3.2.2 PERCENTAGE CRITICAL ELONGATION 3.2.3 YIELD CRITICAL STRENGTH 4 FINAL INSPECTION 3.2.4 BEND TEST CRITICAL
TEST
RANDOM
NESCL SPECIFICATION AND PLANT STANDARD NESCL Specification & IS 2062 NESCL Specification & IS 2062 NESCL Specification & IS 2062 NESCL Specification & IS 2062
INSPECTION REPORT
TEST TEST TEST TEST
SAMPLE AS PER IS; 2062 SAMPLE AS PER IS; 2062 SAMPLE AS PER IS; 2062 SAMPLE AS PER IS; 2062
NESCL Specification & IS 2062 NESCL Specification & IS 2062 NESCL Specification & IS 2062 NESCL Specification & IS 2062
INSPECTION REPORT INSPECTION REPORT INSPECTION REPORT INSPECTION REPORT
P P P P
W W W W
W W W W
3.3 GALVANIZING CHECKS 3.3.1 UNIFORMITY OF ZINC COATING (PREECE DIP TEST) 3.3.2 MASS OF ZINC COATING 3.3.3 ADHESION TEST (PIVOTED HAMMER/ KNIFE TEST) 3.3.4 THICKNESS OF ZINC COATING CRITICAL TEST ONE SAMPLE NESCL Specification, FOR EVERY 20 IS: 2629, IS: 4759 & MT IS: 2633 ONE SAMPLE NESCL Specification, FOR EVERY 20 IS: 2629, IS: 4759 & MT IS: 2633 ONE SAMPLE NESCL Specification, FOR EVERY 20 IS: 2629, IS: 4759 & MT IS: 2633 ONE SAMPLE NESCL Specification, FOR EVERY 20 IS: 2629, IS: 4759 & MT IS: 2633 NESCL Specification, IS: 2629, IS: 4759 & IS: 2633 INSPECTION REPORT P W W
CRITICAL
TEST
NESCL Specification, IS: 2629, IS: 4759 & IS: 2633
INSPECTION REPORT
CRITICAL
TEST
INSPECTION REPORT
CRITICAL
TEST
INSPECTION REPORT
3.4 CHEMICAL COMPOSITION 3.4.1 CHEMICAL TEST CRITICAL TEST SAMPLE NESCL Specification & IS 2062 IS 2062 GRADE-A LAB REPORT V V V SAMPLES OF THE MATERIAL MAY BE TAKEN & SENT TO GOVT. APPROVED LAB FOR CHEMICAL ANALYSIS TEST.
STORAGE
5.1 PROPER STORAGE OF FINISHED MATERIAL
MAJOR
VISUAL
100%
STANDARD PRACTICE
FINISHED PRODUCT SHALL BE STORED ON FLAT COVERED SURFACE WITH NO WATER LOGGING
QC RECORD
PACKING & DESPATCH
VISUAL INSPECTION FOR COMPLETENESS OF ALL COMPONENTS
MAJOR
VISUAL
100%
STANDARD PRACTICE/ PACKING CHECK LIST
PACKING CHECK LIST
DESPATCH REGISTER
LEGEND :
M - MANUFACTURER C - CONTRACTOR N - CUSTOMER -- NESCL P - PERFORM
V - VERIFY W - WITNESS QC - QUALITY CONTROL
SIGNATURE OF THE CONTRACTOR SIGNATURE OF THE MANUFACTURER

ITEM: 11 KV DISC INSULATORS SUB-SYSTEM: QP NO: REV.NO: DATE: Reference Document 7 PROJECT/UTILITY: PACKAGE: CONTRACT NO: MAIN-CONTRACTOR: Acceptance Norms 8 Format of Records 9 M Agency ** C 10 N Record review during final inspection Remarks 11
Sl. No 1
Characteristics 3
Class 4
Type of Check 5
Quantum of Check 6
SECTION:1 RAW MATERIAL INSPECTION SECTION: 1.1 RAW MATERIAL FOR BODY a) Inspection / colour Major Visual 1 Kg/20 MT part thereof S 1201 White QC Report
b) Residue retained on 200 mesh
Major
Test
Do
S 1201
2% Max. the residue shall be free iron particles and magnetic impurities White Should not stick to the container and no specks Vendor's test certificate
QC Report
Do
Quartz Powder
c) fired colour d) Sintering/fired behavior
Major Major
Visual Visual
Do Do
S 1201 S 1201
QC Report QC Report
V V
V V
V V
Do Do
e) Chemical analysis Major Test Sampling Once in 3 month/ 300 MT S 1201
SiO2 Fe2 O3 LOI at 1000oc
98% Min 0.25% Max. 1% Max
Supplier TC/ QC lab/TPL
T/C review during final inspection
a) Inspection / colour
Major
Visual
1 Kg/20 MT part thereof
S 1201
Off White or pink colour 2% Max. the residue shall be free iron particles and magnetic impurities Translucent (glossy white) and low impurities Vendor's test certificate 11% Min 8% Min. 3.5% Max 1% Max 1.5% Max
QC Report
Record review during final inspection Do
Major
Test
Do
S 1201
QC Report
Feldspar powder
c) fired behavior/Sintering d) Chemical analysis K2O+Na2O K2O Na2O Fe2O3 LOI at 1000OC
Major
Visual
Do
S 1201
QC Report
Do
Major
Test
Sampling Once in 3 month/300MT
S 1201

ITEM: 11 KV DISC INSULATORS SUB-SYSTEM: QP NO: REV.NO: DATE: Reference Document 7 S 1201 PROJECT/UTILITY: PACKAGE: CONTRACT NO: MAIN-CONTRACTOR: Acceptance Norms 8 cream/ pink Format of Records 9 QC Report V Agency ** V 10 V Remarks 11 Record review during final inspection Do Do Do Do
Sl. No 1
Characteristics 3 a) Inspection
Class 4 Major
Type of Check 5 Visual
Quantum of Check 6 1 Kg/20 MT or part thereof
b) Residue retained on 200 mesh 3 China clays c) Fired colour d) Dry shrinkage e) Total shrinkage f) Chemical analysis Al2 03 Fe2 03 Tio2 LOI at 1000oc
Test Visual Test Test
Do Do Do Do
S 1201 S 1201 S 1201 S 1201
Major
Test
Once in 3 month/300MT
S 1201
3% Max. the residue shall be free iron QC Report particles and magnetic impurities Snow white/ white QC Report 7% Max QC Report 16% Max QC Report Vendor's test certificate 30% Min 5% Max Supplier TC/ QC lab/TPL 2% Max 18% Max
P V P P
V V V V
V V V V
a) Inspection/ colour
Major
Visual
1 Kg/20 MT or part thereof
S 1201
Dull white/ black
QC Report
Major
Test
Do
S 1201
Ball clay
c) Fired colour d) Dry shrinkage e) Total shrinkage f) Chemical analysis Tio2 Al2 03 Fe2 03 LOI at 1000oc
Major Major Major
Visual Test Test
Do Do Do
S 1201 S 1201 S 1201
Major
Test
S 1201
3% Max. the residue shall be free iron QC Report particles and magnetic impurities Pale cream/dull cream or light QC Report grey/white 7% Max QC Report 18% Max QC Report Vendor's test certificate 3% Min 25% Max Supplier TC/ QC lab/TPL 2% Max 13% Max
V P P
V V V
V V V
Do Do Do
SECTION: 1.2 RAW MATERIAL FOR GLAZE a) Inspection/ colour b) Residue retained on 200 mesh 5 Iron oxide c) Fired colour of 1% iron oxide in feldspar powder d) Chemical analysis Fe2O3 content Major Visual 1 Kg/05 MT or part thereof Do Do S 1201 Red coloured powder QC Report V V V Record review during final inspection Do Do T/C review during final inspection Record review during final inspection Do Do T/C review during final inspection
Major Major
Test Visual
S 1201 S 1201
2% Max Should match with the standard reference sample Vendor's test certificate approx 82% Min Black coloured powder 10% Max Should match with the standard reference sample Vendor's test certificate 78% Min
QC Report QC Report
P V
V V
V V
Major
Test
Sampling Once in 6 month/ 10 MT
S 1201
a) Inspection/ colour b) Residue retained on 200 mesh c) Fired colour of 2% manganese dioxide in feldspar powder d) Chemical analysis MnO2 content
Major
Visual
1 Kg/05 MT or part thereof Do Do
S 1201
QC Report
Major Major
Test Visual
S 1201 S 1201
QC Report QC Report
P V
V V
V V
Manganese di-oxide
Major
Test
S 1201

ITEM: 11 KV DISC INSULATORS SUB-SYSTEM: QP NO: REV.NO: DATE: Reference Document 7 S 1201 PROJECT/UTILITY: PACKAGE: CONTRACT NO: MAIN-CONTRACTOR: Acceptance Norms 8 Green coloured powder 2% Max Should match with the standard reference sample Vendor's test certificate 90% Min Format of Records 9 QC Report V Agency ** V 10 V Remarks 11 Record review during final inspection Do Do T/C review during final inspection Record review during final inspection
Sl. No 1
Characteristics 3 a) Inspection/ colour b) Residue retained on 200 mesh c) Fired colour of 3% chromium oxide in feldspar powder d) Chemical analysis Cr2O3 content
Class 4 Major
Quantum of Check 6 1 Kg/05 MT or part thereof Do Do
Major Major
Test Visual
S 1201 S 1201
QC Report QC Report
P V
V V
V V
Chromium oxide
Major
Test
S 1201
Major
Visual
S 1201
Off or dull white 5% Max of the residue shall be free from iron particles and magnetic impurities Free from ferrous/ferric impurities Vendor's test certificate 40% Min 0.5% Max 5% Max
QC Report
b) Residue retained on 200 mesh 8 Calcite powder Fired characteristic d) Chemical analysis CaO Fe2O3 SiO2
Major
Test
Do
S 1201
QC Report
Do
Major
Visual
Do
S 1201
QC Report
Do
Major
Test
S 1201
Sl. No 1
Characteristics 3
Class 4
Type of Check 5
Quantum of Check 6
Reference Document 7
Acceptance Norms 8
Format of Records 9 M
Agency ** C V 10 N V
Remarks 11 Record review during final inspection Do Do Record review during final inspection Do
SECTION:2 ASSEMBLY MATERIALS INSPECTION a) Inspection 9 Cement b) Compressive strength c) Expansion (Autoclave) Major Major Test Test Do Do Major Visual 0.01% of total quantity received IS 12269 S 1003 IS 12269 S 1004 IS 12269 S 1005 S 1003 S 1003 No lumpiness QC Report
380 Kg/cm2 Min 0.8% Max
QC Report Supplier TC/ QC lab/TPL
P P
V V
V V
10
Cork sheet
a) Thickness b) specific gravity
Major Major
Visual Test
5Nos/ 5000 Nos Do
1-2mm 0.20.1
QC Report QC Report
V P
V V
V V

ITEM: 11 KV DISC INSULATORS SUB-SYSTEM: QP NO: REV.NO: DATE: Reference Document 7 Reference Document 7 PROJECT/UTILITY: PACKAGE: CONTRACT NO: MAIN-CONTRACTOR: Acceptance Norms 8 Format of Records 9 Agency ** 10 Remarks 11
Sl. No 1 Sl. No 1
Characteristics 3
Class 4
Type of Check 5
Quantum of Check 6
Characteristics 3
Class 4
Type of Check 5
Quantum of Check 6
Acceptance Norms 8
Remarks 11 Record review during final inspection Record review during final inspection & T/C review Record review during final inspection Do T/C review during final inspection Do Record review during final inspection
SECTION:3 METAL PARTS INSPECTION a) Inspection (Black & Galvanizing stage) Major Visual 100% S 1201 No sharp edges QC Report
b) Gauge checking (black & Galvanizing stage)
Major
Test
100%
S 1201
As per IS:2486 part-II
QC Report
c) Dimension ( black & Galvanizing stage) d) Mechanical failing load test ( black & Galvanizing stage) e) Yield strength, Tensile Strength & % Elongation on test bar f) Hardness g) Galvanizing
Major
Test
Major
Test
Lot 1-1000 1000+ Lot 1-1000 1000+
sample 5 10 sample 3 5 Do Do
S 1201
As per Drawing
QC Report
S 1201
As per Drawing
QC Report
11
Ball Pin & Tongue Pin
Major Major Major
Test Test Test
S 1201 S 1201 S 1201
NESCL spec. Do As per IS:2633 Vendor's test certificate 0.15-0.45 0.6-1.00 0.05-0.35 0.60 Max 0.06 Max Time & Temp chart NESCL spec.
QC Report QC Report QC Report
P P P
V V V
V V V
Lot sample 1-10000 3 1000+ 5
h) Chemical Analysis Carbon Manganese Silicon Sulphur Phosphorous i) Heat Treatment j) M.P.I
Major
Test
Each consignment
S 1201
V T/C review during final inspection
Major Major
Test Test
100% 100%
S 1201 S 1201
Supplier TC/ QC lab/TPL Supplier TC/ QC lab/TPL
P P
V V
V V
Do Do

ITEM: 11 KV DISC INSULATORS SUB-SYSTEM: QP NO: REV.NO: DATE: Reference Document 7 S 1201 PROJECT/UTILITY: PACKAGE: CONTRACT NO: MAIN-CONTRACTOR: Acceptance Norms 8 No blow Holes Format of Records 9 QC Report V Agency ** V 10 V Remarks 11 Record review during final inspection Do
Sl. No 1
Characteristics 3 a) Inspection (Black & Galvanizing stage) b) Gauge checking (black & Galvanizing stage) c) Dimension ( black & Galvanizing stage) d) Mechanical failing load test ( black & Galvanizing stage) e) Galvanizing
Class 4 Major
Quantum of Check 6 100%
Major
Test
100%
S 1201
QC Report
Major
Major Major Major
Lot sample 5 Measurement 1-1000 1000+ 10 Lot sample 1-1000 3 Test 1000+ 5 Test Do Test Lot 1-1000 1000+ Do sample 3 5 Do Do Each consignment 100% 1 No/Lot
S 1201
As per Drawing
QC Report
Do
S 1201 S 1201 S 1201
As per Drawing As per IS:2633 350 N/mm Min

2
P P P
V V V
V V V
Do Do T/C review during final inspection Do Do Do Do Do Do Record review during final inspection Do T/C review during final inspection Do Record review during final inspection Do T/C review during final inspection
12
M.C.I. Cap (Socket/ Clevis) f) Tensile Strength on test bar g) 0.2% Proof stress on test bar h) Elongation on test bar i) Hardness
Major Major Major Major Major Major
Test Test Test Test Test Test
S 1201 S 1201 S 1201 S 1201 S 1201 S 1201
200 N/mm2 Min 10% Min 150 BHN Max Vendor's T/C as per BM 350 Gr. Of IS 14329 0.12% max NESCL spec. Do
QC Report QC Report QC Report QC Report QC Report Supplier TC/ QC lab/TPL
P P P P P P
V V V V V V
V V V V V V
j) Chemical Analysis Phosphorous k) M.P.L l) Micro Structure
Major a) Inspection 13 Security Clip (W/R Clip) b) Dimension c) Chemical Analysis i) Phosphorous Major
Visual Lot Measurement 1-1000 1000+ Test
100% sample 3 5
S 1201
No sharp edges
QC Report
S 1201
As per Drawing
QC Report
Major
Each consignment
S 1201
Vendor's T/C as per Supplier TC/ QC lab/TPL IS:7814 Gr.I Vendor's T/C as per Supplier TC/ QC lab/TPL AISI 304 As per Drawing As per IS:2633 Vendor's T/C as per IS:410 CuZn3OGrI QC Report QC Report QC Report
ii) Stainless W/R clip a) mechanical failing load test Cotter Pin (for T& C Cap) 15 Brass split Pin ( for Tic Cap) Chemical Analysis b) Galvanizing
Major
Test Lot 1-1000 1000+
Do sample 3 5 Do Do
S 1201
14
Major Major Major
Test Test Test
S 1201 S 1201 S 1201
P P P
V V V
V V V

Sl. No 1 Sl. No 1
Characteristics 3
Class 4
Type of Check 5
Quantum of Check 6
Characteristics 3
Class 4
Type of Check 5
Quantum of Check 6
Acceptance Norms 8
Remarks 11 Record review during final inspection Do Do Do Do Record review during final inspection Record review during final inspection Do Record review during final inspection Do Do Record review during final inspection Do
SECTION: 4 IN PROCESS INSPECTION Major 16 Wet grinding of ceramic body a) Inspection b) Residue retained on 200 mesh c) Litre Weight a) Residue retained on 300 mesh b) Litre Weight a) De airing checking Visual Each charge Off White to cream colour with no visual impurities S 1003 S 1003 S 1003 S 1003 S 1003 0.2% Max. 1350-1450 0.4% Max. 1500-1650 Min. 700mm of Hg vacuum QC Report
Major Major Major Major Major
Test Test Test Test Test
Do Do Each charge Do Every 30 Mins
QC Report QC Report QC Report QC Report QC Report
P P P P P
V V V V V
V V V V V
17
Glaze Preparation
18 Pug mill's clay blank
19
Properties of unfired porcelain
a) Dry MOR
Major
Test
Sampling Once in 3 month Sampling Once in month
S 1003
28 Kgs/cm2 Min
QC Report
b) Linear shrinkage
Major
Test
S 1003
Max. 14%
QC Report
a) Making cavity check ( Dimension) 20 Shaping b) Finishing dimension c) Moisture
Major Major Major
Measurement Measurement Test
Once in every shift Do Once daily
As per Drawing Do S 1003
As per Drawing Do 8% before entry into drier 50-80oC 1.5% Max
P P P
V V V
V V V
21
Drying
a) Hot rooms temperature b) moisture content
Major Major
Visual Test
Once in a day 3 samples per day
S 1003 S 1003
QC Report QC Report
V P
V V
V V

ITEM: 11 KV DISC INSULATORS SUB-SYSTEM: QP NO: REV.NO: DATE: Reference Document 7 PROJECT/UTILITY: PACKAGE: CONTRACT NO: MAIN-CONTRACTOR: Acceptance Norms 8 Unglazed 750 kg/cm2 Min glazed 850 kg/cm2 Min As per IS:731 Format of Records 9 Agency ** 10 Remarks 11 Record review during final inspection Do
Sl. No 1
Characteristics 3
Class 4
Type of Check 5
Quantum of Check 6 Sampling Once in 3 month All cars of every shuttle kiln & any one unloaded car of tunnel kiln daily & each kiln
a) Fired M.O.R
Major
Test
S 1003
QC Report
22 Properties of fired porcelain b) porosity c) Bulk density/Water absorption a) Inspection 23 Glazing (Brown glaze) b) Sp.gravity c) Moisture % Temperature during firing of 24 green wares a) Inspection 25 Sorting of fired insulator b) Dimension Major Major Major Major Major Test Test Visual Visual Measurement Major Test
As per IS:731
QC Report
Major
Test
S 1003
2.38 Min / 0.2% Light buff colour slurry with no visual impurities
QC Report
Do Record review during final inspection Do Do Do Do Do
Major
Visual
100% Every hour 3 samples per day Every hour 100% 5 Nos/day S 1003 S 1003 S 1003 Ref.sample S 1003
QC Report QC Report QC Report QC Report QC Report QC Report
V P P V V P
V V V V V V
V V V V V V
1.49-1.51 2.5% Max As per firing Graph As per IS:731 As per NESCL approved specified drawings As per IS:731 For 5 Minutes
26
Routine electrical Test on Shell ( Power frequency test) Hydraulic proof load test on shell (if applicable)
Major
Test
100%
AS per IS 731
QC Report
Do
27
Major
Test
100%
NESCL spec
NESCL spec
QC Report
Do
Routine electrical (power frequency) & Mechanical 28 Routine Mechanical Test on a) Routine Mechanical test Assembled insulators b) Routine Electrical test a) Inspection 29 Packing Crate b) Dimension
Test Test Test Visual Test
100% 100% 100% 100% Lot sample 1-1000 5 1000+ 10
AS per IS 731 AS per IS 732 AS per IS 733 S 1201 S 1201
As per IS:731 For 5 Minutes 40% of rated Ems for 5 minutes As per IS:731 For 5 Minutes No broken planks S 1201
QC Report QC Report QC Report QC Report QC Report
P P P V P
V V V V V
V V V V V
Do Do Do Do Do

Sl. No 1 Sl. No 1
Characteristics 3
Class 4
Type of Check 5
Quantum of Check 6
Characteristics 3
Class 4
Type of Check 5
Quantum of Check 6
Acceptance Norms 8
Agency 10 C W W W W W W V V V W W W W W W W W W W W N W W W W W W V V V W W W W W W W W W W W
Remarks 11
SECTION:5 FINAL INSPECTION a) Dimension checking b) Temperature cycle test 30 Acceptance test on assembled insulators c) Puncture Test d) Galvanizing test e) Electromechanical failing load test f) Porosity test a) Visual Examination b) Electrical Tests c) Mechanical tests a) Visual Examination b) Verification of Dimensions c) Visible discharge test d) Impulse withstand voltage test e) Wet power frequency withstand voltage test 32 Type Test * f) Temperature cycle test g) Puncture test h) Porosity test i) Galvanizing test J) Electro-mechanical failing load test k) Thermal Mechanical Performance Tests Major Major Major Major Major Major Test Test Test Test Test Test As per IS: 731 As per IS: 731 As per IS:731 As per IS: 731 As per IS: 731 As per IS: 731 As per IS: 731 As per IS: 731 As per IS:731 As per IS: 731 As per IS: 731 As per IS: 731 As per IS: 731 As per IS: 731 As per IS:731 As per IS: 731 As per IS: 731 As per IS: 731 TPL TPL TPL TPL TPL TPL Major Major Major Major Major Major Major Major Major Major Major Major Major Major Measurement Test Test Test Test Test Test Test Test Visually Measurement Test Test Test As per IS:731 As per IS:731 As per IS:731 As per IS:731 As per IS:731 As per IS:731 100% 100% 100% As per IS: 731 As per IS: 731 As per IS: 731 As per IS: 731 As per IS: 731 As per IS:731 As per IS:731 As per IS:731 As per IS:2633 As per IS:731 As per IS:731 As per IS:731 As per IS:731 As per IS:731 As per IS: 731 As per IS: 731 As per IS: 731 As per IS: 731 As per IS: 731 As per IS:731 As per IS:731 As per IS:731 As per IS:2633 As per IS:731 As per IS:731 As per IS:731 As per IS:731 As per IS:731 As per IS: 731 As per IS: 731 As per IS: 731 As per IS: 731 As per IS: 731 QC Report QC Report QC Report QC Report QC Report QC Report QC Report QC Report QC Report TPL TPL TPL TPL TPL
P P P P P P P P P W W W W W W W W W W W
CHP CHP CHP CHP CHP CHP
31
Routine Tests
CHP CHP CHP CHP CHP CHP CHP CHP CHP CHP CHP
*-All type tests to be carried out as per NESCL specification, Contract Agreement and as per minutes of the meeting between NESCL and main contractor. Approval of type tests by Engineering department of NESCL or waival thereof to be shown at the time final inspection to enable NESCL issue MDCC. - Record identified'' "tick mark" shall be essentially included by supplier in QA Documentations.

MANUFACTURE'S NAME & ADDRESS: ITEM: LT PVC Un-Armoured Cable QP NO: REV.NO: DATE: No of pages:3 Reference Document 7 PROJECT/UTILITY: PACKAGE: Guna CONTRACT NO: IVRCL, Myur MAIN-CONTRACTOR: Acceptance Norms 8 Format of Records 9 D* M IS 5484 & P.S do do do IS 1554(Pt-1) &P.S do do do IS 5831 & P.S do do do IS 10418 & P.S Agency ** 10 C N V V V V V V V V V V V V V C V V V V V V V V V V V V V V V V V V V V V V N V V V V V V V V V Review of Supplier's Test Certificate at the time of final inspection do do do do do do do do Remarks 11 Review of Supplier's Test Certificate at the time of final inspection do do do Review of Supplier's Test Certificate at the time of final inspection do do do Review of Supplier's Test Certificate at the time of final inspection do do do do
SUB-SYSTEM: Sl.N o 1 Component & operation 2 Characteristics 3 Class Type of Check Quantum of Check 6
4 5 SECTION: 1 RAW MATERIALS M/A Physical Physical Physical Electrical Physical Physical Physical Electrical Physical Physical Physical Physical Measurement
a) Dimension 1 Aluminium Rod M/A b) Tensile Strength c) Elongation M/A d) Resistivity / Conductivity M/A M/A 2 PVC for insulation (Type-A) a) Thermal Stabilty b) Tensile Strength c) Elongation d) Volume Resistivity (Insulation Resisrance) M/A M/A M/A M/A 3 PVC for Sheath (Type-ST1) a) Specific Gravity b) Thermal Stabilty c) Tensile Strength d) Elongation Dimension M/A M/A M/A M/I
One sample from each lot do do do One sample from each lot do do do One sample from each lot do do do As per IS 10418
IS 5484 & NESCL Spec.

do do do IS 1554(Pt-1) NESCL Spec. do do do IS 5831 & NESCL Spec. do do do IS 10418 & NESCL Spec.
QC report QC report QC report QC report QC report QC report QC report QC report QC report QC report QC report QC report QC report
P P P P P P P P P P P P P M
Wooden Drum
SECTION: 2 IN PROCESS INSPECTION M/A 5 Wire Drawing a) Dimension b) Tensile Strength c) Wrapping test M/A M/A M/A 6 Insulation (Extrusion) a) Thickness b) Surface Finish c) Spark Test d) Colour e) Tensile Strength f) Elongation M/A M/A M/A M/A M/A Measurement Physical Physical Measurement Visual Electrical Visual Physical Physical 10% do do 100% do do do do do IS 8130 do do IS 1554 (Pt-I) & P.S do do do do do
IS 8130 & A.D.S do do IS 1554 (PtI)NESCL Spec.& A.D.S do do do do do
QC report do do QC report do do do do do
P P P P P P P P P
Page 1 of 2

MANUFACTURE'S NAME & ADDRESS: ITEM: LT PVC Un-Armoured Cable QP NO: REV.NO: DATE: No of pages:3 Reference Document 7 PROJECT/UTILITY: PACKAGE: Guna CONTRACT NO: IVRCL, Myur MAIN-CONTRACTOR: Acceptance Norms 8 IS 1554 (Pt-I) NESCL Spec.& A.D.S do do do do do Format of Records 9 D* Agency ** 10 Remarks 11 Review of Supplier's Test Certificate at the time of final inspection do do do do do
SUB-SYSTEM: Sl.N o 1 Component & operation 2 Characteristics 3 Class 4 Type of Check 5 Quantum of Check 6
d) Surface Finish 7 Outer Sheath
M/A
Visual
100% do do do do do
IS 1554 (Pt-I) & P.S do do do do do
QC report do do do do do
P P P P P P M P P V
V V V V V V C V V V
V V V V V V N V V V
b) Sheath Thickness M/A Measurement M/A Measurement c) Diameter Over outer sheath d) Tensile Strength M/A Physical f) Elongation M/A Physical f) Embossing M/A Visual SECTION: 3 Final Testing Critical a) Conductor resistance b) High Voltage Critical Critical Electrical Electrical Electrical
Routine test
100% do Sample As per sampling plan of IS 1554(Pt-I)/1988 do do do do do do do Random
As per IS1554(PtI)/1988 do
As per IS1554(PtI) /1988
QC report do Type Test Report
Type Test
Type Tests
10
Acceptance test
Critical a) Conductor resitance b) Test for thickness of Critical insulation & sheath c) Tensile strength & elongation test for Critical Insulation & Sheath d) High voltage test Critical e) Annealing ( for Copper) Critical f) Wrapping for Aluminium Critical g) Tensile for Aluminium Critical h) Insulation Resistance ( V. R) Critical Major
Electrical Physical Physical Electrical Electrical Electrical Electrical Electrical Visual
do As per IS1554(PtI) /1988 As per IS, A.D.S & As per IS1554(PtNESCL I)/1988 Specification As per IS1554(PtI)/1988 do do do do do do do NESCL specification P.S= Plant Standard A.D.S= Approved Data Sheet M/I=Minor do do do do do do do NESCL specification
Routine test certificate will be furnished for verification during final inspection do Type Test Clearance from NESCL Engineering Department
QC report do do do do do do do do
P P P P P P P P P
W W W W W W W W V
W W W W W W W W V
11
Packing & Marking
M= Manufacturer N= Customer (NESCL) C = Contactor SIGNATURE OF THE MANUFACTURER
P= Performed By V= Verified By W= Witness of test M/A= Major
Page 2 of 2
1
MANUFACTURERS NAME AND ADDRESS :

ITEM :11 KV HG FUSE QP NO.: REV. NO.: Date:
REFERENCE DOCUMENT
PROJECT/ UTILITY: PACKAGE: CONTRACT NO.: MAIN-SUPPLIER:
NO
COMPONENT & OPERATIONS
CHARACTERISTICS
CLASS
TYPE OF CHECK
QUANTUM OF CHECK
ACCEPTANCE NORMS
FORMAT OF RECORDS
AGENCY
REMARKS
CTIION: 1 RAW MATERIAL

IS-191 IS-191 Part-IV, IS-1897 IS-191 Part-II IS-1897 IS-191 Part-IV, IS-1897 IS-191 Part-II IS-1897 Review of Manufacturer QC RECORD P V V ----DO--QC RECORD P V V
Visual Examination
Major
PH
Part-IV, IS-1897 IS-191
Review Of Records At The Time Of Final Inspection
Dimension
Major
PH
Part-II IS-1897
Tensile Strength
COPPER FLATS
Major
ME
IS-1608
IS-1608
IS-1608
SUPPLIER TC
IS-191
IS-191 Part-IV IS-1897 IS-191 Part-IV IS-1897 IS-191 Part-IV IS-1897 IS-5082 IS-3965
IS-191 Part-IV IS-1897 IS-191 Part-IV IS-1897 IS-191 Part-IV IS-1897 IS-5082 IS-3965 QC RECORD QC RECORD P P V V V V Review Of Records At The Time Of Final Inspection ---DO--Review of Manufacturer SUPPLIER TC V V V ---DO--SUPPLIER TC V V V ---DO--SUPPLIER TC V V V ---DO---
Major
CH
Bend Test
Major
ME
Resistivity /Conductivity
Major
Part-IV IS-1897
Visual Examination Dimension
Major Major
PH PH
IS-5082 IS-3965
Tensile Strength
ALUMINIUM FLATS
Major
ME
SUPPLIER TC IS-1608 IS-5082 IS-5082 IS-5082 IS-1608 IS-5082 IS-5082 IS-5082 IS-1608 IS-5082 IS-5082 IS-5082 SUPPLIER TC SUPPLIER TC SUPPLIER TC
Bend Test Resistivity /Conductivity Chemical Composition
Major Major
ME E CH
V V V
V V V
V V V
---DO-----DO-----DO---
Major
2
NO COMPONENT & OPERATIONS 2. CHARACTERISTICS CLASS TYPE OF CHECK 5. QUANTUM OF CHECK 6. REFERENCE DOCUMENT 7. ACCEPTANCE NORMS 8. FORMAT OF AGENCY RECORDS M C 9.
QC RECORD
3.
4. Major
10. P V V
Visual Examination
PH
IS-2062
IS-2062
IS-2062
IS-808, Dimension Major PH IS-1730, IS-1732, IS-3954 MILD STEEL SECTIONS Tensile Strength Major ME IS-1608
IS-808, IS-1730, IS-1732, IS-3954
IS-808, IS-1730, IS-1732, IS-3954 Review of Manufacturer

SUPPLIER TC QC RECORD
---DO---
IS-1608
IS-1608
Major
CH
IS-2062
IS-2062
IS-2062
SUPPLIER TC
---DO--Review Of
Bend Test
Major
ME
IS-2062
IS-2062
IS-2062
QC RECORD
Visual Examination
Major
PH
100% 10 Nos.
PLANT STANDARD PLANT STANDARD PLANT
PLANT STANDARD PLANT STANDARD PLANT STANDARD PLANT STANDARD
QC RECORD
---DO---
Dimension CONTACT SPRIGS Functional check
Major
PH
QC RECORD
per lot --DO--
---DO---
Major
PH
QC RECORD
STANDARD PLANT
---DO---
Fitment/Springs
Major
PH
--DO--
QC RECORD
STANDARD
---DO---
3
NO COMPONENT & OPERATIONS 2. CHARACTERISTICS CLASS TYPE OF CHECK 5. QUANTUM OF CHECK 6. REFERENCE DOCUMENT 7. ACCEPTANCE NORMS 8. FORMAT OF RECORDS AGENCY REMARKS M 10. P V V C N 11. Review Of Visual Examination Major PH IS-1367-III IS-1367-III IS-1367-III
QC RECORD
3.
4.
9.
Dimension
Major
PH
IS-1363
IS-1363
IS-1363
QC RECORD
FASTNERS
Wedge Test
Major
ME
IS-1367-III
IS-1367-III
IS-1367-III
SUPPLIER TC
Hardness
Major
ME
IS-1367-III
IS-1367-III
IS-1367-III
SUPPLIER TC
---DO---
Galvanizing
Major
Major
CH
IS-1367-XIII
IS-1367-XIII
IS-1367-XIII
SUPPLIER TC
---DO--Review Of Records
Visual
PH
IS-2486- II
IS-2486- II
IS-2486- II
QC RECORD
GI PINS
Dimension
Major
PH
IS-2486- II
IS-2486- II
IS-2486- II
QC RECORD
Galvanization Checks
Major
CH
IS-4759
IS-4759
IS-4759
SUPPLIER TC
4
COMPONENT & OPERATIONS 2. CHARACTERISTICS CLASS TYPE OF CHECK 5. QUANTUM OF CHECK 6. REFERENCE DOCUMENT 7. IS-2544 Visual Major PH 100% IS-5350 IS-731 IS-2544 Dimension Major PH IS-5350 IS-731 Major IS-2544 IS-731 IS-2544 IS-731 IS-2544 IS-731 IS-2544 IS-731 IS-2544 IS-731 IS-2544 Galvanizing test Major CH IS-4759 IS-731 AL. ALLOY ZINC Chemical Composition Chemical Composition Major Major CH CH IS-617 IS-209 IS-13229 IS-2544 IS-731 IS-2544 IS-731 IS-2544 IS-731 IS-2544 IS-731 IS-2544 IS-731 IS-2544 IS-4759 IS-731 SI-617 IS-209 IS-13229 IS-2544 IS-731 IS-2544 IS-731 IS-2544 IS-731 IS-2544 IS-731 IS-2544 IS-731 IS-2544 IS-4759 IS-731 IS-617 IS-209, IS-4759
SUPPLIER TC SUPPLIER TC SUPPLIER TC SUPPLIER TC SUPPLIER TC
NO
ACCEPTANCE NORMS 8. IS-2544 IS-5350 Is-731
FORMAT OF RECORDS 9.
AGENCY M C 10. N
REMARKS
3.
4.
11. NGK Birla/ WSI/ Jayshree
QC RECORD
Makes only. Insulators will be Inspected at the manufacturers factory
Approved Drgs.
Approved Drgs.
QC RECORD
---DO---
Review of Manufacturer
SUPPLIER TC
High Voltage Test
INSULATOR
Temperature Cycle
Major
SUPPLIER TC
-----DO----
Mechanical Strength/Failing load Test
Major
ME
-----DO----
Puncture Test
Major
-----DO----
Porosity Test
Major
PH
-----DO----
-----DO----
V V
V V
V V
---DO-----DO---
SUPPLIER TC
5
COMPONENT & OPERATIONS 2. CHARACTERISTICS CLASS TYPE OF CHECK 5. QUANTUM OF CHECK 6. REFERENCE DOCUMENT 7. ACCEPTANCE NORMS 8. FORMAT OF RECORDS 9.
QC RECORD
AGENCY M 10. P V V C N
NO
REMARKS
3.
4. Major
Visual
PH
IS-1239
IS-1239
IS-1239
Dimension
Major
PH
IS-1239
Approved Drgs
IS-1239
QC RECORD
-----DO---Review of Manufacturer
Chemical Analysis
Major
CH
IS-1239
IS-1239
IS-1239
SUPPLIER TC
GI TUBES
Tensile Strength
Major
ME
IS-1239
IS-1239
IS-1239
SUPPLIER TC
-----DO----
Elongation
Major
ME
IS-1239
IS-1239
IS-1239
SUPPLIER TC
-----DO----
Bend Test
Major
ME
IS-1239
IS-1239
IS-1239
QC RECORD
Review Of Records At The Time Of Final Inspection Review of Manufacturer
Galvanizing
Major
CH
IS-1239
IS-1239
IS-1239
SUPPLIER TC
6
NO COMPONENT & OPERATIONS 2. CHARACTERISTICS CLASS TYPE OF CHECK 5. QUANTUM OF CHECK 6. REFERENCE DOCUMENT 7. ACCEPTANCE NORMS 8. FORMAT OF RECORDS 9. AGENCY REMARKS M 10. C N 11.
3.
4.
CTIION: 2 INPROCESS INSPECTION

Review Of Records
Visual Examination
Major
PH
100%
-FQP
-FQP
QC RECORD
WELDED/FABRICATED M.S. COMPONENT Dimension Major PH
Min. five sample per lot
-FQP
-FQP
QC RECORD
----DO---
Fitment/Assembly
Major
PH
One sample per lot 100% Min. five sample per lot One sample per lot
-FQP
-FQP
QC RECORD
----DO---
Visual Examination FABRICATION OF COPPER CONTACTS Fitment /Assembly Dimension
Major Major
PH PH PH
-FQP -FQP
-FQP -FQP
QC RECORD
P P P
V V V
V V V
----DO-----DO------DO---
QC RECORD
Major
-FQP
-FQP
QC RECORD
Visual Examination
Major
PH
100% One sample
IS-4759
IS-4759
QC RECORD
----DO---
Appearance HOT DIP GALVANIZING Uniformity Mass of zinc
Major
PH
of each component per lot
IS-2629
IS-2629
QC RECORD
----DO---
Major Major
CH CH
-----DO-------DO----
IS-2633 IS-6745
IS-2633 IS-6745
QC RECORD
P P
V V
V V
----DO------DO---
QC RECORD
7
NO COMPONENT & OPERATIONS 2. CHARACTERISTICS CLASS TYPE OF CHECK 5. QUANTUM OF CHECK 6. REFERENCE DOCUMENT 7. ACCEPTANCE NORMS 8. FORMAT OF RECORDS 9. AGENCY M 3. 4. Major Visual Examination PH 100% IS-5561 IS-5561
QC RECORD
C 10.
Dimension
Major
PH
One sample perApprove lot d drags.
Approved Drgs.
QC RECORD
-----DO---Review of type test
Major Tensile TERMINALS CONNECTOR ME Type test IS-5561 IS-5561 TYPE TEST REPORT W V V
from CPRI/NABL approved lab on similar connector.
Resistance
Major
Type test
IS-5561
IS-5561
TYPE TEST REPORT
V -----DO----
Temperature Rise
Major
Type test
IS-5561
IS-5561
TYPE TEST REPORT
-----DO----
-----DO---Short Time Current test Major E Type test IS-5561 IS-5561 TYPE TEST REPORT W V V Review Of Visual Examination Major PH 100% IS-3203 IS-6012 IS-3203 IS-6012 SV W V V Inspection Records At The Time of Final Inspection One sample Thickness of plating Major PH of each components per lot IS-3203 IS-6012 IS-3203 IS-6012 SV W V V ---DO---
ELECTROPLATING
8
NO COMPONENT & OPERATIONS 2. CHARACTERISTICS CLASS TYPE OF CHECK 5. PH QUANTUM OF CHECK 6. 100% REFERENCE DOCUMENT 7. -FQP Approved/Floor Drgs. Approved/Floor Drgs. ACCEPTANCE NORMS 8. -FQP Approved/Floor Drgs. Approved/Floor Drgs. FORMAT OF AGENCY RECORDS M C 9. QC RECORD P 10. V
V REMARKS
N
3. Visual Examination
4. Major
Dimension ASSEMBLIES/SUBASSEMBLIES Verification of components
Major
PH
10%
QC RECORD P
---DO---
Major
PH
10% Min. one
QC RECORD P
---DO---
Functional check
Major
PH
sample per lot
-FQP
-FQP
QC RECORD P
---DO--V
PACKING
Visual
Major
PH
100%
QC RECORD P
Verification of packing List at the time of final inspection & review
9
COMPONENT & OPERATIONS CHARACTERISTICS CLASS TYPE OF CHECK QUANTUM OF CHECK REFERENCE DOCUMENT ACCEPTANCE NORMS FORMAT OF RECORDS AGENCY REMARKS M C N
L. NO
ECTIION: 3 PRODUCT TESTING IS-9385 & NESCL Technical specification IS-9385, NESCL Technical specification, Approved Drgs. QC RECORD P V V Type Test Clearance W V V from NESCL Engineering Department Review Of Routine test reports during final Inspection
TYPE TEST HG FUSE
All type tests as per relevant IS & Technical Specifications
Major
TTR
Prototype
IS-9385, NESCL Technical specification
TYPE TEST REPORT
1) ROUTINE TEST-HG FUSE 2)
Dielectric Tests Temperature Rise Major
Routine Checks
IS-9385, NESCL 100% Tech. Spec., Approved Drgs.
Tests at rated current
1) Visual Examination
Major
PH
100%
IS-9385, Part-I-V
IS-9385, Part-I-V
Test Report P
2) Dimension
Major
PH
Sample as Per IS: 2500
Approved Drgs.
Approved Drgs.
Test Report
ACCEPTANCE TESTSHG FUSE
3) Verification of component
Major
PH
Sample as Per IS: 2500 Sample as
Approved Drgs
Approved Drgs
Test Report
4)
Dry Power Frequency withstand voltage test Major
Per IS: 2500
IS-9385, Part-I-V
IS-9385, Part-I-V
Test Report Test Report Test Report
5) Temperature Rise Tests at rated current 6) used Test for composition and
Major
Sample as Per IS: 2500 Sample as Per IS: 2500
IS-9385, Part-I-V
IS-9385, Part-I-V
mechanical strength of Aluminum
Major
IS-9385, Part-I-V
IS-9385, Part-I-V
Please mention name of SubVendor for Aluminum
SECTIION: 5 REMARKS The MQP should be read in conjunction with NESCL specification and shall deem to include additional tests if any required as per contract. In case of any contradiction between the manufacturers manufacturer FQP & NESCL FQP, this MQP and NESCL specification following precedence shall be followed: a) NESCL specification b) This Manufacturing Quality Plan c) Manufacturers FQP. It is the responsibility of the manufacturer to ensure that this document is readily available at their works as well as at the works of their sub vendors in order to avoid any delay at the time of inspection. In case of any tests being carried out at third party lab, such lab/facility should be NABL accredited / accepted by NESCL.
10
The raw material/bought out items should be procured from reputed sources. The manufacturer shall maintain the proper co-relation of test certificates from raw material stage to finished product stage and the records should be available during inspection by NESCL. Any material rejected during power grid inspection shall be disposed off with the approval of NESCL. For destructive disposal NESCL may depute its representative for witnessing. In case the material is to be returned to sub vendor, all such items shall be indelibly marked (to prevent mixing) at the works of the manufacturer and offered to NESCL Inspector for verification of marking. Insulators shall be procured from M/S Birla NGK (JSI)/ India pottery only. LEGEND M: MANUFACTURER/SUB-SUPPLIER C: SUPPLIER/ NOMINATED INSPECTION AGENCY (SUBJECT TO PRIOR APPROVAL OF NESCL), N: NESCL P: PERFORM W: WITNESS AND V: VERIFICATION. AS APPROPRIATE, ,PH:PHYSICAL, E:ELECTRICAL ME:MECHANICAL,CH:CHEMICAL CHP: NESCL SHALL IDENTIFIED IN COLUM N DOC. NO.: REV CAT..
ANUFACTURER
MAINSUPPLIER
UB-SUPPLIER SIGNATURE
FOR NESCL USE REVIEWED BY APPROVED BY APPROVAL SEAL
10

Item : : Name of the Contractor Name of the Sub- contractor Name of the Package LOA No LOA Date Sl.No M S FABRICATED ITEMS : : : : : Characteristics Class Type of Check Quantum of Check Reference Document Acceptance Norms MQP NO: Format of Records M C 1.1 PHYSICAL RAW MATERIAL (MS PROPERTIES SECTIONS, ANGLES, CHANNELS, FLATS, 1.2 CHEMICAL RODS, SHEETS ETC.) PROPERTIES MAJOR DOCUMENT VERIFICATION DOCUMENT VERIFICATION 100% NESCL Specification & IS 2062 NESCL Specification & IS 2062 IS 2062 GRADE-A Supplier TC V V N V SOURCING FROM NESCL APPROVED SUPPLIERS ONLY THE SAMPLE SHALL BE TESTED AT THIRD PARTY LAB OR MFG'S OWN LAB AS DESIRED BY NESCL THE MANUFACTURING PROCESS CHART RELEVANT TO THE MACHINE SHALL BE DISPLAYED AT THE RESPECTIVE WORK AREAS Agency Remarks
MAJOR
100%
IS 2062 GRADE-A
Supplier TC
2.1 DRILLING
MAJOR
VISUAL/ MEASURE MENT VISUAL/ MEASURE MENT VISUAL/ MEASURE MENT VISUAL/ MEASURE MENT
100%
PLANT STANDARD
AS PER APPROVED FABRICATION DRAWINGS AS PER APPROVED FABRICATION DRAWINGS AS PER APPROVED FABRICATION DRAWINGS AS PER APPROVED FABRICATION DRAWINGS
QC Record
2.2 CUTTING 2.3 BENDING 2.4 ARC WELDING 2.4.1 SELECTION OF ELECTRODE SIZE & CURRENT RANGE MANUFACTURING PROCESSES
MAJOR MAJOR MAJOR
100% 100% 100%
PLANT STANDARD PLANT STANDARD AS PER WELDING PROCESS SPECIFICATION PLANT STANDARD
P P P
V V V
V V V QUALIFIED AND EXPERIENCED WELDERS SHALL BE ENGAGED NESCL APPROVED WELDING ELETRODES SHALL BE USED. CHART RELEVANT TO THE WELDING PROCESS SHALL BE DISPLAYED
MAJOR
VISUAL
100%
PLANT STANDARD
QC Record
2.4.2 PROCESS OF WELDING
MAJOR
VISUAL
100%
WELDING SHOULD BE FREE FROM DEFECTS SUCH AS BLOW HOLES, BURN THROUGH, INCLUSIONS, LACK OF FUSION, INCOMPLETE PENETRATION, CRACKING Etc PROPER EDGE PLANT STANDARD PREPARATION, CORRECT WELD CURRENT RANGE SUITABLE TRAVEL OF THE ELECTRODE, REMOVING THE SLAG FROM PREVIOUS RUNS BY BUFFING E.T.C SHOULD BE ADHERED TO FOR GOOD WELDING PLANT STANDARD NO VISIBLE CRACKS, BLOW HOLES ALLOWED ON THE WELDMENTS
QC Record
THE PROBABLE CAUSES FOR THE WELD DEFECTS SHALL BE DISPLAYED IN THE WELDING AREA AND THE WELDERS AND HELPERS SHOULD BE REGULARLY TRAINED IN WELDING
2.4.3 POST WELD INSPECTION 3 GALVANISATION
MAJOR
DP TEST
RANDOM
QC Record
SEPARATE QUALITY PLAN IS TO BE SUBMITTED FOR GALVANISATION PROCESS COVERING ALL SEVEN TANK PROCESSES AS PER IS: 2629
3.1 DIMENSIONAL CHECKS 1 CLEANED SURFACES OF THE COMPONENTS 2 SMOOTH WELDMENT SURFACES 3. DIMENSIONS OF THE COMPONENTS AS PER DRAWINGS CHECKED WITH USE OF JIGS AND FIXTURES
3.1.1 DIMENSIONAL CHECKS
CRITICAL
VISUAL AND DIMENSIONAL
RANDOM
NESCL SPECIFICATION AND PLANT STANDARD
INSPECTION REPORT
3.2 MECHANICAL PROPERTIES 3.2.1 ULTIMATE TENSILE STRENGTH CRITICAL (UTS) 3.2.2 PERCENTAGE CRITICAL ELONGATION 3.2.3 YIELD CRITICAL STRENGTH 3.2.4 BEND TEST 4 FINAL INSPECTION CRITICAL
TEST TEST TEST TEST
SAMPLE AS PER IS; 2062 SAMPLE AS PER IS; 2062 SAMPLE AS PER IS; 2062 SAMPLE AS PER IS; 2062
INSPECTION REPORT INSPECTION REPORT INSPECTION REPORT INSPECTION REPORT
P P P P
W W W W
W W W W
3.3 GALVANIZING CHECKS 3.3.1 UNIFORMITY OF ZINC COATING (PREECE DIP TEST) 3.3.2 MASS OF ZINC COATING 3.3.3 ADHESION TEST (PIVOTED HAMMER/ KNIFE TEST) 3.3.4 THICKNESS OF ZINC COATING CRITICAL TEST ONE SAMPLE NESCL Specification, FOR EVERY 20 IS: 2629, IS: 4759 & MT IS: 2633 ONE SAMPLE NESCL Specification, FOR EVERY 20 IS: 2629, IS: 4759 & MT IS: 2633 ONE SAMPLE NESCL Specification, FOR EVERY 20 IS: 2629, IS: 4759 & MT IS: 2633 ONE SAMPLE NESCL Specification, FOR EVERY 20 IS: 2629, IS: 4759 & MT IS: 2633 NESCL Specification, IS: 2629, IS: 4759 & IS: 2633 INSPECTION REPORT P W W
CRITICAL
TEST
INSPECTION REPORT
CRITICAL
TEST
INSPECTION REPORT
CRITICAL
TEST
INSPECTION REPORT
3.4 CHEMICAL COMPOSITION 3.4.1 CHEMICAL TEST CRITICAL TEST SAMPLE NESCL Specification & IS 2062 IS 2062 GRADE-A LAB REPORT V V V SAMPLES OF THE MATERIAL MAY BE TAKEN & SENT TO GOVT. APPROVED LAB FOR CHEMICAL ANALYSIS TEST.
STORAGE
5.1 PROPER STORAGE OF FINISHED MATERIAL
MAJOR
VISUAL
100%
STANDARD PRACTICE
FINISHED PRODUCT SHALL BE STORED ON FLAT COVERED SURFACE WITH NO WATER LOGGING
QC RECORD
PACKING & DESPATCH
VISUAL INSPECTION FOR COMPLETENESS OF ALL COMPONENTS
MAJOR
VISUAL
100%
STANDARD PRACTICE/ PACKING CHECK LIST
PACKING CHECK LIST
DESPATCH REGISTER
LEGEND :
M - MANUFACTURER C - CONTRACTOR N - CUSTOMER -- NESCL P - PERFORM
V - VERIFY W - WITNESS QC - QUALITY CONTROL
SIGNATURE OF THE CONTRACTOR SIGNATURE OF THE MANUFACTURER
MANUFACTUER'S NAME & ADDRESS:

ITEM: PIN INSULATORS UPTO 33 Kv SUB-SYSTEM: QP NO: REV.NO: DATE: PAGE:.OF.. Quantum of Check 6 Reference Document 7 Acceptance Norms 8 PROJECT/UTILITY: PACKAGE: CONTRACT NO: MAIN-CONTRACTOR: Format of Records 9 M White/off White, deep cream colour in raw form 4% Max. The residue shall be free from iron impurities white to cream, free from black specks. Supplier test certificate approx 30-40% 40-55% <4% <2% 16-19% 6% Max 18% Max white to deep cream/ yellow colour < 5% The residue shall be free from iron impurities White/off white to cream/Buff free from impurities. Supplier test certificate approx >25% 50-60% < 3% < 3% < 13% 6% Max 18% Max QC Report QC Report QC Report V P V Agency ** C V V V 10 N V V V Record review during final inspection Do Do Remarks 11
Sl.No 1
Characteristics 3
Class 4
Type of Check 5
SECTION: RAW MATERIALS INSPECTION a) Inspection b) Residue retained on 300 mesh (BSS) c) Fired colour d) Chemical analysis 1 China clays Al2 03 Sio2 Fe2 03 Tio2 LOI at 1220 c e) Dry shrinkage f) Total shrinkage a) Inspection b) Residue retained on 240 mesh c) fired colour d) Chemical analysis Al2 03 Sio2 Fe2 03 Tio2 LOI at 1220oc e) Dry shrinkage f) Total shrinkage Major Major Test Test Do Do Major Major Major Major Test Test Visual Test Do Do 0.01% in the total wt Do
o
Major Major Major
Visual Test Visual
0.01% in the total wt Do Do
IRM/CD/TP/2 Major Test Sampling Once in 250 MT
Supplier TC/ QC lab/TPL Supplier TC/ QC lab/TPL QC Report QC Report
P P V P
V V V V
V V V V
Record review during final inspection Do Record review during final inspection Do
Major
Visual
Do
QC Report
Do
Ball clays
IRM/CD/TP/2 Major Test Once in 250 MT
P P
V V
V V
Record review during final inspection Record review during final inspection
Sl.No 1
Characteristics 3 a) Inspection b) Residue retained on 240 mesh (BSS) c) fired colour
Class 4 Major
Quantum of Check 6 0.01% in the total wt Do
Acceptance Norms 8 White to off White raw colour < 3%Max The residue shall be free from iron particles and magnetic impurities Off white to White free from impurities Nil, No vitrification Supplier test certificate approx 98% Min 0.25% Max. 0.5% Max
Format of Records 9 QC Report V
Agency ** V 10 V
Remarks 11 Record review during final inspection Do
Major
Test
QC Report
Major Major
Visual Visual
Do Do IRM/CD/TP/1
QC Report QC Report
V V
V V
V V
Do Do
Quartz Powder
d) Sintering
e) Chemical analysis SiO2 Fe2 O3 LOI at 1000 c

o
Major
Test
Sampling Once in 250 MT
a) Inspection b) Residue retained on 240 mesh c) fired colour d) Firing behavior 4 Feldspar powder e) Chemical analysis K2O+Na2O K2O Na2O Fe2O3 LOI at 1000OC
Major
Visual
0.01% in the total wt Do Do Do IRM/CD/TP/1
White to light pink colour < 3% Max The residue shall be free from iron particles and magnetic impurities Grayish/off white to white Vitirified mass free from impurities Suppliertest certificate approx 13% Min 11% Min. 3.5% Max 0.2% Max 0.5% Max
QC Report
Record review during final inspection Do Do Do
Major Major Major
Test Visual Test
P V P
V V V
V V V
Major
Test
Once in 250 MT
a) Inspection b) Residue retained on 300 mesh 5 Iron oxide c) Fired colour d) Chemical analysis Fe2O3 content
Major Major Major
Visual Test Visual
500 gms/MT or part thereof Do Do IRM/CD/TP/1
Dark brown colour 0.5% Max Block/Greyish black free from impurities Supplier test certificate approx 85% Min
V P V
V V V
V V V
Record review during final inspection Do Do T/C review during final inspection
Major
Test
Once in 1 MT
Sl.No 1
Characteristics 3 a) Inspection b) Residue retained on 300 mesh
Class 4 Major Major Major
Type of Check 5 Visual Test Visual
Quantum of Check 6 500 gms/MT or part thereof Do Do
Acceptance Norms 8 Dark Grey to black colour free from impurities 0.5% Max
Format of Records 9 QC Report QC Report QC Report V P V
Agency ** V V V 10 V V V
Remarks 11 Record review during final inspection Do Do T/C review during final inspection Record review during final inspection Do Do T/C review during final inspection Record review during final inspection Do Do T/C review during final inspection
Manganese di-oxide
c) Fired colour d) Chemical analysis MnO2 content
IRM/CD/TP/1
Black/ balckish violet free from impurities Supplier Test certificate 85% Min Bottle Green colour 0.5% Max
Major
Test
Once in 10 MT 500 gms/MT or part thereof Do Do IRM/CD/TP/1
a) Inspection b) Residue retained on 300 mesh 7 Chromium oxide c) Fired colour d) Chemical analysis Cr2O3 content
Major Major Major
Visual Test Visual
V P V
V V V
V V V
Dark Green free from impurities Supplier Test certificate 85% Min White to cream raw colour. Free from impurities
Major
Test
Once in 10 MT
a) Inspection b) Residue retained on 300 mesh c) Fired colour d) Chemical analysis CaO content
Visual Test Visual Test
500 gms/MT or part thereof Do Do Once in 10 MT IRM/CD/TP/1
QC Report QC Report QC Report Supplier TC/ QC lab/TPL
V P V P M
V V V V C V V V C V
V V V V N V V V N V
Calcite powder
3% Max Light greenish Supplier Test certificate 50% Min
SECTION: ASSEMBLY MATERIALS INSPECTION a) Inspection 9 Cement b) Compressive strength c) Expansion Major Visual Major Major Test Test 0.01% of total quantity received Do Each consignment IS: 12269 IRM/CD/TP/3 QC Report
No lumpiness/solidification. 380 Kg/cm2 0.8% Max
V P P M
Record review during final inspection T/C review during final inspection Do
QC lab/TPL QC lab/TPL
SECTION: METAL PARTS INSPECTION a) Inspection Major Visual 100% Lot sample size size (nos) (nos) 1-500 4 501-1000 6 1001+ 10 Do As per IS:2486 part-II No sharp / rough edges. QC Report
Record review during final inspection
11
Lead Thimble
b) Dimension
Major
Measurement
As per drawing
QC Report
Do
c) Gauge Checking
Major
Visual
QC Report
Do
Sl.No 1
Characteristics 3
Class 4
Type of Check 5
Quantum of Check 6
Acceptance Norms 8
Agency ** C V V V V V V V V V V V V V V V 10 N V V V V V V V V V V V V V V V
Remarks 11
SECTION: IN-PROCESS INSPECTION a) Inspection 12 Wet grinding of ceramic b) Residue retained on 300 body mesh c) Particle size Analysis 13 14 15 16 Slip's Litre Weight a) Moisture % Pug mill's clay blank b) De airing checking Major Major Major Major Major Major Major Major Major Major Major Major Major Major Major Visual Test Test Test Test Test Test Test Test Test Measurement Test Visual Test Test Each charge Do Once in week Daily once Twice in a shift Do Each charge Once in a day Once in week Once in a shift Do Once in a day Once in a day 3 samples per day Once in 3 month IP/CD/TP/1 IP/CD/TP/1 IP/CD/TP/1 Pale white to cream colour with no visual impurities < 30 grms/Ltrs <10 Microns-Min 70% < 30 Microns-Min 97% 1.40-1.50 Kg/litre 16.5-19% Min. 700mm of Hg vaccum Max. 2% Max. 2% 30 Kgs/cm Min As per drawing As per drawing 8 to 12% ( depending upon climate condition) Ambient-85oC 0.8% Max. Unglazed 750 Kgs/cm2 Min Glazed 850 gs/cm2 Min
2
QC Report QC Report QC Report QC Report QC Report QC Report QC Report QC Report QC Report QC Report QC Report QC Report QC Report QC Report QC Report
V P P P P P P P P P P P V P P
Record review during final inspection Do Do Do Do Do Do Do Do Do Do Do Do Do Do
Residue retained on 300 During glaze preparation mesh Properties of unfired porcelain a) Linear shrinkage b) Dry MOR a) Making cavity check b) Finishing dimension c) Moisture % before entry into dryer a) Hot rooms temperature
17
Shaping
18
Drying b) moisture content
a) Linear shrinkage 19 Properties of fired porcelain Fired MOR b) porosity c) Bulk density d) Water absorption
Major
Test Once in a day
< 14% 4 pieces from every unloaded car of Tunnel Kiln Daily once Daily once
QC Report
Major Major Major
Test Test Test
As per IS: 731
As per IS: 731 & 5300 2.38 Min 0.2% Max
P P P
V V V
V V V
Do Do Do
Sl.No 1
Class 4 Major Major Major Major
Type of Check 5 Visual Test Test Visual Visual Measurement
Quantum of Check 6 100% 3 samples per day Twice in a day. Hourly 100% 3 Nos/day
Acceptance Norms 8 Rose pink slip colour slurry with no visual impurities 2-3% Max 1.4-1.45 1220-1230 C depending on cycle As per IS:731 As per NESCL approved specified drawings
o
Format of Records 9 QC Report QC Report QC Report QC Report QC Report QC Report V P P V V P
Agency ** V V V V V V 10 V V V V V V
Remarks 11 Do Do
20
Glazing (Brown glaze) b) Moissture % c) Sp.gravity
20
Temperrature during firing of green wares a) Inspection Sorting of fired insulator b) Dimension & weight
Do Do Do
Major Major
21 Routine electrical (power a) Routine Electrical test frequency) & Mechnical Test on Assembled insulators b) Routine Mechanical test a) Inspection Major Test 100% As per IS 731 for Min. 5 minutes As per IS 731 for Min. 5 minutes
As per IS 731 for Min. 5 minutes As per IS 731 for Min. 5 minutes No broken planks
QC Report
Do
22
Major Major
Test Visual
100% 100% Lot sample size size (nos) (nos) 1-500 4 501-1000 6 1001+ 10
QC Report QC Report
P V
V V
V V
Do Do
23
Packing ( wooden ) crate
b) Dimension
Major
Measurement
As per Approved Drawing
QC Report
Do
SECTION: FINAL INSPECTION a) Dimension checking b) Temperature cycle test 24 Acceptance Tests c) Mechanical failing load test d) Porosity test e) Puncture Test a) Visual Examination b) Electrical Tests c) Mechanical tests a) Visual Examination b)Verification of Dimensions c) Visible Discharge test d) Impulse Withstand voltage test e) Wet power frequnecy withstand voltage test f) Dry power frequnecy withstand voltage test g) Temperature cycle test h) Mechanical failing load test i) Puncture test j) Porosity test Major Major Major Major Major Major Major Major Major Major Major Major Major Major Major Major Major Major Measurement Test Test Test Test Test Test Test Visual Measurement Test Test Test Test Test Test Test Test As per IS:731 As per IS:731 As per IS:731 As per IS:731 As per IS:731 100% 100% 100% As per IS:731 As per IS:731 As per IS:731 As per IS:731 As per IS:731 As per IS:731 As per IS:731 As per IS:731 As per IS:731 As per IS:731 As per IS:731 As per IS:731 As per IS:731 As per IS:731 As per IS:731 As per IS:731 As per IS:731 As per IS:731 As per IS:731 As per IS:731 As per IS:731 As per IS:731 As per IS:731 As per IS:731 As per IS:731 As per IS:731 As per IS:731 As per IS:731 As per IS:731 As per IS:731 As per IS:731 As per IS:731 As per IS:731 As per IS:731 As per IS:731 As per IS:731 As per IS:731 As per IS:731 As per IS:731 As per IS:731 As per IS:731 As per IS:731 As per IS:731 As per IS:731 As per IS:731 As per IS:731 QC Report QC Report QC Report QC Report QC Report QC Report QC Report QC Report TPL TPL TPL TPL TPL TPL TPL TPL TPL TPL
M P P P P P P P P W W W W W W W W W W
C W W W W W V V V W W W W W W W W W W
N W W W W W V V V W W W W W W W W W W CHP CHP CHP CHP CHP
25
Routine Tests
CHP CHP CHP CHP CHP CHP CHP CHP CHP CHP
26
Type Tests*
4/4/2008
STANDARD MANUFACTURING QUALITY PLAN- PSCC POLES

Item Name of the Contractor Name of the Sub- contractor Name of the Package LOA No LOA Date Sl.No 1 a) Dimensions High tensile Prestressing Cold Drawn Indented wire : : : : : : Characteristics Class Type of Quantum of Check Check RAW MATERIAL Measure As per IS:6003 As per IS:6003 As per IS:6003 As per IS:280 As per IS:209 Reference Document Acceptance Norms Format of Records M IS: 6003 IS: 6003 Supplier TC V MQP NO: PRE-STRESSED CEMENT CONCRETE POLES
Date:
Component & operation Agency C V N V SOURCING : _________________ _______________ Remarks
Major
1.1
b) Chemical Analysis
Major
Test
IS: 6003
IS: 6003
Supplier TC
c) Tensile strength a) Chemical Composition b) Zinc Grade 1.2 GI Wire for Earthing c) Zinc Coating d) Galvanizing a) Chemical Composition b) Physical Test 1.3 Cement 43Grade, OPC c) Setting Time d) Compressive Strength
Major
Test
IS: 6003
IS: 6003
Supplier TC
Test Test Test
IS:280 IS:209 As per IS:4826
IS:280 IS:209 As per IS:4826 IS:2629/6745/ 2633 IS: 8112 (1989) IS: 8112 (1989) IS: 8112 (1989) IS: 8112 (1989)
Supplier TC Supplier TC Supplier TC Supplier TC
V V V V
V V V V
V V V V
One Sample per Spool Visual As per IS:8112 As per IS:8112 As per IS:8112 As per IS:8112
IS:2629/6745/ 2633 IS:8112 IS:8112 IS:8112 IS:8112
Test Test Test Cube Test
Supplier TC Supplier TC Supplier TC supplier TC
V V V V
V V V V
V V V V SOURCING: _________________ _______________
4/4/2008
Sl.No
Characteristics
Class
Size 1.4 AGGREGATES Crushing Strength a) Physical 1.5 Steel Stirrups b) Chemical a) Check Casting Moulds for Dimensions, soundness,supports,al ignment and Cleanliness
Type of Quantum of Check Check RAW MATERIAL Sieve As per Major Analysis IS:2430 As per Major Mech IS:2386
Reference Document
Acceptance Norms
Format of Records
Agency
Remarks
IS : 383 IS:2386 IS:432 / IS:1786 IS:432 / IS:1786
IS : 383/Shall not exceed QC Record 12 mm

IS:2386 IS:432 / IS:1786 IS:432 / IS:1786 QC Record supplier TC supplier TC
P P P P
V V V V
V V V V
Major Major
visual Test
Eatch Batch Eatch Batch
Major
Measure
100%
NESCL Spec
NESCL Spec/Approved drg
QC Record
b) Pre-stressing of HT wires
c) Concrete Mix M420 2 MANUFACTURING d) Casting
Major
Measure
100% Sample as per IS:516
NESCL Spec/IS:1343 IS:516
NESCL Spec/IS:1343 IS:516/28 days strength shall not be less than 400 kg/sq.cm IS:456/ Standard Practice
QC Record
V Samples shall be tested at third party lab if desired by NESCL
Major
Cube Test
QC Record
Major
Visual
100%
IS:456/ Standard Practice
QC Record
e) Position, Nos. and Dimensions of Lifting Hooks f) Demoulding and Detensioning g) Curing a) Dimensional check for overall length, cross-sectional Dimensions and uprightness b) Transverse Strength Test
Major
Visual
For every casting
NESCL NESCL Spec/Approved Spec/Approved drg drg
QC Record
Major
Physical
100%
Detensioing shall be Standard done when the concrete Practice / attains 200 Kg/cm2/ NESCL Specs NESCL Spec
Plant Standard Plant Standard
QC Record
Major
Physical
100%
QC Record
Critical
Measure
Sampled as per IS:1678 Sampled as per IS:1678
IS:1678 /Approved drg
QC Record
FINAL PRODUCT TESTING
Critical
Test
IS : 2905
IS : 2905
QC Record
4/4/2008
Sl.No
Characteristics
c) Test for Cover
Type of Quantum of Check Check RAW MATERIAL Sampled as Critical Test per IS:1678 Class
Reference Document
Acceptance Norms
Format of Records
Agency
Remarks
QC Record
Poles Tested for Ultimate Transverse Strength Shall be tested for Cover
4/4/2008
Sl.No
Characteristics
Class
MARKING ABOVE THE PLANTING DEPTH
Project name : RGGVY NESCL Month&Year of Manufacture Transverse Strength of pole Makers Serial No. and Mark Coloured indelible depth marker at 1.5 mtrs, from bottom to verify planting depth a) Stacking
Type of Quantum of Check Check RAW MATERIAL
Reference Document
Acceptance Norms
Format of Records
Agency
Remarks
Major
Visual
100%
NESCL NESCL Specs/Approved Specs/Approve drg d drg
QC Record
Major Major Major
Visual Visual Visual/ Physical
Random Random 100%
NESCL Specs NESCL Specs
stacking with broader face vertical,Max. 4 nos. of vertical layers NESCL Specs No physical Damage
P P P
V V V
V V V
Pre-Shipment
b) Handling/ Transportation c) Physical Inspection
LEGEND :
M - MANUFACTURER C - CONTRACTOR N - CUSTOMER -- NESCL P - PERFOM
V - VERIFICATION W - WITNESSING QC-QUALITY CONTROL
Prepared By : Sh. Malay Mandal, Sr. Engineer(QA&I)
Reviewed By: Sh. Malay Mandal, Sr. Engineer(QA&I)
Approved By: Sh. A. K. Sharma, DGM (QA&I)

ITEM: SHACKLE INSULATORS SUB-SYSTEM: QP NO: REV.NO: DATE: Reference Document 7 PROJECT/UTILITY: PACKAGE: CONTRACT NO: MAIN-CONTRACTOR: Acceptance Norms 8 Format of Records 9 Agency ** 10 Remarks 11
Sl. No 1
Characteristics 3
Class 4
Type of Check 5
Quantum of Check 6
SECTION:1 RAW MATERIAL INSPECTION SECTION: 1.1 RAW MATERIAL FOR BODY a) Inspection / colour b) Residue retained on 200 mesh c) fired colour 1 Quartz Powder d) Sintering/fired behavior Major Visual 1 Kg/20 MT part thereof S 1201 White 2% Max. the residue shall be free iron particles and magnetic impurities White Should not stick to the container and no specks Vendor's test certificate Major Test Sampling Once in 3 month/ 300 MT S 1201 98% Min 0.25% Max. 1% Max Off White or pink colour 2% Max. the residue shall be free iron particles and magnetic impurities Translucent (glossy white) and low impurities Vendor's test certificate 11% Min 8% Min. 3.5% Max 1% Max 1.5% Max Supplier TC/ QC lab/TPL QC Report
M C N Record review during final inspection Do Do Do
V V V
Major Major Major
Test Visual Visual
Do Do Do
S 1201 S 1201 S 1201
P V V V V V V V V
e) Chemical analysis
SiO2 Fe2 O3 o LOI at 1000 c a) Inspection / colour b) Residue retained on 200 mesh
P V V
Major
Visual
1 Kg/20 MT part thereof
S 1201
QC Report
V V V
Major
Test
Do
S 1201
QC Report
P V V
c) fired behavior/Sintering 2 Feldspar powder d) Chemical analysis K2O+Na2O K2O Na2O Fe2O3 LOI at 1000OC
Major
Visual
Do
S 1201
QC Report
V V V
Do
Major
Test
Sampling Once in 3 month/300MT
S 1201
P V V
a) Inspection b) Residue retained on 200 mesh c) Fired colour d) Dry shrinkage e) Total shrinkage f) Chemical analysis Al2 03 Fe2 03 Tio2 LOI at 1000oc a) Inspection/ colour b) Residue retained on 200 mesh
Major
Visual
S 1201
cream/ pink 3% Max. the residue shall be free iron particles and magnetic impurities Snow white/ white 7% Max 16% Max Vendor's test certificate 30% Min 5% Max 2% Max 18% Max Dull white/ black 3% Max. the residue shall be free iron particles and magnetic impurities Pale cream/dull cream or light grey/white 7% Max 18% Max Vendor's test certificate 3% Min 25% Max 2% Max 13% Max
QC Report
V V V
Record review during final inspection Do Do Do Do
Test Visual Test Test
Do Do Do Do
S 1201 S 1201 S 1201 S 1201
QC Report QC Report QC Report QC Report
P V V V V V P V V P V V
China clays
Major
Test
S 1201
P V V
Major
Visual
S 1201
QC Report
P V V
Major
Test
Do
S 1201
QC Report
P V V
c) Fired colour 4 Ball clay d) Dry shrinkage e) Total shrinkage f) Chemical analysis Tio2 Al2 03 Fe2 03 LOI at 1000 c
o
Major Major Major
Visual Test Test
Do Do Do
S 1201 S 1201 S 1201
V V V P V V P V V
Do Do Do
Major
Test
S 1201
P V V
SECTION: 1.2 RAW MATERIAL FOR GLAZE a) Inspection/ colour b) Residue retained on 200 mesh 5 Iron oxide c) Fired colour of 1% iron oxide in feldspar powder d) Chemical analysis Fe2O3 content Major Visual 1 Kg/05 MT or part thereof S 1201 Red coloured powder QC Report V V V Record review during final inspection Do Do
Major Major
Test Visual
Do Do
S 1201 S 1201
2% Max Should match with the standard reference sample Vendor's test certificate approx 82% Min Black coloured powder 10% Max Should match with the standard reference sample Vendor's test certificate 78% Min
QC Report QC Report
P V V V V V
Major
Test
Sampling Once in 6 month/ 10 MT 1 Kg/05 MT or part thereof Do Do
S 1201
Supplier TC/ QC lab/TPL QC Report QC Report QC Report
P V V
T/C review during final inspection Record review during final inspection Do Do
a) Inspection/ colour b) Residue retained on 200 mesh c) Fired colour of 2% manganese dioxide in feldspar powder d) Chemical analysis MnO2 content
Major Major Major
Visual Test Visual
S 1201 S 1201 S 1201
V V V P V V V V V
Manganese di-oxide
Major
Test
S 1201
P V V
a) Inspection/ colour b) Residue retained on 200 mesh c) Fired colour of 3% chromium oxide in feldspar powder d) Chemical analysis Cr2O3 content
Major Major Major
Visual Test Visual
1 Kg/05 MT or part thereof Do Do
S 1201 S 1201 S 1201
Green coloured powder 2% Max Should match with the standard reference sample Vendor's test certificate 90% Min Off or dull white 5% Max of the residue shall be free from iron particles and magnetic impurities Free from ferrous/ferric impurities Vendor's test certificate 40% Min 0.5% Max 5% Max
V V V P V V V V V
Record review during final inspection Do Do
Chromium oxide
Major
Test
Sampling Once in 6 month/ 10 MT 1 Kg/05 MT or part thereof
S 1201
Supplier TC/ QC lab/TPL QC Report
P V V
T/C review during final inspection Record review during final inspection
Major
Visual
S 1201
V V V
Major
Test
Do
S 1201
QC Report
P V V
Do
Calcite powder
Fired characteristic d) Chemical analysis CaO Fe2O3 SiO2
Major
Visual
Do
S 1201
QC Report
V V V
Do
Major
Test
S 1201
P V V
Sl. No 1
Characteristics 3
Class 4
Type of Check 5
Quantum of Check 6
Acceptance Norms 8 Off White to cream colour with no visual impurities
Format of Records 9
Agency ** 10
Remarks 11
SECTION: 2 IN PROCESS INSPECTION Major 9 Wet grinding of ceramic body a) Inspection b) Residue retained on 200 mesh c) Litre Weight a) Residue retained on 300 mesh b) Litre Weight a) De airing checking Major Major Major Major Major Visual Test Test Test Test Test Each charge Do Do Each charge Do Every 30 Mins S 1003 S 1003 S 1003 S 1003 S 1003 QC Report QC Report QC Report QC Report QC Report QC Report
M C N V V V P V V P V V P V V P V V P V V Record review during final inspection Do Do Do Do Record review during final inspection Record review during final inspection Do
0.2% Max. 1350-1450 0.4% Max. 1500-1650 Min. 700mm of Hg vacuum 28 Kgs/cm2 Min Max. 14%
10
Glaze Preparation
11 Pug mill's clay blank
12
Properties of unfired porcelain
a) Dry MOR b) Linear shrinkage
Major Major
Test Test
Sampling Once in 3 month Sampling Once in month
S 1003 S 1003
QC Report QC Report
P V V P V V
13
Shaping
a) Making cavity check ( Dimension) b) Finishing dimension c) Moisture
Major Major Major Major Major Major
Measurement Measurement Test Visual Test Test
Once in every shift Do Once daily Once in a day 3 samples per day Sampling Once in 3 month All cars of every shuttle kiln & any one unloaded car of tunnel kiln daily & each kiln 100% Every hour 3 samples per day Every hour 100% 5 Nos/day
As per Drawing Do S 1003 S 1003 S 1003 S 1003
As per Drawing Do 8% before entry into drier 50-80 C 1.5% Max 2 Unglazed 750 kg/cm Min 2 glazed 850 kg/cm Min As per IS: 1445 2.38 Min / 0.2% Light buff colour slurry with no visual impurities 1.49-1.51 2.5% Max As per firing Graph As per IS: 1445 As per NESCL approved specified drawings Insulator to be free from cracks and physical distortion of shape No broken planks
o
QC Report QC Report QC Report QC Report QC Report QC Report
P V V P V V P V V V V V P V V P V V
Record review during final inspection Do Do Record review during final inspection Do Record review during final inspection
14
Drying
a) Hot rooms temperature b) moisture content a) Fired M.O.R
15 Properties of fired porcelain b) porosity c) Bulk density/Water absorption a) Inspection 16 Glazing (Brown glaze) b) Sp.gravity c) Moisture % Temperature during firing of 17 green wares a) Inspection 18 Sorting of fired insulator b) Dimension Major Major Major Major Major Test Test Visual Visual Measurement Major Major Major Test Test Visual
As per IS 1445 S 1003
QC Report QC Report QC Report QC Report QC Report QC Report QC Report QC Report
P V V P V V V V V P V V P V V V V V V V V P V V
Do Do Record review during final inspection Do Do Do Do Do
S 1003 S 1003 S 1003 Ref.sample S 1003
19 20 Sl. No 1
Routine Test Packing Crate
Visual Examination a) Inspection
Major Major
Visual Visual
100% 100%
AS per IS 1445 S 1003 Reference Document 7 As per IS 1445 As per IS 1445 As per IS 1445 As per IS 1445 As per IS 1445 As per IS 1445 As per IS 1445 As per IS: 1445 As per IS: 1445 As per IS: 1445 As per IS 1445 As per IS 1445 As per IS 1445
QC Report QC Report
V V V V V V
Do Do
Characteristics 3 a) Visual Examination
Class 4 Major Major Major Major Major Major Major Major Major Major Major Major Major
Type of Check 5 Test Test Test Measurement Test Test Test Visually Measurement Test Test Test Test
Quantum of Check 6 100% 100% 100% As per IS: 1445 As per IS: 1445 As per IS: 1445 As per IS: 1445 As per IS 1445 As per IS 1445 As per IS 1445 As per IS 1445 As per IS 1445 As per IS 1445
Acceptance Norms 8 As per IS: 1445 As per IS: 1445 As per IS: 1445 As per IS: 1445 As per IS: 1445 As per IS: 1445 As per IS: 1445 As per IS 1445 As per IS 1445 As per IS 1445 As per IS 1445 As per IS 1445 As per IS 1445
Format of Records 9 QC Report QC Report QC Report QC Report QC Report QC Report QC Report TPL TPL TPL TPL TPL TPL
Agency 10 M C N P V V P V V P V V P W W P W W P W W P W W V V V V V V V V V V V V V V V V V V
Remarks 11
SECTION: 3 FINAL INSPECTION Routine Tests b) Electrical Tests c) Mechanical tests a) Verification of Dimension 21 Acceptance Tests b) Temperature cycle test c) Mechanical failing load test d) Porosity test a) Visual Examination b) Verification of Dimensions c) Visible discharge test d) Wet power frequency withstand voltage test e) Dry power frequency withstand voltage test f) Temperature cycle test
22
Type Tests
g) Porosity test Major Test As per IS: 1445 As per IS 1445 As per IS: 1445 TPL V V V h) Puncture test Major Test As per IS: 1445 As per IS 1445 As per IS: 1445 TPL V V V *-All type tests to be carried out as per NESCL specification, Contract Agreement and as per minutes of the meeting between NESCL and MAIN CONTRACTOR. Approval of type tests by Engineering department of NESCL or waival thereof to be shown at the time final inspection to enable NESCL issue MDCC. - Record identified'' "tick mark" shall be essentially included by supplier in QA Documentations.

MANUFACTURER'S NAME & ADDRESS: ITEM: 8 SWG (4.00mm) GI wire SUB-SYSTEM: Sl.N o 1 Component & operation 2 Characteristics 3 Class Type of Check Quantum of Check 6 Reference Document 7 Acceptance Norms 8 QP NO: REV.NO: DATE: PROJECT/UTILITY: PACKAGE: CONTRACT NO: MAIN-CONTRACTOR: Format of Records 9 D M 2 samples per Heat per lot 4 samples per Heat per lot 4 samples per heat per lot IS 7887/Plant standard IS 7887/Plant standard IS7904 NESCL Spec., QC P Agency 10 C V N V Remarks 11
4 5 SECTION : 1 RAW MATERIAL Major Test
a) Chemical analasis b) Ultimate Tensile Strength c) Diameter of the Wire Rod and Vovality Major Major Test Measurement Min 45Kg / mm2 Dia 8.00 .04 and Vovality 0.6 mm Max. The wire rod shall be round & free from fins, splits, surface flows, imperfect edges, rough, jagged surface and other harmful surface defects. Min. purity of Zinc 99.95 do do P P V V V V
Review of manufacuturers test certificates at the time of final inspection.

do do
M.S wire Rod
d) Cleanliness and surface integrity
Major
Visual
100% each coil
IS 7887/Plant standard
do
do
Electrolytic Zinc
a) Chemical analasis
Major
Test
1 sample per lot of 50 Mt
IS 209
QC report
P P
V V V
V V V
SECTION: 2 IN PROCESS INSPECTION 3 In Process Control a) Pickling in HCL solution Major Test
one sample from the pickling bath daily
Plant Standard
Strenth of the solution between 4 to 18% max, Iron = 18% max
QC Records
Sl.N o 1
Characteristics
SECTION: 3 DRAWING OF ROD INTO STEEL WIRE Quantum of Class Type of Check Check 3 4 5 6 Major Measurement
Reference Document 7 Plant Standard
Acceptance Norms 8 Nom 3.92 mm min 3.86 mm Max 3.98 mm the wire shall be smooth & free from all imperfections such as spills, splits, scale inclusion, die mark, scratches, fittings, blowholes etc.
Format of Records 9 QC Records D P
Agency 10 V V
Remarks 11
a) Diameter
one sample from each coil
b) Surface Integrity and Winding
Major
Visual
100%
Plant Standard
Drawing of Steel Wire c) Breaking Load / Tensile Test Major Measurement 10% of coils Plant Standard Min 816 Kg QC Records P V V
d) Wraping Test
Major
Test
10% of coils
IS 1755
the wire shall not crack or break
QC Records
Page 1 of 2

MANUFACTURER'S NAME & ADDRESS: ITEM: 8 SWG (4.00mm) GI wire SUB-SYSTEM: QP NO: REV.NO: DATE: PROJECT/UTILITY: PACKAGE: CONTRACT NO: MAIN-CONTRACTOR:
e) Joints Sl.N o 1
Major
Visual
100% on each coils Quantum of Check 6
Plant Standard Reference Document 7
No Joint allowed
QC Records
Characteristics 3
Class
Type of Check
Acceptance Norms 8 Galvanized wire shall be free from defects such as bare patches, ash, flux, dross, inclusion / carry over etc. Nom 4.0 mm Min 3.90 mm Max 4.10 mm NESCL Spec. the wire shall not crack or break 3 Dips x 1 Min the sepcimen shall not show any red deposit of copper upon base metal Min 275 Grams per m
2
Format of Records 9 D P
Agency 10 V V
4 5 SECTION: 4 FINAL INSPECTION
a) Surface Smoothness
Major
Visual
100%
IS 4826
QC Records
b) Diameter c) Breaking Load Tensile Test d) Wraping Test
Major Critical Critical
Measurement Test Test
As per IS: 280 As per IS: 280 As per IS: 280
Plant Standard Plant Standard IS 1755
QC Records QC Records QC Records
P P P
W W W
W W W
Tests after Galvanisation
e) Preece Test
Critical
Test
As per IS: 280
IS 4826 / IS 2633
QC Records
f) Zinc Coating
Critical
Test
As per IS: 280
IS 4826 / IS 6745
QC Records
g) Adhesion Test
Critical
Test
As per IS: 280
IS 4826
The Zinc Coating shall remain adherent to the steel wire when wound 10 turns on a mandrel having dia equal to 6 times the dia of the wire,
No Joint allowed
QC Records
h) Joints
Critical
Visual
100%
SECTION: 5 PACKING & MARKING a) Packing 6 b) Marking LEGEND : M - MANUFACTURER C - CONTRACTOR N - CUSTOMER-NESCL SIGNATURE OF THE CONTRACTOR Major Visual 100% Major Visual 100% IS 280 / 1979 (Cl 3.1) IS 280 / 1972 (Cl. 14.1 & 14.1.1 Each coil shall be between 50 - 100 Kgs. QC Records QC Records P P V V V V
IS 280 / 1972 (Cl. 14.1 & 14.1.1)

P - PERFOM
V - VERIFICATION W - WITNESSING QC - QUALITY CONTROL SIGNATURE OF THE MANUFACTURER
Page 2 of 2

MANUFACTURE'S NAME & ADDRESS: ITEM:7/10 SWG (7/3.15mm)G.I Stranded Wire SUB-SYSTEM: Sl.No 1 Component & operation 2 Characteristics 3 Quantum of Check 4 5 6 SECTION-I: RAW MATERIAL INSPECTION Class Type of Check Major Test 2 samples per Heat per lot 4 samples per Heat per lot do Reference Document 7 IS:2141/Plant standard Plant Standard Acceptance Norms 8 S0.06%(Max). P0.06%(Max) Dia._8.000.4mm Ovality _ 0.60mm Max. Min._45Kg/mm2. QP NO: REV.NO: DATE: PROJECT/UTILITY: PACKAGE: CONTRACT NO: MAIN-CONTRACTOR: Format of Agency Records 10 D 9 M C N QC report P V V
Remarks 11 Review of manufacturer's Test Certificate at the time of final inspection Review of manufacturer's Test Certificate at the time of final inspection Review of manufacturer's Test Certificate at the time of final inspection
a)Chemical analysis b)Daimeter of the Wire Rod and Ovality c) Ultimate Tensile Strength 1 M.S. WIRE ROD
Major
Measurement
QC report
Major
Test
Plant Standard
QC report
d) Cleanliness & Surfacfce Integriety
Major
Visual
100% on each coil
Plant Standard
The wire rod shall be round & free from fins, splits, surface flaws, QC report imperfect edges, rough, jagged surface and other harmful surface defects min purity of Zinc 99.95 Acceptance Norms 8 Strength of the Test Report
Review of manufacturer's Test Certificate at the time of final inspection
2 Sl.No 1
ELECTROLYTIC ZINC Component & operation 2
a) Chemical Analysis Characteristics 3
1 sample per Lot of 50 MT or part thereof Quantum of Class Type of Check Check 4 5 6 SECTION: 2 IN PROCESS INSPECTION
Major Test 1 sample from the pickling bath daily
IS : 209 Reference Document 7 Plant Standared
QC report Format of Records D 9
V Agency
Review of manufacturer's Test Certificate at the time of final inspection Remarks 11
M solution between 4 to 18% Plant Standared max. Iron
10 C
N Review of manufacturer's Test Certificate at the time of final inspection Review of manufacturer's Test Certificate at the time of final inspection
Process Control
a) Pickling in Hydro chlo acid solution to be followed by rinsing in cold water
Major
Test
a) Diameter
Major
Measurement
1 sample from each coil Plant Standared
content 18% max Specification : Min : 3.06 mm Nom : 3.10 mm Max : 3.14 mm The wire shall be smooth & free from all imperfections such as spills, splits, scale inclusion, die mark, scratches, fittings blowholes etc. Min 640 Kg or 6.27 Kn The wire shall not crack or break The wire shall not crack or break
Test Report
b) Surface finish & winding 4 Drawing of Rod into steel wire c) Breaking load / Tensile Test
Major
Visual
100% on each coil
Test Report
Major
Visual
1 sample from each coil 10% of coil 100% on each coil
Plant Standared
Test Report Test Report Test Report
d) Wrapping test
Major
Electal
IS : 1755
e) Joints
Major
Visual
No Joint allowed.
Review of manufacturer's Test Certificate at the time of final inspection Review of manufacturer's Test Certificate at the time of final inspection Review of manufacturer's Test Certificate at the time of final inspection
Page 1 of 4

MANUFACTURE'S NAME & ADDRESS: ITEM:7/10 SWG (7/3.15mm)G.I Stranded Wire SUB-SYSTEM: QP NO: REV.NO: DATE: PROJECT/UTILITY: PACKAGE: CONTRACT NO: MAIN-CONTRACTOR:
a) Surface Smoothness
Major
Measurement
100% on each coil
As per IS : 4826
b) Diameter
Major
Measurement
1 sample from each coil 2 sample from each coil 20% of coils
As per IS Specification
Galvanised wire shall be free from defects such as bare patches, ash, flux, dross, inclusion / carry over etc. Min : 3.07mm Nom : 3.15 mm Max : 3.23 mm
Min Breaking load 5.46 KN Min 6% on a gauage length of 600 mm The wire shall not crack or break 1 Min into 3 Dips at the end of the specified number of dips, the specimen shall not show any red deposit of copper upon base metal
Test Report
Review of manufacturer's Test Certificate at the time of final inspection Review of manufacturer's Test Certificate at the time of final inspection Review of manufacturer's Test Certificate at the time of final inspection Review of manufacturer's Test Certificate at the time of final inspection Review of manufacturer's Test Certificate at the time of final inspection
Test Report Test Report Test Report Test Report
c) Breaking Laod / Tensile Test
Major
Measurement
IS : 2141
d) Transfer to stranding
Major
Measurement
Plant Standared IS : 1755
e) Wrapping Test
Major
Measurement
20% of coils
TESTS AFTER GALVANISATION
f) Preece Test
Major
Measurement
20% of coils
IS : 4826
Test Report
g) Weight of Zinc Coating
Major
Measurement
20% of coils
IS : 4826 IS : 6745 Min 250 g/m2
Min 250 g/m
Test Report
h) Adhesion Test
Major
Test
20% of coils
IS: 4826
The Zinc coating shall remain adherent to the steel wire when wound 10 turns on a mandrel having dia equal to 4 times to the dia of wire
No joints allowed
Test Report
i) Joints
Major
Visual
100% on each coil
Plant Standared
Test Report
Page 2 of 4

MANUFACTURE'S NAME & ADDRESS: ITEM:7/10 SWG (7/3.15mm)G.I Stranded Wire SUB-SYSTEM: QP NO: REV.NO: DATE: PROJECT/UTILITY: PACKAGE: CONTRACT NO: MAIN-CONTRACTOR:
a) Lay Length / Direction & Compactness b) Overall dia of the G.I Staranded Wire c) Breaking load of G.I Stranded Wire
Major
Measurement
100% on each coil One sample from each drum/coil One sample from each drum/coil 100%
Plant Standared
Min - 113.4 mm Max. - 170.1 mm Righan Hand Nom-9.45 mm
QC Records QC Records QC Records QC Records QC Records
Review of manufacturer's Test Certificate at the time of final inspection Review of manufacturer's Test Certificate at the time of final inspection Review of manufacturer's Test Certificate at the time of final inspection Review of manufacturer's Test Certificate at the time of final inspection Review of manufacturer's Test Certificate at the time of final inspection
Major
Measurement
As per NESCL specification
Major
Test
IS 2141
Min 36.26 KN
STRANDING
d) Strandand Length / Coil weight
Major
Test
e) Joints
Major
Visual
100% on each drum / coil;
Plant Standared
No joints allowed
f) Surface Cleanliness
Major
Visual
100%
The wire rod shall be round & free from fins, splits, surface flows, QC imperfect edges, Records rough, jagged surface and other harmful surface defects.
SECTION: 3 FINAL INSPECTION & TESTING a) Test on GI Standard wire Sample plan as i) Overall Diameter Critical Measurement per IS 2141 ii) Lay Length & Direction iii) Breaking Load / UTS iv) Joints Critical Critical Critical Measurement Test Visual do do do
M As per NESCL specification Plant Standared IS 2141 Plant Standared Nom-9.45 mm Min - 113.4 mm Max. - 170.1 mm Righan Hand Min 36.26 KN No joints allowed Test Report Test Report Test Report Test Report P P P P
C W W W W
N W W W W
Page 3 of 4

MANUFACTURE'S NAME & ADDRESS: ITEM:7/10 SWG (7/3.15mm)G.I Stranded Wire SUB-SYSTEM: QP NO: REV.NO: DATE: PROJECT/UTILITY: PACKAGE: CONTRACT NO: MAIN-CONTRACTOR: Test P W Report
v) Tensile & Elongation vi) Surface Integrity & cleanliness b) Test on Individual Galvanised wire 7 ACCEPTANCE TEST i) Preece Test
Critical Critical
Test Visual
do do do
As per NESCL specification As per NESCL specification
Min 6% GI strandard wire shall be free from surface defects
W W
Test Report
Critical
Test
do
1 Min x 2 dips, 1 min x 1/2 dips at the end of the specified no. of dips the specimen IS : 4826, IS 2633 shall not show any red deposit of copper upon base metal IS 4826, IS 6745 Min 237.5 gms / m2
Test Report
ii) Weight of the Zinc Coating
Critical
Test
do
Test Report
iii) Adhesion Test
Critical
Test
do
IS 4826
The Zinc coating shall remain adherent to the steel wire when wound 10 turns on a mandrel having dia equal to 4 times to the dia of wire
S0.06%(Max). P0.06%(Max) Each coil shall be between 50 - 100 Kgs.
Test Report
v) Chemical Analysis of steel
Critical
Test
do
IS 2141 IS 2141 / 1968 (Cl.9.1) IS 6594 / 1979 IS 2141 / 1979 (Cl. 11) Plant Standard
Test Report
SECTION: 4 PACKING & MARKING a) Packing 8 b) Marking Major Visual 100% Major Visual 100% QC Records P V V
IS 2141 / 1968 (Cl.8.1 QC TO 8.1.1,) IS 2141 / 1979 (Cl. 10 Records & 10.1)
P= V= W=
P.S= Plant Standard A.D.S= Approved Data SIGNATURE OF THE CONTRACTOR
Sheet
N = NESCL M = Manufacturer C = CONTRACTOR SIGNATURE OF THE MANUFACTURER
Page 4 of 4

MANUFACTURE'S NAME & ADDRESS: QP NO: ITEM: LTDB FOR DISTRIBUTION TRANSFORMER SUBSTATION SUB-SYSTEM: Sl.N o 1 Component & operation 2 Characteristics 3 1) VISUAL EXAMINATION 1 MS SHEET 2) DIMENSION 1) VISUAL EXAMINATION 2 ALUMINUM BUS BAR 2) DIMENSION 3) CHEMICAL ANALYSIS 1)RATING AND MAKE 3 MCCB 2) ROUTINE TESTS I) MECHANICAL OPERATION TEST II)CALIBRATION TEST III) DIELECTRIC TESTS MAJOR MAJOR MAJOR MAJOR MAJOR MEASUREMENT VISUAL MEASUREMENT TEST VISUAL RANDOM RANDOM RANDOM RANDOM RANDOM Class 4 MAJOR Quantum of Check 5 6 SECTION: 1 RAW MATERIALS Type of Check VISUAL RANDOM Reference Document 7 PLANT STANDARD PLANT STANDARD PLANT STANDARD PLANT STANDARD IS 617 / NESCL SPEC APP.DRG / NESCL SPEC NESCL SPEC NESCL SPEC NESCL SPEC Acceptance Norms 8 NESCL APPROVED DRAWING NESCL APPROVED DRAWING NESCL APPROVED DRAWING NESCL APPROVED DRAWING NESCL SPEC NESCL SPEC REV.NO: DATE: PROJECT/UTILITY: PACKAGE: CONTRACT NO: MAIN-CONTRACTOR: Format of Records 9 QC RECORD QC RECORD QC RECORD QC RECORD SUPPLIER TC SUPPLIER TC D M P P P P V V Agency 10 C V V V V V V N V V V V V V Remarks 11
MAJOR
TEST
100%
NESCL SPEC NESCL SPEC NESCL SPEC
SUPPLIER TC SUPPLIER TC SUPPLIER TC
V V V M
V V V C
V V V N VERIFICATION OF RECORD AT THE TIME OF FINAL INSPECTION
MAJOR TEST 100% MAJOR TEST 100% SECTION: 2 FINAL INSPECTION AND TESTING
a) VISUAL CHECK
MAJOR
VISUAL
100%
PLANT STANDARD
PLANT STANDARD
QC RECORD
b) VERIFICATION OF COMPONENT RATING c) OTHER CHECK I) EASY ACCESSIBILITY AND MAINTENANCE II) COLOUR CODING PROVIDED BY COLOURED TAPES
MAJOR
VISUAL
100%
PLANT STANDARD PLANT STANDARD PLANT STANDARD PLANT STANDARD PLANT STANDARD PLANT STANDARD PLANT STANDARD PLANT STANDARD PLANT STANDARD PLANT STANDARD PLANT STANDARD SUPLIER TC
AS PER APPROVED DRAWING AND NESCL SPEC PLANT STANDARD
QC RECORD
DO
MAJOR
VISUAL
100%
QC RECORD
DO
MAJOR
VISUAL
100%
PLANT STANDARD AS PER APPROVED DRAWING AND NESCL SPEC NESCL SPEC APPROVED NESCL DRAWING PLANT STANDARD PLANT STANDARD APPROVED NESCL DRAWING PLANT STANDARD DRY FILM THICKNESS 4060 MICRON SUPLIER TC
QC RECORD
DO
ROUTINE TEST
III) BUS BAR DIMENSIONS IV) DEGREE OF PROTECTION CHECK BY PAPER d) DIMENSION CHECK e) INSULATION RESISTANCE TESTS f) MECHANICAL OPERATION TESTS g) BUS BAR SUPPORT AND CLEARANCE h) CONTINUITY OF CIRCUITS AND FUNCTION I) PAINTING j) OVERLOAD RELEASE SETTING OF THE MCCB
MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR
MEASUREMENT TEST MEASUREMENT ELECTRICAL TEST MECHANICAL TEST MEASUREMENT ELECTRICAL AND MECHANICAL TEST MEASUREMENT ELECTRICAL TEST VISUAL / MEASUREMENT/ ELECTRICAL/ MECHANICAL
100% 100% 100% 100% 100% 100% 100% 100% 100% PLANT STANDARD
QC RECORD QC RECORD QC RECORD QC RECORD QC RECORD QC RECORD QC RECORD QC RECORD QC RECORD TYPE TEST REPORTS
P P P P P P P P V
V V V V V V V V V
V V V V V V V V V
DO
DO DO DO DO DO DO DO TYPE TEST CLEARANCE FROM NECSL ENGINEERING DEPARTMENT
TYPE TEST*
ALL TYPE TEST AS PER IS: 13947 & IS:8623
CRITICAL
IS 8623
NESCL SPEC

MANUFACTURE'S NAME & ADDRESS: QP NO: ITEM: LTDB FOR DISTRIBUTION TRANSFORMER SUBSTATION SUB-SYSTEM: Sl.N o 1 Component & operation 2 Characteristics 3 Class 4 Type of Check 5 Quantum of Check 6 SAMPLE AS PER IS: 2500 Reference Document 7 PLANT STANDARD Acceptance Norms 8 REV.NO: DATE: PROJECT/UTILITY: PACKAGE: CONTRACT NO: MAIN-CONTRACTOR: Format of Records 9 D Agency 10 Remarks 11
a) VISUAL CHECK
MAJOR
VISUAL
PLANT STANDARD
QC RECORD
b) VERIFICATION OF COMPONENT RATING c) OTHER CHECK I) COLOUR CODING PROVIDED BY COLOURED TAPES
MAJOR
VISUAL
SAMPLE AS PER IS: 2500
PLANT STANDARD
AS PER APPROVED DRAWING AND NESCL SPEC
QC RECORD
MAJOR
VISUAL
SAMPLE AS PER IS: 2500 SAMPLE AS PER IS: 2500 SAMPLE AS PER IS: 2500 SAMPLE AS PER IS: 2500 SAMPLE AS PER IS: 2500 SAMPLE AS PER IS: 2500 SAMPLE AS PER IS: 2500 SAMPLE AS PER IS: 2500 SAMPLE AS PER IS: 2500 SAMPLE AS PER IS: 2500 SAMPLE AS PER IS: 2500
PLANT STANDARD PLANT STANDARD PLANT STANDARD PLANT STANDARD PLANT STANDARD PLANT STANDARD PLANT STANDARD PLANT STANDARD PLANT STANDARD PLANT STANDARD PLANT STANDARD
PLANT STANDARD AS PER APPROVED DRAWING AND NESCL SPEC NESCL SPEC NESCL SPEC APPROVED NESCL DRAWING PLANT STANDARD PLANT STANDARD APPROVED NESCL DRAWING PLANT STANDARD DRY FILM THICKNESS 4060 MICRON DRY FILM THICKNESS 4060 MICRON
QC RECORD
II) BUS BAR DIMENSIONS 6 ACCEPTANCE TEST III) DEGREE OF PROTECTION CHECK BY PAPER IV) EASY ACCESSIBILITY AND MAINATENANCE d) DIMENSION CHECK e) INSULATION RESISTANCE TESTS f) MECHANICAL OPERATION TESTS g) BUS BAR SUPPORT AND CLEARANCE h) CONTINUITY OF CIRCUITS AND FUNCTION I) PAINTING j) OVERLOAD RELEASE SETTING OF THE MCCB
MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR
MEASUREMENT TEST TEST MEASUREMENT ELECTRICAL TEST MECHANICAL TEST MEASUREMENT ELECTRICAL AND MECHANICAL TEST MEASUREMENT MEASUREMENT
QC RECORD QC RECORD QC RECORD QC RECORD QC RECORD QC RECORD QC RECORD QC RECORD QC RECORD QC RECORD
P P P P P P P P P P
W W W W W W W W W W
W W W W W W W W W W
LEGEND :
M - MANUFACTURER C - CONTRACTOR N - CUSTOMER-NESCL SIGNATURE OF THE CONTRACTOR
P - PERFORM V - VERIFICATION W - WITNESSING QC - QUALITY CONTROL SIGNATURE OF THE MANUFACTURER

MANUFACTURE'S NAME & ADDRESS: ITEM: 1.1 KV LT XLPE AERIAL BUNCHED CABLE( 2X16+25 SINGLE PHASE, 4X16+25 THREE PHASE) SUB-SYSTEM: Sl.No 1 Component & operation 2 Characteristics 3 Class Type of Check Quantum of Check 6 QP NO: REV.NO: DATE: No.of pages: Reference Document 7 Manufacturer Specification & IS 5484 do do do Manufacturer Specification & IS 9997 do do do Manufacture Specification & As per IS 7098 PtI) do do do Manufacturer Specification & IS 398 do do PROJECT/UTILITY: PACKAGE: CONTRACT NO: MAIN-CONTRACTOR: Acceptance Norms 8 Format of Records 9 D M One sample from each lot do do do One sample from each lot do do do One sample from each lot do do do One sample from each lot do do IS 8130 & PS do do do IS 398 & PS QC report do do do QC report P P P P P Agency 10 C V V V V V N V V V V V Review of Manufacturer's Test Certificate at the time of final inspection do do do Review of Manufacturer's Test Certificate at the time of final inspection do do do Review of Manufacturer's Test Certificate at the time of final inspection do do do Review of Manufacturer's Test Certificate at the time of final inspection do do Remarks 11
4 5 SECTION: 1 RAW MATERIALS Major Measurement Test Test Electrical Test Measurement
Aluminum Rod
a) Diameter b) Tensile Strength c) Elongation d) Resistivity / Conductivity Major Major Major Major a) Diameter
Alloy Rod
b) Tensile Strength c) Elongation d) Resistivity / Conductivity
Major Major Major
Test Test Electrical Test
do do do IS 7098 Pt-I) and PS do do do
do do do
P P P
V V V
V V V
Major a) Hot set 3 XLPE Compound b) Tensile Strength c) Elongation d) Volume Resistivity ( Insulation Resistance) Major Major Major
Test
QC report
Test Test Electrical Test
do do do
P P P
V V V
V V V
Major 4 Messenger Wire a) Diameter b) Tensile Strength c) Elongation Major Major
As per IS 398 & PS do do
QC report do do
P P P
V V V
V V V
Page 1 of 3

MANUFACTURE'S NAME & ADDRESS: ITEM: 1.1 KV LT XLPE AERIAL BUNCHED CABLE( 2X16+25 SINGLE PHASE, 4X16+25 THREE PHASE) SUB-SYSTEM: Sl.No 1 Component & operation 2 Characteristics 3 Class Type of Check Quantum of Check 6 QP NO: REV.NO: DATE: No.of pages: Reference Document 7 IS 8130, IS 398 & PS do do do IS 8130 & IS 398 & PS do do do do do IS 7098 & PS do do do do do do do do do do PROJECT/UTILITY: PACKAGE: CONTRACT NO: MAIN-CONTRACTOR: Acceptance Norms 8 IS 8130, IS 398 & PS do do do IS 8130 & IS 398 & PS do do do do do IS 7098 Pt-I), PS and Approved Data Sheet do do do do do do do do do do Format of Records 9 D M 10% do do do 100% do do do do do 100% 100% do do do do do 1 spool do do do 100% do do Page 2 of 3 QC report do do do QC report do do do do do QC report do do do do do do do do do do QC report do do P P P P P P P P P P P P P P P P P P P P P P P P Agency 10 C V V V V V V V V V V V V V V V V V V V V V V V V N V V V V V V V V V V V V V V V V V V V V V V V V Review of the records at the time of final inspection do do do do do do do do do do do do do do do do do do do do do do do Remarks 11
4 5 SECTION: 2 IN PROCESS INSPECTION Major Measurement Test Test Visual Measurement Visual Visual Electrical Test Visual Visual Visual Measurement Visual Visual Visual Visual Visual Test Test Test Electrical Test Visual Measurement Measurement
a) Dimension 5 Wire Drawing ( Aluminum / Alloy) b) Tensile Strength c) Wrapping test d) Surface Finish a) Dimension b) No./ Diameter of Wire 6 Stranding Phase/Messenger Wire c) Sequence d) D.C Conductor Resistance e) Surface Finish f) Lay / compactness Major Major Major Major Major Major Major Major Major Major a) Type of component b) Thickness c) Colour d) Identification Ridge 7 Insulation e) Surface Finish f) Embossing g) Curing h) Hot set test i) Tensile Strength j) Elongation k) Volume Resistivity Major Major Major Major Major Major Major Major Major Major Major 8 Laying Up a) Core Sequence b) Laid Up diameter c) Length Minor Major
IS 7098 Pt-I) & ADS IS 7098 Pt-I) & PS By hot water do do do do

MANUFACTURE'S NAME & ADDRESS: ITEM: 1.1 KV LT XLPE AERIAL BUNCHED CABLE( 2X16+25 SINGLE PHASE, 4X16+25 THREE PHASE) SUB-SYSTEM: Sl.No 1 9 10 Component & operation 2 Routine test Type Test* Characteristics 3 a) Conductor resistance b) High Voltage Type Tests a) Test for Phase Conductor i) Tensile test ii) Wrapping test iii) Resistance test b) Test for thickness of insulation and sheath c) Insulation resistance test ( Volume resistivity) 11 Acceptance test d) High voltage test Including water immersion test e) Test for Messenger Class Type of Check Quantum of Check 6 100% do Sample QP NO: REV.NO: DATE: No.of pages: Reference Document 7 IS 14255 & PS do IS 14255 & PS PROJECT/UTILITY: PACKAGE: CONTRACT NO: MAIN-CONTRACTOR: Acceptance Norms 8 IS 14255 & PS do IS 14255 & PS Format of Records 9 QC report do Type Test Report D M P P V Agency 10 C V V V N V V V type test clearnce from NESCL Engg Remarks 11
4 5 SECTION: 3 Final Testing Major Electrical Test Major Electrical Test Major Electrical Test
Critical Critical Critical Critical
Test Test Electrical Test Test
As per sampling As per IS 8130/PS & Acceptance plan of IS 7098 As per IS8130 & PS NESCLSpecification test certificate Part I) do do do do do As per IS 7098 Part I & PS do IS 10810 Part IV do do As per IS 7098 Part I /PS & NESCLSpecification do NESCLSpecification do do do
P P P P
W W W W
W W W W
Critical Critical
Electrical Test Electrical Test
do do
do do
P P
W W
W W
Critical i) Breaking Load test ii) Elongation test iii) Resistance test IV) Test for thickness & dimensions conductor and messenger f) Bending test on complete cable 12 Packing & Marking Critical Critical Critical
Test Test Test Test
As per IS 398Part-IV do do As per sampling plan of IS As per sampling plan of IS Random
As per IS 398 & PS do do As per NESCL Specification As per NESCL Specification NESCL specification
As per IS & NESCLSpecification do do As per NESCL Specification As per NESCL Specification/ No crakes visible to naked eye NESCL specification
QC report do do do
P P P P
W W W W
W W W W
Critical
Test
do
Major
Visual
do
*-All type tests to be carried out as per NESCL specification & Contract Agreement. - Record identified'' "tick mark" shall be essentially included by supplier in QA Documentations. P= V= W= Performed By Verified By Witness of test
PS = Plant Standar ADS = Approved Data Sheet SIGNATURE OF THE CONTRACTOR SIGNATURE OF THE MANUFACTURER Page 3 of 3
M= Manufacturer N= Customer (NESCL) C = Contactor
MANUFACTURING QUALITY PLANItem : : Name of the Contractor Name of the Sub- contractor Name of the Package LOA No LOA Date Sl.N Component & operation o HOT DIP GALVANIZATION OF M.S. COMPONENTS : : : : : Characteristics Class Type of Check Document Verification Quantum of Check Reference Document MQP NO: Acceptance Norms Format of Records M RAW MATERIAL Zinc Purity Major 100% Supplier TC IS:209 Supplier TC Agency C N Sourcing of Zinc from Hindusthan Zinc Ltd Remarks
1.1 Degreasing
Major
Test
DAILY ONE SAMPLE
IS 2629
Stength of solution 5% minimum
QC Record
1.2 Pickling , a) Acid content
Major
Test
DAILY ONE SAMPLE
IS 2629
Stength of solution 40 to 180 gms per litre
QC Record
b) Iron content 1 PREPARATION OF METAL SURFACE 1.3 Rinsing
Major
Test
DAILY ONE SAMPLE
IS 2629
maximum 120 gmsper litre
QC Record
Major
Test
DAILY ONE SAMPLE
IS 2629
QC Record
Only in the Absence of auto neutrualization of Flux solution
1.4 Fluxing in (Zinc chloride and ammonium chloride Solution) 1.5 Pre heating Hot Plate /Dry air oven
Major
Test
DAILY ONE SAMPLE
IS 2629
Concentration 200 to 400gms per litre. Specific gravity 1.16to 1.32, PH value -3.5
QC Record
Major
Test
100%
IS 2629
70 to 110 Degrees centigrade
QC Record
Sl.N Component & operation o
Characteristics
Class
Type of Check
Quantum of Check
Reference Document
Acceptance Norms
Format of Records
Agency
Remarks
2.1 Dipping (Galvanising) a) Zinc Bath
Major
Measure ment
Hourly Check
IS 2629
Zinc bath temperature 445-465 Degrees QC Record centigrade
Zinc Bath Temperature Continous display on the control panel and actual verification by thermo-couple
b) Immersion Time and Withdrawal time 2 GALVANISING
Major
Physical Observation
100%
IS 2629
Articles to be immersed till reaction takes place which is indicated by stoppage of Bubbling. With drawal should be controlled, so that zinc drains freely
2.2 Queching in Water
Major
Visual
100%
2.3 Dichromating proprietary Chemicals
Major
Test
DAILY ONE SAMPLE
IS 2629
0.2% to 1.5% Sodium Dichromate and 0.5% of Sulphuric Acid. Temperature of Solution < 65 degrees Centigrade.
3.1 Visual Checking TESTING AND INSPECTION 3.2 Thickness of Zinc Coating
Critical
Visual
100%
IS 2629
Surface to be Free from Bare/ Black Spots heavy Ash and Fux inclusions, Lumps, Pimples, Runs e.t.c
Inspection report
Critical
Measure ment
Random
IS 4759
NESCL Specification/Approved Drawings
Inspection report
Sl.N Component & operation o
Characteristics
Class
Type of Check
Quantum of Check
Reference Document
Acceptance Norms
Format of Records
Agency
Remarks
3.3 Weight of the Zinc coating
Critical
Measure ment
Random
IS 4759/ IS 6745
NESCL Specification/Approved Drawings
Inspection report
TESTING AND INSPECTION
3.4 Uniformity of Zinc Coating
Critical
Measure ment
Random
IS 2629/ IS2633
Samples to withstand four dips of one minute, without showing the signs of copper deposits.
Inspection report
3.5 Adhesion test of Zinc Coating (Pivoted Hammer Test)
Critical
Test
Random
IS 2629
No Removal or lifting of coating at areas of hammer impression
Inspection report
FINAL INSPECTION 4.1 Galvanised BEFORE DESPATCH M.S Components
Critical
Visual
Random
free from Visible flaws and defects
Inspection report
LEGEND :
M - MANUFACTURER C - CONTRACTOR N - CUSTOMER -- NESCL P - PERFOM
V - VERIFIY W - WITNESS QC - QUALITY CONTROL

MANUFACTURE'S NAME & ADDRESS: ITEM : 33/11 KV TRANSFORMER CONTROL AND RELAY PANEL SUB-SYSTEM: Sl.N o 1 Component & operation 2 Characteristics Class Type of Check Quantum of Check Reference Document Acceptance Norms 8 QP NO: REV.NO: DATE: PROJECT/UTILITY: PACKAGE: CONTRACT NO: MAIN-CONTRACTOR: Format of Records 9 D M SUPPLIER TC P Agency * 10 C V N V VERIFICATION OF RECORD / SUPPLIER TC AT THE TIME OF FINAL INSPECTION Remarks 11
3 4 5 6 7 SECTION: 1 RAW MATERIALS, FABRICATION, SURFACE TREATMENT, INSTRUMENTS, EQUIPMENT AND PANEL ACCESSORIES THICKNESS CHECK :: 3 & 2 mm SURFACE FINISH (VISUAL CHECK) MAJOR MEASUREMENT AQL 2.5N NESCL SPECIFICATION/NESCL APP.DWG NESCL SPECIFICATION/NESCL APP.DWG DO DO
1.1
SHEET STEEL CRCA/ HOT ROLLED FABRICATION SHEARING, PUNCHING, BENDING, WELDING AND DEBURRUNG
NESCL SPECIFICATION/NESCL APP.DWG NESCL SPECIFICATION/NESCL APP.DWG DO DO
1.2
1.DIMENSIONAL CHECK
MAJOR MAJOR MAJOR
MEASUREMENT VISUAL VISUAL
1 Pc OF EACH TYPE 100% DO 100%
QC RECORD DO SUPPLIER TC SUPPLIER TC/ QC RECORD DO DO
P P
V V
V V DO DO
1.3
2.VISUAL CHECK VISUAL CHECK FOR REMOVAL PRE-TREATMENT BY 7 TANK OF SCALE, OIL,GREASE,DIRT,SWARF AND PROCESS PHOSPHATE COAT 1. VISUAL CHECK 2.COAT THICKNESS CHECK 60 100 microns 3.SURFACE FINISH(VISUAL) CHECK 4.CHECK FOR SHADE 692 OF IS 5 FOR EXTERIOR, GLOSSY WHITE FOR INTERIOR AND BLACK FRAME 5.ADHESION CHECK
MAJOR MAJOR MAJOR
VISUAL MEASUREMENT VISUAL
RANDOM RANDOM 100%
DO DO DO
DO DO DO
P P P
V V V
V V V
DO DO DO
1.4
POWDER COATING
MAJOR VISUAL MAJOR TEST
100%
SHADE CARD NESCL SPECIFICATION/NESCL APP.DWG NESCL SPECIFICATION / NESCL APP.DWG / GTP DO DO DO DO DO DO DO
NESCL SPEC / IS 5 OF 692 NESCL SPECIFICATION/NESCL APP.DWG NESCL SPECIFICATION / NESCL APP.DWG / GTP DO NESCL APP.MAKE NESCL SPECIFICATION / NESCL APP.DWG / GTP DO DO DO DO
DO
V DO
RANDOM
QC RECORD
P P
V V V V V V V V V V
V V V V V V V V V V DO DO DO DO DO DO DO DO DO DO
1.5
PANEL ACCESSORIES 1.VISUAL CHECK MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR VISUAL VISUAL VISUAL TEST VISUAL VISUAL VISUAL TEST 1 Pc PER LOT DO DO DO DO DO DO DO SUPPLIER TC DO DO DO DO DO DO DO
P P P P P P P P
1.5.1
SPACE HEATER
I.DAMAGE II)MAKE,VOLTAGE AND WATTAGE MARKINGS 2.FUNCTIONAL CHECK 1.VISUAL CHECK
1.5.2
MCB FOR AC/DC SUPPLY ISOLATION
a).DAMAGE b). /SCHNEIDER/MDS/INDO KOPP TYPE 2.FUNCTIONAL CHECK
Page 1 of 6

MANUFACTURE'S NAME & ADDRESS: ITEM : 33/11 KV TRANSFORMER CONTROL AND RELAY PANEL SUB-SYSTEM: Sl.N o 1 Component & operation 2 Characteristics 3 1.VISUAL CHECK 1.5.3 ON-OFF TOGGLE SWITCH FOR HEATER a). MARKING 2.FUNCTIONAL CHECK 1.VISUAL CHECK 1.5.4 15 A SOCKET & SWITCH a) DAMAGE AND MAKE 2.FUNCTIONAL CHECK MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR VISUAL TEST VISUAL VISUAL TEST VISUAL VISUAL TEST VISUAL VISUAL TEST MEASUREMENT TEST TEST VISUAL MEASUREMENT VISUAL VISUAL TEST DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO Class 4 MAJOR Type of Check 5 VISUAL Quantum of Check 6 1 Pc PER LOT Reference Document 7 NESCL SPECIFICATION / NESCL APP.DWG / GTP DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO Acceptance Norms 8 NESCL SPECIFICATION / NESCL APP.DWG / GTP DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO QP NO: REV.NO: DATE: PROJECT/UTILITY: PACKAGE: CONTRACT NO: MAIN-CONTRACTOR: Format of Records 9 SUPPLIER TC DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO D P P P P P P P P P P P P P P P P P P P P Agency * 10 V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V Remarks 11 VERIFICATION OF RECORD / SUPPLIER TC AT THE TIME OF FINAL INSPECTION DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO
1.5.5
VISUAL CHECK CFL LIGHT 15 WATT + DOOR SWITCH a) DAMAGE AND MAKE 2.FUNCTIONAL CHECK VISUAL CHECK
1.5.6 FUSE WITH HRC FUSE LLINK
a) DAMAGE b) RATING AND MAKE 1. DIMENSION, SURFACE FINISH 2. TINNED SURFACE TREATMENT 1. SHORE HARDNESS 2. TYPE OF RUBBER (NEOPRENE) 3. DIMENSION AND FINISH VISUAL 1. DAMAGE 2. RATING AND MAKE
1.5.7
COPPER EARTH BUSH 6 mm
25X
1.5.8
GASKET
1.5.9
THERMO STATE
1.MAKE, TYPE & RATING
MAJOR
ELECTRICAL
100%
1.6
RELAYS ( MAKE)
2.FUNCTIONAL CHECK 3.PICK UP CHECK 4.TIMING CHECK 5. CONTACT CONFIGURATION CHECK 6.INDICATION CHECK 7. HV TEST (2KV FOR 1 MIN)
MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR
ELECTRICAL ELECTRICAL ELECTRICAL ELECTRICAL ELECTRICAL ELECTRICAL
100% 100% 100% 100% 100% 100%
DO DO DO DO DO DO DO DO NESCL NESCL SPECIFICATION/NESCL SPECIFICATION/NESCL APP.DWG/QUALITY PLAN APP.DWG/QUALITY PLAN FOR STANDARD FOR STANDARD PRODUCT IMYN 2006 02- PRODUCT IMYN 2006 02046 046 DO DO DO DO DO DO DO DO DO Page 2 of 6 DO DO DO
QC RECORD
V DO DO DO DO DO DO DO
DO DO DO DO DO DO
P P P P P P
V V V V V V
V V V V V V

MANUFACTURE'S NAME & ADDRESS: ITEM : 33/11 KV TRANSFORMER CONTROL AND RELAY PANEL SUB-SYSTEM: Sl.N o 1 Component & operation 2 VISUAL a. DAMAGE AND MAKE b. FUNCTIONAL CHECK 1. HIGH VOLTAGE SPARK TEST VISUAL CECK FOR COLOR, TYPE OF CABLE MATERIAL, ANY SPECIAL MARKING, SHIELDING (IF CALLED), CHECK FOR THICKNESS OF INSULATION, OVERALL DIMENSION, CONSTRUCTION & IDENTIFICATION. 2.PHYSCIAL TEST FOR INSULATION a. TENSILE STRENGTH b. ELONGATION AT BREAK TEST c. SHIRINKAGE TEST d.HEAT SOAK TEST e. HOT DEFORMATION TEST f.LOSS OF MASS TEST g. THERMAL AGEING TEST IN AIR 3. FLAMMABILLITY TEST (WHENEVER REQUIRED) 4.HIGH VOLTAGE (WATER IMMERSION TEST) 1.VISUAL CHECK 1.9 CONTROL/SELECTOR SWITHCES a. DAMAGE b.PLATE MARKINGS c. CONTINUITY CHECKS FOR CONTACTS. 2. H.V.TEST Characteristics 3 Class 4 MAJOR MAJOR MAJOR MAJOR Type of Check 5 VISUAL VISUAL TEST ELECTRICAL Quantum of Check 6 100% 100% 1 Pc PER LOT 1 COIL/LOT Reference Document 7 NESCL SPECIFICATION / NESCL APP.DWG DO DO Acceptance Norms 8 NESCL SPECIFICATION / NESCL APP.DWG DO DO QP NO: REV.NO: DATE: PROJECT/UTILITY: PACKAGE: CONTRACT NO: MAIN-CONTRACTOR: Format of Records 9 SUPPLIER TC DO DO SUPPLIER TC D P P P P Agency * 10 V V V V V V V V DO Remarks 11 VERIFICATION OF RECORD / SUPPLIER TC AT THE TIME OF FINAL INSPECTION DO DO
1.7
DC FAIL MODULE WITH AC BUZZER
NESCL SPECIFICATION / NESCL SPECIFICATION / NESCL APP.DWG / IS 694 NESCL APP.DWG / IS 694
MAJOR
VISUAL
DO
DO
DO
DO
DO MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR TEST TEST TEST TEST TEST TEST TEST TEST TEST ELECTRICAL VISUAL VISUAL VISUAL TEST ELECTRICAL RANDOM DO DO DO DO DO DO DO DO DO 100% 100% 100% 100% 1PcPERLOT Page 3 of 6 NESCL SPECIFICATION / NESCL SPECIFICATION / NESCL APP.DWG / IS NESCL APP.DWG / IS 5831 5831 DO DO DO DO DO DO DO DO NESCL SPEC / IS 694 IS 694 NESCL SPEC / NESCL APP.DWG DO DO DO DO DO DO DO DO DO DO NESCL SPEC / IS 694 IS 694 NESCL SPEC / NESCL APP.DWG DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO P P P P P P P P P P P P P P P V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO
1.8
PVC INSULATED WIRES

MANUFACTURE'S NAME & ADDRESS: ITEM : 33/11 KV TRANSFORMER CONTROL AND RELAY PANEL SUB-SYSTEM: Sl.N o 1 Component & operation 2 Characteristics 3 1.VISUAL CHECK 1.10 TERMINALS a. DAMAGE b.TYPE AND MARK 1.11 1.VISUAL CHECK INDICATING LAM PS / PUSH BUTTONS a. DAMAGE b. TYPE FUNCTIONAL CHECK 1.VISUAL CHECK a. DAMAGE b.MAKE TEST TERMINAL BLOCK c. TERMINAL IDENTIFICATION 2.FUNCITIONAL CHECK H.V.TEST VISUAL CHECK 1.13 FERRIULES, MARKERS, STRICKER 1.LAGIBILITY 2.SIZE 3.COLOUR 1.VISUAL CHECK a.. TYPE b.VOLTAGE 2. FUNCIONAL CHECK 1.VISUAL CHECK a.NAME PLATE b.PT RATIO c. RATED BURDEN d. CLASS OF ACCURACY e. INSULATION LEVEL f. TERMINATION g.ANY SPECIAL MARKING h. MOUNTING ACCESSORIES 2. DIMENSIONS MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR VISUAL VISUAL VISUAL VISUAL TEST VISUAL VISUAL VISUAL VISUAL TEST ELECTRICAL VISUAL VISUAL MEASUREMENT VISUAL VISUAL VISUAL VISUAL TEST VISUAL VISUAL VISUAL VISUAL VISUAL VISUAL VISUAL VISUAL VISUAL MEASUREMENT 100% 100% 1PcPERLOT DO DO 1PcPERLOT 1PcPERLOT 1PcPERLOT 1PcPERLOT 100% 1PcPERLOT 10Pc PER LOT DO DO DO 1PcPERLOT DO DO 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 1PcPERLOT Class 4 MAJOR Type of Check 5 VISUAL Quantum of Check 6 100% Reference Document 7 NESCL SPEC / NESCL APP.DWG DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO Acceptance Norms 8 NESCL SPEC / NESCL APP.DWG DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO QP NO: REV.NO: DATE: PROJECT/UTILITY: PACKAGE: CONTRACT NO: MAIN-CONTRACTOR: Format of Records 9 SUPPLIER TC DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO D P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P Agency * 10 V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V Remarks 11 VERIFICATION OF RECORD / SUPPLIER TC AT THE TIME OF FINAL INSPECTION DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO
1.12
1.14
HOOTER,BELL,BUZZER
1.21
INTERPOSING VOLTAGE TRANSFORMER
Page 4 of 6

MANUFACTURE'S NAME & ADDRESS: ITEM : 33/11 KV TRANSFORMER CONTROL AND RELAY PANEL SUB-SYSTEM: Sl.N o 1 Component & operation 2 Characteristics 3 Class 4 Type of Check 5 Quantum of Check 6 Reference Document 7 Acceptance Norms 8 QP NO: REV.NO: DATE: PROJECT/UTILITY: PACKAGE: CONTRACT NO: MAIN-CONTRACTOR: Format of Records 9 D Agency * 10 Remarks 11
2.0 FINAL ASSEMBLY AND WIRING INSPECTION 1.UNWIRED CUBICLES a.PANEL ASSEMBLY AND WORKMANSHIP 2.UNWIRED ASSEMBLED PANEL a. TYPE & QUANTITY OF COMPONENT b. QUALITY OF ASSEMBLY AND WORKMANSHIP c.DEGREE OF PROTECTIN NOT LESS THAN IP-31 AS PER IS:2147 d. ARRANGEMENTS FOR ASSEMBLY OF PANELS AS PER BOARD DESIGN AND CUT OUT FOR THROUGH CABLING AND WIRING WHEN IT IS PLACED SIDE BY SIDE AS PER REQUIREMENTS 3. VISUAL CHECK FOR BASIC ASSEMBLY AND MIMIC DIAGRAM/DIMENSIONAL CONFORMITY 4. VISUAL CHECK FOR MOUNTING AND SPECIFICATION OF ALL EQUIPMENT 5. VERIFICATION OF WIRING a. CONTINUITY CHECK b. FERRULING & COLOUR CODING AS PER IS-375 c.SIZE OF WIRE 2.5 mmsq FOR CT & PT Ckt, AND 2.5 mmsq FOR AC/DC Ckt. MAJOR ELECTRICAL 100% NESCL SPEC / NESCL APP.DWG DO DO NESCL SPEC / NESCL APP.DWG DO DO DO P V V VERIFICATION OF RECORD / SUPPLIER TC AT THE TIME OF FINAL INSPECTION DO NESCL SPEC / NESCL APP.DWG NESCL SPEC / NESCL APP.DWG VERIFICATION OF RECORD / SUPPLIER TC AT THE TIME OF FINAL INSPECTION DO MAJOR VISUAL 100% NESCL SPEC / NESCL APP.DWG NESCL SPEC / NESCL APP.DWG SUPPLIER TC P V V VERIFICATION OF RECORD / SUPPLIER TC AT THE TIME OF FINAL INSPECTION
MAJOR
VISUAL
100%
SUPPLIER TC
MAJOR
VISUAL
100%
DO
DO
DO
MAJOR
VISUAL
100%
DO
DO
DO
V DO
MAJOR
VISUAL
100%
DO
DO
DO
2.1
PANEL ASSEMBLY
DO MAJOR VISUAL 100% DO DO DO P V V DO MAJOR VISUAL 100% DO DO DO P V V DO
MAJOR MAJOR
VISUAL MEASUREMENT
100% 100%
DO DO
P P
V V
V V
DO
Page 5 of 6

MANUFACTURE'S NAME & ADDRESS: ITEM : 33/11 KV TRANSFORMER CONTROL AND RELAY PANEL SUB-SYSTEM: Sl.N o 1 Component & operation 2 FINAL TESTING Characteristics 3 1. DIMENSIONAL CHECK 2. PAINT, SHADE & THICKNESS 3.ADHESIVE CHECK 4. COLOUR CODING & TIGHTNESS OF WIRING 5.MIMIC DIAGRAM 6. CONTINUITY CHECK 7. DEGREE OF PROTECTION 8.OPERATION AND SCHEME TEST FOR ALL RELAYS 3.0 FINAL TESTING Class 4 CRITICAL VISUAL CRITICAL VISUAL CRITICAL VISUAL CRITICAL VISUAL CRITICAL ELECTRICAL CRITICAL ELECTRICAL CRITICAL BY WIRE INSERTION CRITICAL TEST Type of Check 5 Quantum of Check 6 100% 100% 100% 100% 100% 100% 100% 100% Reference Document 7 NESCL SPEC / NESCL APP.DWG DO DO DO DO DO DO DO Acceptance Norms 8 NESCL SPEC / NESCL APP.DWG DO DO DO DO DO DO DO QP NO: REV.NO: DATE: PROJECT/UTILITY: PACKAGE: CONTRACT NO: MAIN-CONTRACTOR: Format of Records 9 QC RECORD DO DO DO DO DO DO DO D P P P P P P P P Agency * 10 W W W W W W W W W W W W W W W W Remarks 11
9.OPERATION TEST (ELECTRICAL CONTROL INTERLOCK & CRITICAL SEQUENTIAL OPERATION) 10. CHECK FOR EARTHING CONTINUITY BETWEEN EACH CRITICAL APPARATUS AND EARTH-BAR BY BUZZER 11.INSULATION RESISTANCE CRITICAL 12. HIGH VOLTAGE TEST 2KV TEST FOR 1 min. BETWEEN ALL CRITICAL TERMINALS AND EARTH HV TEST 13. IR VALUE TEST (AFTER HV TEST) CRITICAL
TEST
100%
DO
DO
DO
TEST ELECTRICAL ELECTRICAL
100% 100% 100%
DO DO DO
DO DO DO
DO DO DO
P P P
W W W
W W W
ELECTRICAL
100%
DO
DO
DO
PACKING AND DESPATCH 1.VERIFICATION OF COMPLETENESS OF ALL ITEMS AS PER CONTRACT/ CUSTOMER SPEC. 2. CHECK FOR SOUNDNESS OF PACKING/ CRATES 3.VERIFICATION OF MARKINGS ON PACKING/ CRATES HANDLING, STORAGE, ADDRESSES etc. MAJOR VISUAL 100% NESCL SPEC / NESCL APP.DWG DO NESCL SPEC / NESCL APP.DWG DO QC RECORD P V V
4.0
PACKING AND DESPATCH
MAJOR
TEST
100%
QC RECORD
MAJOR
VISUAL
100%
DO
DO
QC RECORD
P= V= W=
M= Manufacturer N= Customer (NESCL) C = Contactor SIGNATURE OF THE CONTRACTOR SIGNATURE OF THE MANUFACTURER Page 6 of 6
MANUFCATURER:

ITEM: ISOLATOR RATING: 33 KV
Project/ UTILITY:
Sl. No 1
Characteristics 3
Class 4
Type of Check 5
Quantum of Check 6
PACKAGE: CONTRACT NO.: MAIN-SUPPLIER: Reference Acceptance Format of Document Norms Records 7 8 9
Agency 10 M C N
Remarks 11
SECTION 1: RAW MATERIAL 1 Copper Flats Visual Examination Dimension Tensile Strength Chemical Composition Bend Test Resistivity /Conductivity Visual Examination Dimension Tensile Strength Chemical Composition Bend Test Resistivity /Conductivity Visual Examination Dimension Tensile Strength Chemical Composition Bend Test 4 Contact Spring Visual Examination Dimension Functional check Fitment/Springs Major Major Major Major Major Major Major Major Major Major Major Major Major Major Major Major Major Major Major Major Major Physical As per IS Physical As per IS Mechanical As per IS Chemical As per IS Mechanical As per IS Electrical Physical Physical Mechanical As As As As per per per per IS IS IS IS IS-5082 IS-5082 QC Record QC Record IS-191/ IS-1897 IS-191/ IS-1897 P V P V V V V V V V V V V V V V V V V V V V V V V V V Review of Manufacturer TC/Reputed lab TC at the time of final inspection Review of Manufacturer TC/Reputed lab TC at the time of final inspection
V V Test Certificate V V V P P V V V V V
Review of Manufacturer TC/Reputed lab TC at the time of final inspection
2 Alummiun Flats
QC Record QC Record
Chemical As per IS Mechanical As per IS Electrical As per IS Physical Physical As per IS As per IS
V V Test Certificate V V V V QC Record QC Record P V P V V V Test Certificate V V V V QC Record P V P V P V P V
Mild Steel 3 Sections
Mechanical As per IS Chemical As per IS Mechanical As per IS Physical Physical Physical Physical As per IS As per IS As per IS As per IS
IS-2062
IS-2062
Plant Standard
Plant Standard
5 Fasteners
Visual Examination Dimension Wedge Test Hardness Galvanizing
Major Major Major Major Major Major Major Major Major Major Major Major Major
Physical Physical
As per IS As per IS IS-1367 IS-1368
QC Record QC Record
P V P V V V
V V V V V V V V V V V V V
Mechanical As per IS Mechanical As per IS Chemical Physical Physical Chemical As per IS As per IS As per IS
Test Certificate V V V V QC Record P V
Review of Manufacturer TC/Reputed lab TC at the time of final inspection Review of Manufacturer TC/Reputed lab TC at the time of final inspection
6 GI Pins
Visual Dimension Galvanization Checks Mechanical Strength
IS-2486 As per IS
IS-2486
Mechanical As per IS Physical Physical Electrical Physical As As As As per per per per IS IS IS IS IS: 2544 IS: 2544
QC Record P V Test Certificate P V Test Certificate V V QC Record QC Record P P V V V V V V
Bus Post 7 Insulator
Visual Dimension High Voltage Test Temperature Cycle Mechanical Strength/Failing load Test Puncture Test Porosity Test Galvanizing test Bending Load Test Chemical Composition Chemical Composition Visual Dimension Chemical Analysis Tensile Strength Elongation Bend Test Galvanizing
Major Major Major Major Major Major Major Major Major Major Major Major Major Major
Mechanical Electrical Chemical Chemical Mechanical Chemical Chemical Physical Physical Chemical Mechanical Mechanical Mechanical Chemical
As As As As As
per per per per per
IS IS IS IS IS SI-617 IS-617
Test Certificate V V V V V SUPPLIER TC
V V V V V
V V V V V
8 Al. AlLoy 9 Zinc 10 GI Tubes
As per IS As per IS As As As As As As As
V V V V V V P V P V V V P V V V V V V V V V V V V V V
---DO-----DO---
IS-209/ IS- IS-209/ ISSUPPLIER TC 13229 13229 per IS IS-1239 IS-1239 QC RECORD Approved Approved per IS Drgs Drgs QC RECORD per IS SUPPLIER TC per IS SUPPLIER TC IS-1239 IS-1239 per IS SUPPLIER TC per IS QC RECORD SUPPLIER TC per IS
SECTION 2: IN-PROCESS CHECKS Welded/ Fabricated MS 11 Sections Visual Examination Dimension Fitment/Assembly Fabrication of 12 Contacts Visual Examination Dimension Fitment/Assembly Visual Examination Major Appearance Major Uniformity Major Mass of zinc Major Terminal 14 Connectors Visual Examination Dimension Tensile Resistance Temperature Rise Short Time Current test Visual Examination 15 Electroplating Thickness of plating Major Major Physical Physical Sample Sample IS-3203/ IS-6012 IS-3203/ 6012 IS-QC Record QC Record P V P V Major Major Major Major Major Major Chemical Physical Physical Sample Sample Sample IS: 5561 IS: 5561 Type Test Report Chemical Sample Physical Physical Major Major Major Major Major Major Physical Physical Physical Physical Physical Physical 100% 100% 100% 100% 100% 100% Plant Standard Plant Standard Plant Standard Plant Standard Plant Standard Plant Standard Plant Standard Plant Standard Plant Standard Plant Standard Plant Standard Plant Standard IS: 2629/ Plant Standard IS: 2629/ Plant Standard IS: 2629/ Plant Standard IS: 2629/ Plant Standard QC Record QC Record QC Record QC Record QC Record QC Record P V V Review of QC Records at the time of P V V final inspection P V V P V V Review of QC Records at P V V the time of final inspection P V V P V V QC Record Review of QC Records at the time of final P V V inspection P V V QC Record
Hot Dip 13 Galvanising
IS: 2629/ Plant 100% Standard IS: 2629/ Plant Standard Sample IS: 2629/ Plant Standard IS: 2629/ Plant Standard
QC Record P V V QC Record QC Record QC Record P V V P V V V V V V V V V V Review of QC Records at the time of V final V inspection V V Review of QC V Records at the time of final inspection V
Mechanical Sample Electrical Sample Electrical Sample Electrical Sample
Assemblies/ SubVisual Examination 16 Assemblies Dimension Verification of components Functional check
Physical Physical Physical
Sample Sample Sample
Approved Drgs. Plant Standard
Approved Drgs. Plant Standard
QC Record QC Record QC Record QC Record
P V P V P V P V
V V
Review of QC Records at the time of final V inspection V
Physical Sample SECTION 3: FINAL PRODUCT TESTING
17 Type Tests 18 Routine Tests
All Type Tests Visual Examination Dimension Verification of component Mechanical Operational check Measurement of Resistance on main circuits Voltage Tests on control & Auxiliary Circuits Power Frequency withstand voltage test
Electrical Sample IS: 9921 Electrical 100% IS: 9921 Electrical 100% IS: 9921 Electrical Electrical 100% IS: 9921 100% IS: 9921
IS: 9921 IS: 9921 IS: 9921 IS: 9921 IS: 9921
Type Test Report V V Test Reports P V Test Reports P V Test Reports P V Test Reports P V
Clearance from V NESCL Engg. V V V V
Major
Electrical
100% IS: 9921
IS: 9921
Test Reports P V
Major Major
Electrical Electrical
100% IS: 9921 10% IS: 9921 Plant Standard/ Packing 100% List
IS: 9921 IS: 9921
Test Reports P V Test Reports P W
V W
Acceptance 19 Tests
All Routine Tests
20 Packing
Visual
Major
Physical
Plant Standard/ Packing List Packing List P W
For NESCL
Main Contractor
Sub-Contractor
LEGEND M: MANUFACTURER; C: CONTRACTOR; N: NESCL; P: PERFORM; W: WITNESS; V: VERIFICATION;
Reviewed by:
Approved by:
MANUFACTURER'S NAME & ADDRESS:

ITEM: All Aluminum Alloy Standard QP NO: REV.NO: DATE: No.of pages:5 Quantum of Check Reference Document 7 Acceptance Norms 8
PROJECT/UTILITY: PACKAGE: CONTRACT NO: MAIN-CONTRACTOR: Format of Agency Records ** 10 9 M C N
Conductor (AAAC)
SUB-SYSTEM: Sl.No 1 1.1 Component & operation 2 Characteristics 3 Class 4 Type of Check
Remarks 11
5 6 SECTION I : RAW MATERIAL
1.1.1
a) Chemical Analysis
Major
Test
One sample per heat of 4MT
IS- 9997- 1991 & NESCL SPEC
IS- 9997- 1991 & NESCL SPEC QC RECORD
AL ALLOY WIRE ROD
Review of Mfg test certificate at the time of final inspection. In absence of Mfg TCs and proper correlation, one sample V per lot of 1000 MT or part there of shall be tested at 3rd party lab and TCs from lab shall be reviewed at the time of final inspection V V V V Review of supplier TCs at the time of final inspection. DO DO DO
1.1.2 1.1.3 1.1.4 1.1.5
b) Diameter of AL Alloy Wire Rod c) Breaking Load/ Tensile Test d) Conductivity e) Elongation
Dimensional Test Test Test
One sample from each coil One sample from each coil One sample from each coil One sample from each coil
IS- 9997- 1991 & NESCL SPEC IS- 9997- 1991 & NESCL SPEC IS- 9997- 1991 & NESCL SPEC IS- 9997- 1991 & NESCL SPEC
IS- 9997- 1991 & NESCL SPEC QC RECORD IS- 9997- 1991 & NESCL SPEC QC RECORD IS- 9997- 1991 & NESCL SPEC QC RECORD IS- 9997- 1991 & NESCL SPEC QC RECORD The wire rod shall be smooth & free from pipes, laps, cracks, kinks, twists, scams and other QC RECORD injurious defects with in the limits of good commercial practices.
P P P P
V V V V
1.1.6
f) Cleanliness & surface smoothness
Major
Visual
100% on each coil
IS- 9997- 1991 & NESCL SPEC
Review of supplier TCs at the time of final inspection.
2.1 a)INTERMEDATE DRAWING & SOLUIONISING OF DRAWN BATCH
SECTION II : INPROCESS INSPECTION Solutionising Temp : 510 +/- 30 deg C Soaking time : 60 +/- 10 Minutes QC RECORD Continuous Temp record by graph One Sample from each spool One Sample from each spool One Sample from each spool for each batch IS 398 (P-IV) & NESCL SPEC Plant Stadards Plant Stadards Plant Stadards IS 398 (P-IV) & NESCL SPEC IS 398 (P-IV) & NESCL SPEC IS 398 (P-IV) & NESCL SPEC IS 398 (P-IV) & NESCL SPEC QC RECORD QC RECORD QC RECORD QC RECORD
2.1.1
Major
Visual
This Process is suitable for M or O temper wire rod materials
2.1.2 2.1.3 2.1.4 2.1.5 AL ALLOY drawn wire (Before Ageing)
a) Diameter of drawn Aluminium alloy wire b) Tensile Test c) Resitivity d) Al Alloy wire Ageing process time and temperature control process
Dimensional Test Test Visual
P P P P
V V V V
V V V V
Review of records of the contractor at the time of final inspection DO DO DO

ITEM: All Aluminum Alloy Standard QP NO: REV.NO: DATE: No.of pages:5 Quantum of Check 6 100% on each spool One Sample each Spool One Sample each Spool One Sample each Spool One Sample each Spool One Sample each Spool One Sample per 40 MT or Part there of Reference Document 7 IS 398 (P-IV) & NESCL SPEC IS 398 (P-IV) & NESCL SPEC IS 398 (P-IV) & NESCL SPEC IS 398 (P-IV) & NESCL SPEC IEC 104 & NESCL SPEC IS 398 (P-IV) & NESCL SPEC IS 398 (P-IV) & NESCL SPEC Acceptance Norms 8 The wire shall smooth, uniform and free from all imperfection such as spills, splits, scale IS 398 (P-IV) & NESCL SPEC IS 398 (P-IV) & NESCL SPEC IS 398 (P-IV) & NESCL SPEC IEC 104 & NESCL SPEC IS 398 (P-IV) & NESCL SPEC IS 398 (P-IV) & NESCL SPEC IS 398 (P-IV) & NESCL SPEC IS 398 (P-IV) & NESCL SPEC IS 398 (P-IV) & NESCL SPEC IS 398 (P-IV) & NESCL SPEC
PROJECT/UTILITY: PACKAGE: CONTRACT NO: MAIN-CONTRACTOR: Format of Agency Records ** 10 9 QC RECORD QC RECORD QC RECORD QC RECORD QC RECORD QC RECORD QC RECORD QC RECORD QC RECORD QC RECORD QC RECORD P P P P P P V P P P P V V V V V V V V V V V V V V V V V V V V V V
Conductor (AAAC)
SUB-SYSTEM: Sl.No 1 2.1.6 2.1.7 2.1.8 2.1.9 2.1.10 2.1.11 2.1.12 2.1.13 2.1.14 2.1.15 2.1.16 3.1 3.1.1 a) Lay Ratio/ direction of the Lay and Compactness Major Component & operation 2 AL ALLOY drawn wire (Before Ageing) Characteristics 3 a) Surface finish & winding (Visual check) b) Diameter of AL Alloy Wire c) Breaking Load/ Tensile Test d) Resistance d) Wrapping Test e) Elongation f) Micro Structure g) Density h) Coefficient of linear expansion i) Constant Mass-temperature Coefficient ( ) j) Final Modulus of elasticity Class 4 Major Major Major Major Major Major Major Major Major Major Major Type of Check 5 Visual Dimensional Test Test Test Test Test
Remarks 11 DO DO DO DO DO DO Review of records ( Test is conducted at any approved third party lab) Review of supplier TCs at the time of final inspection. DO DO DO
One Sample each IS 398 (P-IV) & NESCL Test Spool SPEC One Sample each IS 398 (P-IV) & NESCL Test Spool SPEC One Sample each IS 398 (P-IV) & NESCL Test Spool SPEC One Sample each IS 398 (P-IV) & NESCL Test Spool SPEC SECGION IV : FINAL CONDUCTOR STRANDING Each length at the IS 398 (P-IV) & NESCL Visual beginning SPEC
IS 398 (P-IV) & NESCL SPEC
QC RECORD
DO
3.1.2
b) Smoothness/ Surface finish
Major
Visual
100%
The finished conductor shall be smooth, compact, uniform & free from all imperfection including kinks (protrusion of wire) iwre cross cover, over looseness ( wire being dislocated by finger/ hand QC RECORD pressure and or unusual bangle noise on tapping material inclusion or black spot (on account of reaction with trapped rain water) dirt, grease etc.
DO

ITEM: All Aluminum Alloy Standard QP NO: REV.NO: DATE: No.of pages:5 Quantum of Check 6 Reference Document 7 Acceptance Norms 8
PROJECT/UTILITY: PACKAGE: CONTRACT NO: MAIN-CONTRACTOR: Format of Agency Records ** 10 9
Conductor (AAAC)
SUB-SYSTEM: Sl.No 1 Component & operation 2 Characteristics 3 Class 4 Type of Check 5
Remarks 11 Review of records of the contractor at the time of final inspection. The contractor V shall furnish an under taking to this effect at the time of final inspection
3.1.3
c) Joints
Major
Visual
100%
There shall be no Joints.
QC RECORD
3.1.4
d) Surface cleanliness
Major
Visual
100%
AS PER NESCL
After reeling the conducotr the exposed surface of the outer most layer of conductor shall be wrapped with waterproof thick QC RECORD bituminised paper/ polythene paper to preserve the conductor from dirt, grit and damage during transporation & handling
Review of records of the contractor at the time of final inspection.
4.1
SECTION - V : TYPE TEST ON FINAL CONDUCTOR AS APPLICABLE ** AS PER NESCL SPEC AS PER NESCL CONTRACT AGREEMENT, MINUTES OF All the type tests to be carried out QC RECORD THE MEETING AS as per NESCL Specification APPLICABLE Approved Type Test reports or waiver by Engg Dept to be shown at time of final inspection
4.1.1
Type Test of finished conductor
CRITCAL
INSPECTION
5.1 5.1.1 ROUTINE TEST a) Check for Joints Major Visual
100% on each drum
SECTION - VI : FINAL INPECTION & TESTING IS 398 (P-IV) & NESCL SPEC IS 398 (P-IV) & NESCL SPEC
No Joints are allowed The wire shall smooth, uniform and free from all imperfection such as spills, splits, scale
QC RECORD
5.1.2
b) Surface Condition of the strand and stranded conductor
Major
Visual
100% on each drum
QC RECORD
5.1.3
c) All Acceptance test
Major
Test/ Dimensional
20% on each drum and part there of AS PER NESCL SPEC One Sample for Every 10 Drums One Sample for Every 10 Drums One Sample for Every 10 Drums One Sample for Every 10 Drums One Sample for Every 10 Drums One Sample for each order
IS 398 (P-IV) & NESCL SPEC AS PER NESCL SPEC IS 398 (P-IV) & NESCL SPEC IS 398 (P-IV) & NESCL SPEC IS 398 (P-IV) & NESCL SPEC IS 398 (P-IV) & NESCL SPEC IEC 104 & NESCL SPEC
AS PER NESCL SPEC
QC RECORD
5.1.4 5.1.5 ACCEPTANCE TEST 5.1.6 5.1.7 5.1.8 5.1.9 5.1.11
d) Check the drums a) Lay Ratio/ direction of the Lay b) Diameter c) Breaking Load/ Tensile Test d) Resistance d) Wrapping Test f) Micro Structure
Major CRITCAL CRITCAL CRITCAL CRITCAL CRITCAL CRITCAL
Visual/ Dimesional Visual/ Dimesional Dimensional Test Test Test Test
AS PER NESCL SPEC IS 398 (P-IV) & NESCL SPEC IS 398 (P-IV) & NESCL SPEC IS 398 (P-IV) & NESCL SPEC IS 398 (P-IV) & NESCL SPEC IEC 104 & NESCL SPEC Fine Grains
QC RECORD QC RECORD QC RECORD QC RECORD QC RECORD QC RECORD QC RECORD
P P P P P P P
V W W W W W W
Review of records of the contractor Contractor to ensure that there is no surface defects on AL. V Alloy strands of complete conductor as NESCL requirement Review of records of the V contractor at the time of final inspection. Review of records of the V contractor at the time of final inspection. V W W W W W W

ITEM: All Aluminum Alloy Standard QP NO: REV.NO: DATE: No.of pages:5 Quantum of Check 6 One Sample for Every 10 Drums Reference Document 7 IS 398 (P-IV) & NESCL SPEC Acceptance Norms 8 IS 398 (P-IV) & NESCL SPEC
PROJECT/UTILITY: PACKAGE: CONTRACT NO: MAIN-CONTRACTOR: Format of Agency Records ** 10 9 QC RECORD P W W
Conductor (AAAC)
SUB-SYSTEM: Sl.No 1 6.1 7.1 7.1.1 a) Dimensions CRITCAL Component & operation 2 Conductor Length Characteristics 3 a) Checks for Joints, Surface finish and Rewinding the Length of conductor Class 4 CRITCAL Type of Check 5 Test
Remarks 11
SECTION - VII - WOODEN DRUMS One Sample for Every Dimensional 10 Drums Test One Sample for Every 10 Drums
IS - 1778 - 1980 & NESCL SPEC IS - 1778 - 1980 & NESCL SPEC
7.1.2
b) Barrel batten strength test
CRITCAL
7.1.3
c) Chemical test on packing paper, corrugated kraft paper & adhesive
Major
Visual
One Sample for Every 10 Drums
QC RECORD All Dimensions shall correlate with QC RECORD approved drawing Minmum Barrel Strength to be mutully agreed between QC RECORD contractor and customer as per techincal Spec Chloride - 0.05 %Max Sulphate - 0.25%Max QC RECORD Copper - 0.01%Max pH - 5.5 to 7.5 (Aq Extract) The inner cheek of the flange and drum barrel surface shall be secured with carboard or double corrogated or thick bitumised water proof bamboo paper by means of suitable adhesive material. After reeling the QC RECORD conductor the exposed surface of the outer layer of the conductor shall be wrapped with water proof thick bituminsed papar/ polythene paper to preserve the conductor from dirt and demaged during transport and handling
Review of results at the time of final inspection
7.1.4
d) check of wooden drums
Major
Visual
100%
IS - 1778 - 1980 & NESCL SPEC
care shall be taken while handling the drums by lifters Medium grade kraft/ crepe/polythene paper shall be used between the layers of the conductors
8.1 8.1.1 8.1.2 8.1.3 8.1.4 8.1.5 Check for identification and packing a)Application of water proof paper b) Space between outermost layer and inner surface of lagging c) Proper Packing d) Contract/ Award Letter No. e) Name and Consignee Address
SECTIO - VII : PACKING & MARKING Visual Dimensional QC RECORD QC RECORD QC RECORD QC RECORD QC RECORD P P P P P V V V V V V V V V V

ITEM: All Aluminum Alloy Standard QP NO: REV.NO: DATE: No.of pages:5 Quantum of Check 6 Reference Document 7 Acceptance Norms 8
PROJECT/UTILITY: PACKAGE: CONTRACT NO: MAIN-CONTRACTOR: Format of Agency Records ** 10 9 QC RECORD P V QC RECORD P V QC RECORD P V QC RECORD P V QC RECORD P V QC RECORD P V QC RECORD P V QC RECORD QC RECORD P P V V
Conductor (AAAC)
SUB-SYSTEM: Sl.No 1 8.1.6 8.1.7 8.1.8 8.1.9 8.1.10 8.1.11 8.1.12 8.1.13 8.1.14 8.1.15 8.1.16 8.1.17 Component & operation 2 Check for identification and packing Characteristics 3 f) MFG Name and Address g) Drum No. h) Size & code of conductor i) Length of conductor J) Gross weight of drum K) Tare weight of drum L) Net weight M) Arrow marking for unwinding N) Sealing the two outter ends with heat shrinkable sleeves Class 4 Type of Check 5
Remarks 11 V V V V V V V V V
Major Visual
100%
NESCL SPEC
NESCL SPEC
VERIFICATION OF THE INTERNAL DOCUMENTS DURING
o) Lead sealing with plier at both QC RECORD P V V ens p) Marking of CHP/MCHP QC RECORD P V V q) Position of conductor QC RECORD P V V r) Tack welding on the Nuts on 8.1.18 QC RECORD P V V the barrel & hube plate s) Barrel Diameter at three 8.1.19 locations & arrow marking at the QC RECORD P V V location of measurement 8.1.20 t) Project Name Marking Major Visual 100% NESCL SPEC RGGVY by NESCL QC RECORD P V V *-All type tests to be carried out as per NESCL specification, Contract Agreement and as per minutes of the meeting between NESCL and VEL Approval of type tests by Engineering department of NESCL or waival thereof to be shown at the time final inspection to enable NESCL issue MDCC. - Record identified'' "tick mark" shall be essentially included by supplier in QA Documentations. LEGEND : M - MANUFACTURER C - CONTRACTOR N - CUSTOMER P - PERFOM V - VERIFICATION W - WITNESSING QC - QUALITY CONTROL
Prepared By : Sh. Malay Mandal, Sr. Engineer(QA&I)
Reviewed By: Sh.
Approved By: Sh. A. K. Sharma, DGM (QA&I)

ITEM : 33 KV POTENTIAL TRANSFORMERS QP NO: REV.NO:R0 PROJECT/UTILITY: PACKAGE: CONTRACT NO: DATE: SUB-SYSTEM: Sl.N o 1 Component & operation 2 Characteristics 3 Class Type of Check Quantum of Check 6 Reference Document 7 Acceptance Norms 8 MAIN-CONTRACTOR: Format of Records 9 D M 5% 1 PER LOT 1 MTR EACH SIZE 1 SAMPLE PER LOT DO DO 5% 100% 5% PER LOT 1 SAMPLE PER LOT DO DO DO 5% PER LOT 1 SAMPLE PER LOT DO DO 1 SAMPLE PER LOT DO DO DO QAI/01 SEC-2 DO SUPPILER TC SUPPILER TC SUPPILER TC SUPPILER TC QAI/01 SEC-3 DO QAI/01 SEC-4 DO DO VCS/MS/04 DO QAI/01 SEC-4 DO VCS/MS/06 DO QAI/01 SEC-4 VCS/MS/08 DO DO Page 1 of 5 IS 13778 Pt-1 IS 13778 Pt-1 &2 IS 13778 Pt -5 IS 13778 Pt-5 IS 13778 Pt-3 IS 13778 Pt-5 AS PER NESCL SPEC UNIFORMITY UNBLEACHED KRAFT PULP NESCL SPEC 7 KV/mm 660-800 Kg/m3 MD 95 & CMD 40 Nm/gm FREE FROM DAMAGE AS PER NESCL SPEC 1 KV/mm MD 90% TO 110% CMD 3% TO 5% FREE FROM DAMAGE 50 +/- 3 MICRONS 5 KV FOR 50 MICRONS MD 1732 KG/sq.cm CMD 1710 KG/sq.cm VCS/QA/02R DO SUPPLIER TC / VCS LAB REPORT DO DO DO VCS/QA/02R DO VCS/QA/02R DO SUPPLIER TC / VCS LAB REPORT DO DO VCS/QA/02R SUPPLIER TC / VCS LAB REPORT DO DO VCS/QA/02R DO SUPPLIER TC / VCS LAB REPORT DO P P P P P P P P P P P P P P P P P P P P P Agency * 10 C V V V V V V V V V V V V V V V V V V V V V N V V V V V V V V V V V V V V V V V V V V V VERIFICATION OF RECORD / SUPPLIER TC AT THE TIME OF FINAL INSPECTION BY NESCL INSPECTOR DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO Remarks 11
4 5 SECTION: 1 RAW MATERIALS MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR VISUAL MEASUREMENT ELECTRICAL ELECTRICAL MECHANICAL ELECTRICAL MEASUREMENT VISUAL VISUAL MEASUREMENT ELECTRICAL MECHANICAL MECHANICAL VISUAL MEASUREMENT ELECTRICAL MECHANICAL VISUAL MEASUREMENT ELECTRICAL MECHANICAL
1. VISUAL 2.DIAMETER 1 S.E COPPER WIRE 3.RESISTANCE 4.B.D.V 5.ELONGATION 6.CONTINUITY OF ENAMEL COVER 1. DIMENSION 2. VISUAL 1. VISUAL 2. THICKNESS 3 INSULATING KRAFT PAPER 3. ELECTRIC STRENGTH 4. DENSITY 5. TENSILE STRENGTH 1.VISUAL 2. DIMENSIONS 3. ELECTRIC STRENGTH 4.ELONGATION 1.VISUAL 2.DIMENSIONS 5 POLY ETHYLENE TEREPHALATE FILM 3.ELECTRIC STRENGTH 4.TENSILE STRENGTH
CRGO COILS
INSULATING CREEPE PAPER

ITEM : 33 KV POTENTIAL TRANSFORMERS QP NO: REV.NO:R0 PROJECT/UTILITY: PACKAGE: CONTRACT NO: DATE: SUB-SYSTEM: Sl.N o 1 Component & operation 2 1.VISUAL Characteristics 3 Class 4 MAJOR Type of Check 5 VISUAL Quantum of Check 6 1 SAMPLE PER LOT Reference Document 7 QAI/01 SEC-4 Acceptance Norms 8 IS 1576 FREE FROM DAMAGE MAIN-CONTRACTOR: Format of Records 9 VCS/QA/02R D P Agency * 10 V V Remarks 11 VERIFICATION OF RECORD / SUPPLIER TC AT THE TIME OF FINAL INSPECTION BY NESCL INSPECTOR DO
PRESS BOARD/LETHEROID SHEET
2.DIMENSIONS
MAJOR
MEASUREMENT
1. APPEARANCE
MAJOR
VISUAL
2.DENSITY 3.VISCOSITY 4.INTERFACIAL TENSION 5.FLASH POINT 6.POUR POINT 7.NEUTRALIZATION VALUE TOTAL ACIDITY 8.CORROSIVE SULPHUR 9.ELECTRIC STRENGTH UNTREATED NEW OIL /TREATED OIL 10.TAN DELTA AT 90 C 7 TRANSFORMER OIL 11.SPECIFIC RESISTANCE 0 AT 90 C AT 27OC 12.OXIDATION STABILITY NEUTRALIZATION VALUE TOTAL SLUDGE 13.AGEING CHARACTERISTICS SPECIFIC RESISTANCE
0 a)AT 90 C 0
PHYSICAL PHYSICAL PHYSICAL PHYSICAL PHYSICAL CHEMICAL ELECTRICAL ELCTRICAL ELCTRICAL ELCTRICAL
IS 1576 NOMINAL DO THICKNESS OIL SHELL BE CLEAR SUPPLIER TC / SUPPLIER TC / IS TRANSPARENT AND FREE 1 SAMPLE PER LOT VCS LAB REPORT FROM SUSPENEDE 335 PARTICALS SUPPLIER TC / IS DO 0.89gms/CC DO 335 SUPPLIER TC / IS DO 27 CST DO 335 SUPPLIER TC / IS DO 0.04n/m DO 335 DO DO DO DO DO DO DO DO DO SUPPLIER TC / IS 335 SUPPLIER TC / IS 335 SUPPLIER TC / IS 335 SUPPLIER TC / IS 335 IS 335 & QAI/01 SEC-06 SUPPLIER TC / IS 335 SUPPLIER TC / IS 335 SUPPLIER TC / IS 335 1400C MINUS 6 C 0.03mg KOH/gm NIL NON CORROSIVE 30KV rms 60KV rms 0.002 35 X 10 ^ 12 -cm 1500 X 10 ^ 12 -cm 0.04 mg/ KOH/ gm
O
DO
P P P P P P P P P P
V V V V V V V V V V
V V V V V V V V V V
DO DO DO DO DO DO DO DO DO DO
DO DO DO DO VCS/QA/02R SUPPLIER TC / VCS LAB REPORT DO
MAJOR
CHEMICAL
DO
DO
DO
MAJOR
ELCTRICAL
DO
SUPPLIER TC / IS 335 SUPPLIER TC / IS 335 SUPPLIER TC / IS 335 SUPPLIER TC / IS 335 SUPPLIER TC / IS 335 SUPPLIER TC / IS 335 SUPPLIER TC / IS 335 Page 2 of 5
0.2 X 10 ^ 12 -cm
SUPPLIER TC / VCS LAB REPORT DO DO DO DO DO DO
VERIFICATION OF RECORD / SUPPLIER TC AT THE TIME OF FINAL INSPECTION BY NESCL INSPECTOR DO DO DO DO DO DO
b) AT 270C c) TAN DELTA AT 90 C d) TOTAL ACIDITY E) TOTAL SLUDGE 14.PRESENCE OF OXIDATION INHIBITOR 15. WATER CONTENT MAX
0
ELCTRICAL ELCTRICAL CHEMICAL CHEMICAL CHEMICAL CHEMICAL
DO DO DO DO DO DO
2.5 X 10 ^12 -cm 0.2 0.05 mg/KOH/gm 0.05% NIL 50ppm
P P P P P P
V V V V V V
V V V V V V

ITEM : 33 KV POTENTIAL TRANSFORMERS QP NO: REV.NO:R0 PROJECT/UTILITY: PACKAGE: CONTRACT NO: DATE: SUB-SYSTEM: Sl.N o 1 Component & operation 2 1 . VISUAL Characteristics 3 Class 4 MAJOR Type of Check 5 VISUAL Quantum of Check 6 100% Reference Document 7 QA/01 SEC - 7 SUPPLIER TC / IS 5621 / IS2099 DO DO DO QAI/01 SEC-5 DO VCS/MS/13 Acceptance Norms 8 IS5621 MAIN-CONTRACTOR: Format of Records 9 VCS/QA/02R D P Agency * 10 V V Remarks 11 VERIFICATION OF RECORD / SUPPLIER TC AT THE TIME OF FINAL INSPECTION BY NESCL INSPECTOR DO DO DO DO DO DO DO
BUSHINGS ( NESCL APPROVED MAKE)
2 . DIMENSION 3 .ROUTINE ELECTRICAL TEST 4 . POROSITY 5 . TEMP CYCLE TEST 1. VISUAL 2. DIMENSIONS 3. HARDNESS
MEASUREMENT ELECTRICAL PHYSICAL PHYSICAL VISUAL MEASUREMENT PHYSICAL
5 %/LOT DO DO DO 10% 5 % /LOT DO
NESCL APPROVED DRW IS 5621 NO DYE PENTRITATION NO CRACK AFTER TEST FREE FROM DAMAGE AS PER DRAWING / SIZE 70 +/-5 SHORE A
DO SUPPLIER TC / VCS LAB REPORT DO DO VCS/QA/02R DO SUPPLIER TC / VCS LAB REPORT
P P P P P P P
V V V V V V V
V V V V V V V
GASKETS 4. AGEING TEST 7 DAYS IN T/F OIL a ) CHANGE IN WEIGHT MAX b ) CHANGE IN HARDNESS 1.VISUAL 2.DIMENSIONS MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR 2.THICKNESS 3.PIVOT HAMMER TEST MAJOR MECHANICAL 1% / LOT Page 3 of 5 DO COATING SHOULD NOT PEEL OFF PHYSICAL VISUAL MEASUREMENT PHYSICAL VISUAL MEASUREMENT VISUAL MEASUREMENT ELECTRICAL ELECTRICAL VISUAL MEASUREMENT VISUAL MEASUREMENT VISUAL MEASUREMENT 2 % / LOT 10% / LOT DO 100% 10% /LOT 5% / LOT 10% / LOT 5% / LOT 2% / LOT DO 10% / LOT 5% / LOT 1% / LOT 1% / LOT 1% / LOT 1% / LOT DO QAI/01 SEC-9 DO VCS/MS/11 NESCL APP.DWG DO VCS/MS/14 DO QAI/01 SEC-8 DO BOM / NESCL SPEC DO VCS/PS/11 DO DO DO 10 %
DO VS DO SUPPLIER TC / VCS LAB REPORT VCS/QA/02R DO VCS/QA/02R DO DO DO VCS/QA/02R DO VCS/QA/02R DO VCS/QA/02R SUPPLIER TC / VCS LAB REPORT DO
P P P P P P P P P P P P P P P P P
V V V V V V V V V V V V V V V V V
V V V V V V V V V V V V V V V V V
DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO
FREE FROM DAMAGE NESCL APPROVED DRW NO LEAK AT 1.5 KG/sq.cm FOR 15 FREE FROM DAMAGE NESCL APPROVED DRW FREE FROM DAMAGE NESCL APPROVED DRW 2 M OHMS 5KV rms / 1 MINUTE FREE FROM DAMAGE AS PER NESCL DWG FREE FROM DAMAGE 40 MICCRONS MIN FREE FROM DAMAGE 85 MICRONS
10
TANKS 3.LEAK TEST 1.VISUAL 2.DIMENSIONS 1.VISUAL 2.DIMENSIONS 3.INSULATION RESISTANCE 4.DIELECTRIC TEST 1.VISUAL 2.DIMENSIONS 1. VISUAL 2.DIMENSIONS 1.VISUAL
11
PRIMARY TERMINALS
12
SEC.TERMINALS
13 14
HARDWARE PAINTING
15
GALVANIZING

ITEM : 33 KV POTENTIAL TRANSFORMERS QP NO: REV.NO:R0 PROJECT/UTILITY: PACKAGE: CONTRACT NO: DATE: SUB-SYSTEM: Sl.N o 1 Component & operation 2 Characteristics 3 Class Type of Check Quantum of Check 6 Reference Document 7 Acceptance Norms 8 MAIN-CONTRACTOR: Format of Records 9 D Agency * 10 Remarks 11 VERIFICATION OF RECORD / SUPPLIER TC AT THE TIME OF FINAL INSPECTION BY NESCL INSPECTOR DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO
4 5 SECTION: 2 IN-PROCESS MAJOR MEASUREMENT
5%
PL/02 SEC-1 TO 3
FREE FROM DAMAGE
VCS/ PR / 09R
16
L.V & H.V WINDING
1.WINDING WIDTH 2.OVER LAPPING CONDUCTOR 3.INTERLAYER INSULATION 1.PAPER WIDTH & LENGTH 2.OVERLAP FOLDING OF PAPER 3.FINISHED COIL DIMENSION 1.CORE LIMB INSULATION 2.HV-LV INSULATION 3.POLARITY CHECK RATIO & PHASE ANGLE ERRORS 1.TEMP.MEASUREMENT 2.VACUUM MEASURMENT 3.FILTERED OIL BDV CHECK 4.OIL SOAKING TIME 1.PRIMARY CONNECTION 2.SECONDARY CONNECTION 3.LOCKING ARRANGEMENTS 4.SECURING OF ACTIVE PART MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR VISUAL VISUAL ELECTRICAL ELECTRICAL ELECTRICAL VISUAL VISUAL VISUAL ELECTRICAL PHYSICAL PHYSICAL ELECTRICAL PHYSICAL VISUAL VISUAL VISUAL VISUAL 100% 100% 10% 100% 100% 100% 100% 100% 100% EVERY HOUR EVERY HOUR 1 SAMPLE PER LOT 100% 100% 100% 100% 100% PL/02 SEC-1 TO 3 PL/02 SEC-1 TO 3 PL / 02 SEC-4 DO DO PL/02 SEC-5 & 6 DO DO QAI/01 SEC-16 & IS 3156 PL/01 SEC-06 DO DO DO PL/01 SEC-06 DO DO DO AVOID OVER LAPPING NESCL SPEC NESCL SPEC DO DO AS PER IS 2705 DO DO AS PER IS 3156 DO DO DO DO DO DO DO DO DO DO VCS/PR/09R DO DO DO DO DO VCS/QA/04R VCS/PR/010R DO DO DO VCS/PR/09R DO DO DO P P P P P P P P P P P P P P P P P V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V
17
CUTTING , FOLDING & HV TAPING
18 19
CORE & COIL ASSEMBLY STAGE TESTING
20
DRYING & IMPREGNATION
21
MAIN ASSEMBLY
SECTION: 3 FINAL INSPECTION Page 4 of 5

ITEM : 33 KV POTENTIAL TRANSFORMERS QP NO: REV.NO:R0 PROJECT/UTILITY: PACKAGE: CONTRACT NO: DATE: SUB-SYSTEM: Sl.N o 1 Component & operation 2 Characteristics 3 1.VISUAL CHECK 2.NUTS & WASHER FOR EARTH BOLTS 3.EARTHING SYMBOL 4.OIL LEVEL IN GAUGE 5.PRIMARY TERMINAL MARKINGS 6.OIL LEAKS 7.TERMINAL MARKINGS 8.NAME PLATE & CONNECTION DIAGRAM 1. VERIFICATION OF TERMINAL MARKING AND POLARITY 2. POWER FREQUENCY DRY WITHSTAND TESTS ON PRIMARY WINDINGS 3.POWER FREQUENCY DRY WITHSTAND TESTS ON SECONDARY WINDINGS 4 PARTIAL DISCHARGE MEASUREMENT (IF APPLICABLE) 5 RATIO & PHASE ANGLE ERROR 1.TEMPERATURE RISE TEST 2.LIGHTNING IMPULSE VOLTAGE WITHSTAND TEST 3.HIGH VOLTAGE POWER FREQUENCY WET WITHSTAND VOLTAGE TEST 4.DETERMINATION OF ERRORS AND OTHER CHARACTERISTICS ACCORDING TO THE REQUIREMENT OF THE APPROPRIATE DESIGNATION OF ACCURACY CLASS Class 4 CRITICAL CRITICAL CRITICAL CRITICAL CRITICAL CRITICAL CRITICAL CRITICAL Type of Check 5 VISUAL VISUAL VISUAL VISUAL VISUAL VISUAL VISUAL VISUAL Quantum of Check 6 100% 100% 100% 100% 100% 100% 100% 100% Reference Document 7 QAI/01 SEC-20 DO DO DO DO DO DO DO Acceptance Norms 8 AS PER NESCL APP.DRAWING DO DO DO DO DO DO DO AS PER NESCL APP.DRAWING MAIN-CONTRACTOR: Format of Records 9 VCS/PR/009R DO DO DO DO DO DO DO D P P P P P P P P Agency * 10 V V V V V V V V V V V V V V V V Remarks 11
22
FINISHING
MAJOR
VISUAL
100%
QAI/01 SEC-17
VCS/QA/05F
Acceptance Tests shall be done on 10% of the offered lot.
CRITICAL
ELECTRICAL
100%
QAI/01 SEC-19 & IS 3156 DO
AS PER IS 3156
VCS/QA/05F
21
ROUTINE TEST
CRITICAL
ELECTRICAL
100%
DO
DO
CRITICAL CRITICAL
ELECTRICAL ELECTRICAL
100% 100%
DO DO QAI/01 SEC-20 & IS 3156 DO DO
DO DO
DO DO
P P
W W
W W
SECTION: 4 TYPE TEST CRITICAL CRITICAL CRITICAL ELECTRICAL ELECTRICAL ELECTRICAL AS PER IS; 3156 AS PER IS; 3156 AS PER IS; 3156 AS PER IS 3156 DO DO VCS/PR/009R DO DO W W W V V V V V V
23
TYPE TEST
CRITICAL
ELECTRICAL
AS PER IS; 3156
DO
DO
DO
*-All type tests to be carried out as per NESCL specification, Contract Agreement and as per minutes of the meeting between NESCL and VEL Approval of type tests by Engineering department of NESCL or waival thereof to be - Record identified'' "tick mark" shall be essentially included by supplier in QA Documentations. P.S= Plant M= Manufacturer Standard A.D.S= Approved Data Sheet N= Customer (NESCL) P= Performed By M/I=Minor V= Verified By C = Contactor W= Witness of test SIGNATURE OF THE CONTRACTOR SIGNATURE OF THE MANUFACTURER
Page 5 of 5

ITEM: 33 KV CURRENT TRANSFORMER MANUFACTURE'S NAME & ADDRESS: QP NO: REV.NO: PROJECT/UTILITY: PACKAGE: CONTRACT NO: DATE: SUB-SYSTEM: Sl.N o 1 Component & operation 2 Characteristics 3 Class Type of Check Quantum of Check 6 Reference Document 7 PLANT STANDARD QAI/01 SEC-2 DO SUPPLIER TC SUPPLIER TC SUPPLIER TC SUPPLIER TC QAI / 01 SEC-1 Acceptance Norms 8 MAIN-CONTRACTOR: Format of Records 9 D Agency * 10 M C P V N V VERIFICATION OF RECORD / SUPPLIER TC AT THE TIME OF FINAL INSPECTION BY NESCL INSPECTOR DO DO DO DO DO DO Remarks 11
4 5 SECTION: 1 RAW MATERIALS MAJOR VISUAL
1. VISUAL
5% 1 SAMPLE PER LOT 1 MTR EACH SIZE 1 SAMPLE PER LOT DO DO 5% RANDOM
IS 13778 Pt-1
VCS/QA/02R
2.DIAMETER 1 SUPPER ENAMAL COPPER WIRE 3.RESISTANCE 4.B.D.V 5.ELONGATION 6.CONTINUITY OF ENAMEL COVER 1.VISUAL D.C.C (DOUBLE COTTON COVER ) COPPER
MEASUREMENT ELECTRICAL ELECTRICAL MECHANICAL ELECTRICAL VISUAL
IS 13778 Pt-1 &2 RANDOM SAMPLE TESTING AS PER IS 13778 Pt -5 IS 13778 Pt-5 IS 13778 Pt-3 IS 13778 Pt-5 COVERING TO BE UNIFORM WITH SUFFICIENT INSULATION NUMBER OF STRANDS MULTIPLIED BY CROSS SECTION OF EACH STRAND IS 4800 99% MIN / NESCL SPEC AS PER NESCL SPEC UNIFORMITY NESCL SPEC UNIFORMITY 0.35 AT/cm UNBLEACHED KRAFT PULP NESCL SPEC 7 KV/mm 660-800 Kg/m3 MD 95 & CMD 40 Nm/gm
DO SUPPLIER TC / VCS LAB REPORT DO DO DO VCS/QA/02R
P P P P P P
V V V V V V
V V V V V V
2. CROSS SECTION 3. RESISTANCE 4.PURITY OF COPPER 1. DIMENSION 2. VISUAL 1.DIMENSION 2. VISUAL 3. AMPERE TURN TEST 1. VISUAL
MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR
MEASUREMENT ELECTRICAL CHEMICAL MEASUREMENT VISUAL MEASUREMENT VISUAL ELECTRICAL VISUAL
1 SAMPLE PER LOT DO DO 5% 100% 10% PER LOT 100% PER LOT 10% PER LOT 5% PER LOT 1 SAMPLE PER LOT DO DO DO
QAI / 01 SEC-2 SUPPLIER TC DO QAI/01 SEC-3 DO QAI/01 SEC-3 DO DO QAI/01 SEC-4
SUPPLIER TC / VCS LAB REPORT DO DO VCS/QA/02R DO DO DO DO VCS/QA/02R
P P P P P P P P P
V V V V V V V V V
V V V V V V V V V
DO DO DO DO DO DO DO DO VERIFICATION OF RECORD / SUPPLIER TC AT THE TIME OF FINAL INSPECTION BY NESCL INSPECTOR DO DO DO DO
3 4
CRGO COILS TORROIDAL CORE
INSULATING KRAFT PAPER 2. THICKNESS 3. ELECTRIC STRENGTH 4. DENSITY 5. TENSILE STRENGTH
MAJOR MAJOR MAJOR MAJOR
MEASUREMENT ELECTRICAL MECHANICAL MECHANICAL
DO DO VCS/MS/04 DO
DO SUPPLIER TC / VCS LAB REPORT DO DO
P P P P
V V V V
V V V V
Page 1 of 7

ITEM: 33 KV CURRENT TRANSFORMER MANUFACTURE'S NAME & ADDRESS: QP NO: REV.NO: PROJECT/UTILITY: PACKAGE: CONTRACT NO: DATE: SUB-SYSTEM: Sl.N o 1 Component & operation 2 1.VISUAL 6 INSULATING CREEPE PAPER 2. DIMENSIONS 3. ELECTRIC STRENGTH 4.ELONGATION 1.VISUAL 7 POLY ETHYLENE TEREPHALATE FILM 2.DIMENSIONS 3.ELECTRIC STRENGTH 4.TENSILE STRENGTH 1.VISUAL 8 SEMICONDUCTING PAPER 2.DIMENSIONS 3.DENSITY 4.CONDUCTIVITY 1. VISUAL 9 ALUMINIUM FOIL 2. THICKNESS 3.PURITY PRESS BOARD / LETHEROID SHEET 1.VISUAL 2.DIMENSIONS Characteristics 3 Class 4 MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR Type of Check 5 VISUAL MEASUREMENT ELECTRICAL MECHANICAL VISUAL MEASUREMENT ELECTRICAL MECHANICAL VISUAL MEASUREMENT MECHANICAL ELECTRICAL VISUAL MEASUREMENT CHEMICAL VISUAL MEASUREMENT Quantum of Check 6 5% PER LOT 1 SAMPLE PER LOT DO DO 1 SAMPLE PER LOT DO DO DO 1 SAMPLE PER LOT DO DO DO 1 SAMPLE PER LOT DO DO 1 SAMPLE PER LOT DO 1 SAMPLE PER LOT DO DO DO DO DO DO DO DO Reference Document 7 QAI/01 SEC-4 DO VCS/MS/06 DO QAI/01 SEC-4 VCS/MS/08 DO DO VCS/MS/07 DO DO DO VCS/MS/09 DO DO QAI/01 SEC-4 Acceptance Norms 8 FREE FROM DAMAGE AS PER NESCL APP DWG 1 KV/mm MD 90% TO 110% CMD 3% TO 5% FREE FROM DAMAGE 50 +/- 3 MICRONS 5 KV FOR 50 MICRONS MD 1732 KG/sq.cm CMD 1710 KG/sq.cm BLACK FREE FROM DAMAGE 0.45 mm TO 0.55 mm 0.65 gm/cc TO 0.85gm/cc 160 MICRO SIEMENS/cm NO SIGN OF OXIDATION 30 MICRONS +/- 3 99% MIN MAIN-CONTRACTOR: Format of Records 9 VCS/QA/02R SUPPLIER TC / VCS LAB REPORT DO DO VCS/QA/02R DO SUPPLIER TC / VCS LAB REPORT DO SUPPLIER TC / VCS LAB REPORT VCS/QA/02R SUPPLIER TC / VCS LAB REPORT DO SUPPLIER TC / VCS LAB REPORT VCS/QA/02R SUPPLIER TC / VCS LAB REPORT VCS/QA/02R DO SUPPLIER TC / VCS LAB REPORT DO DO DO DO DO DO DO VCS/QA/02R D P P P P P P P P P P P P P P P P P Agency * 10 V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V Remarks 11 DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO VERIFICATION OF RECORD / SUPPLIER TC AT THE TIME OF FINAL INSPECTION BY NESCL INSPECTOR DO DO DO DO DO DO DO DO
10
1. APPEARANCE
MAJOR
VISUAL
2.DENSITY 3.VISCOSITY 4.INTERFACIAL TENSION 5.FLASH POINT 6.POUR POINT 7.NEUTRALIZATION VALUE TOTAL ACIDITY 8.CORROSIVE SULPHUR 9.ELECTRIC STRENGTH UNTREATED NEW OIL /TREATED OIL
MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR
PHYSICAL PHYSICAL PHYSICAL PHYSICAL PHYSICAL CHEMICAL ELECTRICAL ELCTRICAL
IS 1576 / FREE FROM DAMAGE IS 1576 NOMINAL DO THICKNESS IS 335 / OIL SHELL BE SUPPLIER TC / IS CLEAR TRANSPARENT 335 AND FREE FROM SUSPENEDE PARTICALS SUPPLIER TC / IS 0.89gms/CC 335 SUPPLIER TC / IS 27CST 336 SUPPLIER TC / IS .04n/m 337 SUPPLIER TC / IS 1400C 338 SUPPLIER TC / IS MINUS 6 O C 339 SUPPLIER TC / IS 0.03mg KOH/gm 340 NIL SUPPLIER TC / IS NON CORROSIVE 341 QAI/01 SEC-06 30KV rms 60KV rms
P P P P P P P P
V V V V V V V V
V V V V V V V V
Page 2 of 7

ITEM: 33 KV CURRENT TRANSFORMER MANUFACTURE'S NAME & ADDRESS: QP NO: REV.NO: PROJECT/UTILITY: PACKAGE: CONTRACT NO: DATE: SUB-SYSTEM: Sl.N o 1 Component & operation 2 Characteristics 3 10.TAN DELTA AT 900C 11 TRANSFORMER OIL 11.SPECIFIC RESISTANCE AT 900C AT 27OC 12.OXIDATION STABILITY NEUTRALIZATION VALUE TOTAL SLUDGE 13.AGEING CHARACTERISTICS SPECIFIC RESISTANCE a)AT 900C MAJOR ELCTRICAL DO SUPPLIER TC / IS 341 SUPPLIER TC / IS 342 SUPPLIER TC / IS 343 SUPPLIER TC / IS 344 SUPPLIER TC / IS 345 SUPPLIER TC / IS 346 SUPPLIER TC / IS 347 QA/01 SEC - 7 0.2 X 10 ^ 12 -cm SUPPLIER TC / VCS LAB REPORT DO DO DO DO DO DO P V V VERIFICATION OF RECORD / SUPPLIER TC AT THE TIME OF FINAL INSPECTION BY NESCL INSPECTOR DO DO DO DO DO DO VERIFICATION OF RECORD / SUPPLIER TC AT THE TIME OF FINAL INSPECTION BY NESCL INSPECTOR DO DO DO DO DO DO DO Class 4 MAJOR MAJOR Type of Check 5 ELCTRICAL ELCTRICAL Reference Quantum of Check Document 6 7 SUPPLIER TC / IS DO 341 DO SUPPLIER TC / IS 341 SUPPLIER TC / IS 341 Acceptance Norms 8 0.002 35 X 10 ^ 12 -cm 1500 X 10 ^ 12 -cm 0.04 mg/ KOH/ gm MAIN-CONTRACTOR: Format of Records D 9 SUPPLIER TC / VCS LAB REPORT DO Agency * 10 P P V V V V Remarks 11 DO DO
MAJOR
CHEMICAL
DO
DO
DO
b) AT 270C c) TAN DELTA AT 900C d) TOTAL ACIDITY E) TOTAL SLUDGE 14.PRESENCE OF OXIDATION INHIBITOR 15. WATER CONTENT MAX
ELCTRICAL ELCTRICAL CHEMICAL CHEMICAL CHEMICAL CHEMICAL
DO DO DO DO DO DO
2.5 X 10 ^12 -cm 0.2 0.05 mg/KOH/gm 0.05% NIL 50ppm
P P P P P P
V V V V V V
V V V V V V
1 . VISUAL
MAJOR
VISUAL
100%
IS5621 IS 5621 / IS2099 / NESCL APPROVED DRW IS 5621 NO DYE PENTRITATION NO CRACK AFTER TEST FREE FROM DAMAGE AS PER DRAWING / SIZE 70 =/-5 SHORE A 10 %
VCS/QA/02R
12
BUSHINGS ( NESCL APPROVED MAKE)
2 . DIMENSION 3 .ROUTINE ELECTRICAL TEST 4 . POROSITY 5 . TEMP CYCLE TEST 1. VISUAL 2. DIMENSIONS 3. HARDNESS
MEASUREMENT ELECTRICAL PHYSICAL PHYSICAL VISUAL MEASUREMENT PHYSICAL
5 %/LOT DO DO DO 10% 5 % /LOT DO
SUPPLIER TC DO DO DO QAI/01 SEC-5 DO VCS/MS/13
DO SUPPLIER TC / VCS LAB REPORT DO DO VCS/QA/02R DO SUPPLIER TC / VCS LAB REPORT DO VS DO
P P P P P P P
V V V V V V V
V V V V V V V
13
GASKETS
4. AGEING TEST 7 DAYS IN T/F OIL a ) CHANGE IN WEIGHT MAX b ) CHANGE IN HARDNESS 1.VISUAL 2.DIMENSIONS
MAJOR MAJOR MAJOR
PHYSICAL VISUAL MEASUREMENT
2 % / LOT 10% / LOT DO
DO QAI/01 SEC-9 DO
P P P
V V V
V V V
DO DO DO
FREE FROM DAMAGE NESCL APPROVED DRW
14
TANKS
Page 3 of 7

ITEM: 33 KV CURRENT TRANSFORMER MANUFACTURE'S NAME & ADDRESS: QP NO: REV.NO: PROJECT/UTILITY: PACKAGE: CONTRACT NO: DATE: SUB-SYSTEM: Sl.N o 1 Component & operation 2 3.LEAK TEST Characteristics 3 Class 4 MAJOR Type of Check 5 PHYSICAL Quantum of Check 6 100% Reference Document 7 VCS/MS/11 Acceptance Norms 8 NO LEAK AT 1.5 KG/sq.cm FOR 15 MAIN-CONTRACTOR: Format of Records D 9 SUPPLIER TC / VCS LAB REPORT Agency * 10 P V V Remarks 11 DO
Page 4 of 7

ITEM: 33 KV CURRENT TRANSFORMER MANUFACTURE'S NAME & ADDRESS: QP NO: REV.NO: PROJECT/UTILITY: PACKAGE: CONTRACT NO: DATE: SUB-SYSTEM: Sl.N o 1 15 Component & operation 2 PRIMARY TERMINALS 1.VISUAL 2.DIMENSIONS 1.VISUAL 2.DIMENSIONS 3.INSULATION RESISTANCE 4.DIELECTRIC TEST 1.VISUAL 2.DIMENSIONS 18 PORCELAIN COLLAR 1.VISUAL 2.DIMENSIONS 19 20 HARDWARE PAINTING 1.VISUAL 2.DIMENSIONS 1. VISUAL 2.DIMENSIONS 1.VISUAL 2.THICKNESS 3.PIVOT HAMMER TEST Characteristics 3 Class 4 MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR Type of Check 5 VISUAL MEASUREMENT VISUAL MEASUREMENT ELECTRICAL ELECTRICAL VISUAL MEASUREMENT VISUAL MEASUREMENT VISUAL MEASUREMENT VISUAL MEASUREMENT VISUAL MEASUREMENT MECHANICAL Quantum of Check 6 10% /LOT 5% / LOT 10% / LOT 5% / LOT 2% / LOT DO 10% / LOT 5% / LOT 10% / LOT 5% / LOT 10% / LOT 5% / LOT 1% / LOT 1% / LOT 1% / LOT 1% / LOT 1% / LOT Reference Document 7 NESCL APP.DWG DO VCS/MS/14 DO QAI/01 SEC-8 DO NESCL APP.DWG DO NESCL APP.DWG DO BOM / NESCL SPEC DO VCS/PS/11 DO DO DO DO Acceptance Norms 8 FREE FROM DAMAGE NESCL APPROVED DRW FREE FROM DAMAGE NESCL APPROVED DRW 2 M OHMS 5KV rms / 1 MINUTE FREE FROM DAMAGE PARTS DWG FREE FROM DAMAGE PARTS DWG FREE FROM DAMAGE AS PER NESCL DWG FREE FROM DAMAGE 40 MICCRONS MIN FREE FROM DAMAGE 85 MICRONS COATING SHOULD NOT PEEL OFF MAIN-CONTRACTOR: Format of Records 9 VCS/QA/02R DO VCS/QA/02R DO DO DO VCS/QA/02R DO VCS/QA/02R DO VCS/QA/02R DO VCS/QA/02R DO VCS/QA/02R SUPPLIER TC / VCS LAB REPORT DO D P P P P P P P P P P P P P P P P P Agency * 10 V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V Remarks 11 DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO VERIFICATION OF RECORD / SUPPLIER TC AT THE TIME OF FINAL INSPECTION BY NESCL INSPECTOR DO VERIFICATION OF RECORD / SUPPLIER TC AT THE TIME OF FINAL INSPECTION BY NESCL INSPECTOR DO DO DO DO DO DO DO DO DO DO
16
SEC.TERMINALS
17
CHIMNEY PIPE
21
GALVANIZING
SECTION: 2 IN-PROCESS MAJOR 22 SECONDARY WINDING 1.BASIC INSULATION 2.OVERLAPPING CONDUCTOR STAGE 1 TESTING MAJOR ELECTRICAL 100% QAI/01 SEC-10 / IS 2705 DO DO DO DO DO DO DO DO QAI/01 SEC-11 DO Page 5 of 7 AS PER IS 2705 VCS/QA/04R P V V MAJOR VISUAL 100% PL/01 SEC-2 AVOID OVER LAPPING DO P V V VISUAL 100% PL/01 SEC-1 FREE FROM DAMAGE VCS/ PR / 08R P V V
23
PROTECTION CORE
24
METERING CORE
25
P.S CORE
1.RATIO & PHASE ANGLE ERRORS 2.RESISTANCE MEASUREMENT 3.EXCITING CURRENT MEASURENT 4.% COMPOSITE ERROR RATIO & PHASE ANGLE ERROR 1.RESISTANCE MEASUREMENT 2.TURNS RATIO 3.Vk MEASUREMENT 4.MAGNETIZING CURRENT 1.CHIMNEY POSITION 2.TIGHTNESS OF CHIMNEY
ELECTRICAL ELECTRICAL ELECTRICAL ELECTRICAL ELECTRICAL ELECTRICAL ELECTRICAL ELECTRICAL VISUAL ELECTRICAL
100% 100% 100% 100% 100% 100% 100% 100% 100% 100%
DO DO DO DO DO DO DO DO NESCL SPEC NESCL SPEC
DO DO DO DO DO DO DO DO VCS/PR/ 08R DO
P P P P P P P P P P
V V V V V V V V V V
V V V V V V V V V V
26
BUNCHING & CHIMNEY FIXING

ITEM: 33 KV CURRENT TRANSFORMER MANUFACTURE'S NAME & ADDRESS: QP NO: REV.NO: PROJECT/UTILITY: PACKAGE: CONTRACT NO: DATE: SUB-SYSTEM: Sl.N o 1 Component & operation 2 STAGE 2 TESTING PROTECTION CORE & METERING 27 28 29 30 P.S CORE TAPING PRIMARY WINDING 1.POLARITY 2.RATIO & PHASE ANGLE ERRORS 1.POLARITY TURNS RATIO 1.DIMENSION 2.TIGHTNESS OF TAPING 1.CROSS SECTION 2.NO OF TURNS 3.RIGIDITY 1.TEMP.MEASUREMENT 2.VACUUM MEASURMENT 3.FILTERED OIL BDV CHECK 4.OIL SOAKING TIME 1.PRIMARY CONNECTION 2.SECONDARY CONNECTION 3.LOCKING ARRANGEMENTS 4.SECURING OF ACTIVE PART Characteristics 3 Class 4 MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR MAJOR Type of Check 5 ELECTRICAL ELECTRICAL ELECTRICAL ELECTRICAL ELECTRICAL ELECTRICAL MEASUREMENT MEASUREMENT VISUAL PHYSICAL PHYSICAL ELECTRICAL PHYSICAL VISUAL VISUAL VISUAL VISUAL Quantum of Check 6 100% 100% 100% 100% 100% 100% 5% 100% 5% EVERY HOUR EVERY HOUR 1 SAMPLE PER LOT 100% 100% 100% 100% 100% Reference Document 7 QAI/01 SEC-11 AND IS 2705 DO DO DO QAI/01 SEC-12 DO QAI/01 SEC-13 DO QAI/01 SEC-14 DO DO DO DO QAI/01 SEC-15 DO DO DO Acceptance Norms 8 AS PER IS 2705 DO DO DO DO DO NESCL SPEC DO DO DO DO DO DO DO DO DO DO MAIN-CONTRACTOR: Format of Records 9 VCS/QA/04R DO DO DO VCS/PR/08R DO DO DO DO VCS/PR/010R DO DO DO VCS/PR/08R DO DO DO D P P P P P P P P P P P P P P P P P P Agency * 10 V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V Remarks 11 DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO
31
DRYING & IMPREGNATION
32
MAIN ASSEMBLY
SECTION: 3 FINAL INSPECTION 1. VERIFICATION OF TERMINAL MARKING AND POLARITY CRITICAL ELECTRICAL 100% QAI/01 SEC-18 & IS 2705 DO AS PER IS 2705 VCS/QA/05F P W W
33
ROUTINE TEST
2. POWER FREQUENCY DRY WITHSTAND TESTS ON CRITICAL ELECTRICAL PRIMARY WINDINGS 3.POWER FREQUENCY DRY WITHSTAND TESTS ON CRITICAL ELECTRICAL SECONDARY WINDINGS 4. OVER VOLTAGE INTERTURN CRITICAL ELECTRICAL TEST 5 PARTIAL DISCHARGE MEASUREMENT (IF CRITICAL ELECTRICAL APPLICABLE) 6 RATIO & PHASE ANGLE CRITICAL ELECTRICAL ERROR ADDITIONAL TEST AS PER NESCL TECHNICAL SPECIFICATIONS 7) MEASUREMENT OF CRITICAL ELECTRICAL CAPACITANCE 8) OIL LEAKAGE TEST (PROCESS TO BE MUTUALLY CRITICAL ELECTRICAL AGREED) 9) MEASUREMENT OF TAN DELTA AT 0.3, 0.7, 1.0 & 1.1 Um CRITICAL ELECTRICAL
100%
DO
DO
100% 100% 100% 100%
DO DO DO DO
DO DO DO DO
DO DO DO DO
P P P P
W W W W
W W W W
100% 100%
DO DO
DO DO
DO DO
W W
W W
W W
100%
DO
DO
DO
Page 6 of 7

ITEM: 33 KV CURRENT TRANSFORMER MANUFACTURE'S NAME & ADDRESS: QP NO: REV.NO: PROJECT/UTILITY: PACKAGE: CONTRACT NO: DATE: SUB-SYSTEM: Sl.N o 1 Component & operation 2 Characteristics 3 1.SHORT-TIME CURRENT TEST 2.TEMPERATURE RISE TEST 3.LIGHTNING IMPULSE VOLTAGE WITHSTAND TEST 4.HIGH VOLTAGE POWER FREQUENCY WET WITHSTAND VOLTAGE TEST 5.DETERMINATION OF ERRORS AND OTHER CHARACTERISTICS ACCORDING TO THE REQUIREMENT OF THE APPROPRIATE DESIGNATION OF ACCURACY CLASS 1.VISUAL CHECK 2.NUTS & WASHER FOR EARTH BOLTS 3.EARTHING SYMBOL 4.OIL LEVEL IN GAUGE 5.PRIMARY TERMINAL MARKINGS 6.OIL LEAKS 7.TERMINAL MARKINGS 8.NAME PLATE & CONNECTION DIAGRAM Class 4 CRITICAL CRITICAL CRITICAL CRITICAL Type of Check 5 ELECTRICAL ELECTRICAL ELECTRICAL ELECTRICAL Quantum of Check 6 1 SAMPLE 1 SAMPLE 1 SAMPLE 1 SAMPLE Reference Document 7 QAI/01 & IS-2705 DO DO DO Acceptance Norms 8 AS PER IS 2705 DO DO DO MAIN-CONTRACTOR: Format of Records 9 VCS/PR/008R DO DO DO D W W W W Agency * 10 V V V V V V V V Remarks 11
39
TYPE TESTS*
CRITICAL
ELECTRICAL
1 SAMPLE
DO
DO
DO
CRITICAL CRITICAL CRITICAL CRITICAL CRITICAL CRITICAL CRITICAL CRITICAL
VISUAL VISUAL VISUAL VISUAL VISUAL VISUAL VISUAL VISUAL
100% 100% 100% 100% 100% 100% 100% 100%
QAI/01 SEC-20 DO DO DO DO DO DO DO
DO DO DO DO DO DO DO DO
VCS/PR/008R DO DO DO DO DO DO DO
P P P P P P P P
V V V V V V V V
V V V V V V V V
38
FINISHING
*-All type tests to be carried out as per NESCL specification, Contract Agreement and as per minutes of the meeting between NESCL and Main Contractor. Approval of type tests by Engineering department of NESCL or waival - Record identified'' "tick mark" shall be essentially included by supplier in QA Documentations. P.S= Plant M= Manufacturer Standard P= Performed By N= Customer (NESCL) V= Verified By C = Contactor W= Witness of test SIGNATURE OF THE CONTRACTOR SIGNATURE OF THE MANUFACTURER
PREPARED BY
REVIEWED BY
APPROVED BY
Page 7 of 7

MANUFACTURER'S NAME & ADDRESS: QP NO: ITEM: 11 KV XLPE INSULATED CABLE REV.NO: DATE: SUB-SYSTEM: No.of pages:4 Reference Class Type of Check Quantum of Check Document 4 5 6 7 SECTION: 1 RAW MATERIALS Manufacturer One sample from each Major Measurement Specification lot & IS 5484 Major Major Major Major Major Major Major Critical Major Major Major Major Major Major Critical Critical Major Major Major Major Major Major Critical Critical Test Test Electrical Test Test Test Test Electrical Test Test Measurement Electrical Test Test Test Test Test Test Test Test Measurement Test Test Electrical Test Test Chemical Chemical do do do One sample from each lot do do do do One sample from each lot do do do One sample from each lot do do do do 10% do do do do do do do do do Manufacturer Specification & As per IS 7098 do do do do Manufacturer Specification & As per P.S do do do Manufacturer Specification & As per IS 5831 do do do do Manufacturer Specification & IS 3975 do do do do do do PROJECT/UTILITY: PACKAGE: CONTRACT NO: MAIN-CONTRACTOR: Format of Records D 9 M QC report do do do QC report do do do do QC report do do do QC report do do do do QC report do do do do do do P P P P P P P P P P P P P P P P P P P P P P P P P
Sl.N o 1
Characteristics 3
Acceptance Norms 8 As per IS 8130 & As per NESCL Spec do do do As per IS 7098 and NESCL Spec do do do do As per IS 8130 & As per NESCL Spec do do do As per IS 5831 & As per NESCL Spec do do do do As per IS 3975 & As perNESCL Spec do do do do do do
Agency 10 C V V V V V V V V V V V V V V V V V V V V V V V V V N V V V V V V V V V V V V V V V V V V V V V V V V V
Remarks 11 Review of Manufacturer's Test Certificate at the time of final inspection do do do Review of Manufacturer's Test Certificate at the time of final inspection do do do do Review of Manufacturer's Test Certificate at the time of final inspection do do do Review of Manufacturer's Test Certificate at the time of final inspection do do do do Review of Manufacturer's Test Certificate at the time of final inspection do do do do do do
a) Diameter 1 Aluminium Rod b) Tensile Strength c) Elongation d) Resistivity / Conductivity a) Hot set b) Tensile Strength XLPE
c) Elongation d) Volume Resistivity ( Insulation Resistance) e) Thermal Ageing Shelf Life-One Year Contamination & Voids a) Dimension
Copper Tape
b) Resistivity / Conductivity c) Elongation d) Yield Strength a) Tensile Strength b) Elongation c) Thermal Stability d) Thermal Aging e) Loss in mass a) Dimension b) Tensile Strength c) Elongation d) Resistivity e) Torsion / Winding f) Weight of Zinc coating g) Dip Test
PVC Compound
Armour

MANUFACTURER'S NAME & ADDRESS: QP NO: ITEM: 11 KV XLPE INSULATED CABLE REV.NO: DATE: SUB-SYSTEM: No.of pages:4 Reference Characteristics Class Type of Check Quantum of Check Document 3 4 5 6 7 SECTION: 2 IN PROCESS INSPECTION Major Major Major Major Major Major Major Major Major Major Measurement Test Test Visual Measurement Visual Visual Electrical Test Visual Visual 10% do do do 100% do do do do do IS 8130, IS 398 & P.S do do do IS 8130 & IS 398 & P.S do do do do do PROJECT/UTILITY: PACKAGE: CONTRACT NO: MAIN-CONTRACTOR: Format of Records D 9 M QC report do do do QC report do do do do do P P P P P P P P P P
Sl.N o 1
Acceptance Norms 8 As per IS 8130, IS 398 & NESCL Spec do do do As per IS 8130 & IS 398 & NESCL Spec do do do do do
Agency 10 C V V V V V V V V V V N V V V V V V V V V V
Remarks 11 Review of the records at the time of final inspection do do do do do do do do do
a) Dimension 6 Wire Drawing ( Aluminium) b) Tensile Strength c) Wrapping test d) Surface Finish a) Dimension b) No./ Diameter of Wire c) Sequence d) Conductor Resistance e) Surface Finish f) Lay length, compact & ovality & Direction a) Type of component b) Thickness c) Colour d) Surface Finish e) Curing f) Hot set test g) Tensile Strength h) Elongation i) Volume Resistivity a) Dimension of Tape 9 Copper Taping b) Surface finish c) Over lapping d) Continuity a) Core Sequence 10 Laying Up b) Laid Up diameter c) Length a) Type of component 11 Inner Sheath b) Colour of Sheath c) Surface finish d) Diameter Over inner Sheath a) No. of strip 12 Armour b) Lay length & Direction c) Coverage d) Diameter Over Armour a) Type of compound b) Sheath thickness c) Colour of Sheath d) Diameter over sheath e) Surface Finish f) Embossing g) Sequential marking
Stranding
Major Major Major Major Major Major Major Major Major Major Major Major Major Major Major Major Major Major Major Major Major Major Major Major Major Major Major Major Major Major Major
Visual Measurement Visual Visual Visual Test Test Test Electrical Test Measurement Visual Visual Electrical Test Visual Measurement Measurement Visual Visual Visual Measurement Visual Measurement Measurement Measurement _ Measurement Visual Measurement Visual Visual Visual
_ 100% do do do 1 spool do do do 100% do do do 100% do do 100% do do do 100% do do do 100% do do do do do do
As per IS 7098, IS 7098 & P.S P.S and Approved Data Sheet do do do do do do do do do do do do do do do do
QC report do do do do do do do do QC report do do do QC report do do QC report do do do QC report do do do QC report do do do do do do
P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P
V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V
V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V
do do do do do do do do do do do do do do do do do do do do do do do do do do do do do do do
Insulation
IS 7098 & P.S IS 7098 & A.D.S do do do IS 7098 & P.S do do IS 7098 & P.S do do do IS 7098(Pt-II) & P.S do do do IS 7098(Pt-II) & P.S do do do do do do do do do IS 7098 & A.D.S By hot water IS 7098 & A.D.S IS 7098 & A.D.S IS 7098 & A.D.S do do do IS 7098(Pt-II) & A.D.S do do do IS 7098(Pt-II) & A.D.S do do do do do do
13
Outer Sheath

MANUFACTURER'S NAME & ADDRESS: QP NO: ITEM: 11 KV XLPE INSULATED CABLE REV.NO: DATE: SUB-SYSTEM: No.of pages:4 Reference Class Type of Check Quantum of Check Document 4 5 6 7 SECTION: 3 Final Testing Major Major Major Critical Electrical Test Electrical Test Electrical Test Electrical Test 100% do do Sample As per IS 7098(Pt-II) do do As per IS 7098(Pt-II) PROJECT/UTILITY: PACKAGE: CONTRACT NO: MAIN-CONTRACTOR: Format of Records D 9 M QC report do do QC report P P P V
Sl.N o 1
Characteristics 3
Acceptance Norms 8 IS 7098(Pt-II) & A.D.S do do IS 7098(Pt-II) & A.D.S
Agency 10 C V V V V N V V V V
Remarks 11 Routine test certificate will be furnished for verification during final inspection do do Type Test Clearance from NESCL Engineering Department
a) Conductor resistance 14 Routine test b) High Voltage c) Partial Discharge Test 15 All Type tests as per NESCL Technical Specifications Type Tests

MANUFACTURER'S NAME & ADDRESS: QP NO: ITEM: 11 KV XLPE INSULATED CABLE REV.NO: DATE: No.of pages:4 SUB-SYSTEM: Reference Type of Check Quantum of Check Document 5 6 7 Electrical Test As per sampling plan of IS 7098(Pt-II) As per IS 7098(Pt-II) PROJECT/UTILITY: PACKAGE: CONTRACT NO: MAIN-CONTRACTOR: Format of Records D 9 P
Sl.N o 1
Characteristics 3 a) Conductor resitance
Class 4 Critical
Acceptance Norms 8 As per IS 7098(PtAcceptance II), A.D.S & test NESCL Certificate Specification do do
Agency 10 W W
Remarks 11
b) Tensile test
Critical
Test
do
do
c) Wrapping Test d) Test for thickness of insulation and sheath e) Hot set test for insulation
Critical
Test
do
do
do
do
Critical
Test
do
do
do
do
16
Acceptance test
Critical
Test
do
do
do
do
f) Partial discharge test g) Tensile strength & elongation at break for insulation & outer sheath h) High voltage test i) Insulation resistance ( V. R) 14 Packing & Marking Pre-Despatch packing
Critical
Electrical Test
do
do
do
do
Critical Critical Critical Major
Test Electrical Test Electrical Test Visual
do do do Random
do do do NESCL specification
do do do NESCL specification
do do do do
P P P P
W W W V
W W W V
*-All type tests to be carried out as per NESCL specification. - Record identified'' "tick mark" shall be essentially included by supplier in QA Documentations.
Note: Manufacturing, inspection & testing as per IS 7098 (pt-II) P= Performed By V= Verified By W= Witness of test SIGNATURE OF THE CONTRACTOR
PS = Plant Stan ADS = Approved Data Sheet
M= Manufacturer N= Customer (NESCL) C = Contactor

MANUFACTURE'S NAME & ADDRESS: ITEM: 11 KV HT XLPE AERIAL BUNCHED CABLE (3X35+70) SUB-SYSTEM: Sl.No 1 Component & operation 2 Characteristics 3 Class Type of Check Quantum of Check 6 QP NO: REV.NO: DATE: No.of pages:5 Reference Document Acceptance Norms 7 Manufacturer Specification & IS 5484 do do do Manufacturer Specification & IS 9997 do do do Manufacturer Specification & As per IS 7098 (part-II) do do do do Manufacturer Specification & IS 398 do do 8 PROJECT/UTILITY: PACKAGE: CONTRACT NO: MAIN-CONTRACTOR: Format of Records 9 D M One sample from each lot do do do One sample from each lot do do do One sample from each lot do do do do IS 8130 , IS 613 & NESCL Spec. do do do IS 398 & NESCL Spec. do do do IS 7098 (part-II) and NESCL Spec. do do do do QC report do do do QC report do do do QC report do do do do P P P P P P P P P P P P P Agency 10 C V V V V V V V V V V V V V N V V V V V V V V V V V V V Review of manufacturers test certificates at the time of final inspection do do do Review of manufacturers test certificates at the time of final inspection do do do Review of manufacturers test certificates at the time of final inspection do do do do Review of Manufacturer's Test Certificate at the time of final inspection do do Remarks 11
4 5 SECTION: 1 RAW MATERIALS Major Major Major Major Major Major Major Major Critical Major Major Major Critical Measurement Test Test Electrical Test Measurement Test Test Electrical Test Test Test Test Electrical Test Test
a) Diameter 1 Aluminium Rod b) Tensile Strength c) Elongation d) Resistivity / Conductivity a) Diameter 2 Alloy Rod b) Tensile Strength c) Elongation d) Resistivity / Conductivity a) Hot set b) Tensile Strength c) Elongation d) Volume Resistivity ( Insulation Resistance) e) Thermal Ageing Shelf LifeOne Year Contamination & Voids a) Diameter 4 Messenger Wire b) Tensile Strength c) Elongation
XLPE Compound
Major Major Major
One sample from each lot do do
As per IS 398 & NESCL Spec. do do
QC report do do
P P P
V V V
V V V
Page 1 of 4

MANUFACTURE'S NAME & ADDRESS: ITEM: 11 KV HT XLPE AERIAL BUNCHED CABLE (3X35+70) SUB-SYSTEM: Sl.No 1 Component & operation 2 Characteristics 3 Quantum of Check 4 5 6 SECTION: 2 IN PROCESS INSPECTION Class Type of Check Major Major Major Major Major Major Major Major Major Major Major Major Major Major Major Measurement Test Test Visual Measurement Visual Visual Electrical Test Visual Visual Visual Test Test Test Visual 10% do do do 100% do do do do do do One sample from each lot do do 100% QP NO: REV.NO: DATE: No.of pages:5 Reference Document Acceptance Norms 7 8 PROJECT/UTILITY: PACKAGE: CONTRACT NO: MAIN-CONTRACTOR: Format of Records 9 D M IS 8130, IS 398 & P.S do do do IS 8130 & IS 398 & P.S do do do do do do Manufacturer Specification & IS 398 do do IS 7098 (part-II) & P.S do do do do do do do do do do do do IS 8130, IS 398 & NESCL Spec. do do do IS 8130 , IS 398 & NESCL Spec. do do do do do do IS 398 & NESCL Spec. do do IS 7098 (part-II) , P.S and Approved Data Sheet do do do do do do do / By Hot water do do do do do QC report do do do QC report do do do do do do do do do QC report P P P P P P P P P P P P P P P Agency 10 C V V V V V V V V V V V V V V V N V V V V V V V V V V V V V V V Review of manufacturers test certificates at the time of final inspection do do do Review of manufacturers test certificates at the time of final inspection do do do do do do do do do Review of manufacturers test certificates at the time of final inspection do do do do do do do do do do do do Remarks 11
a) Dimension 5 Wire Drawing ( Aluminium/Alloy) b) Tensile Strength c) Wrapping test d) Surface Finish a) Dimension b) No./ Diameter of Wire c) Sequence d) D.C Conductor Resistance e) Surface Finish f) Lay length, compact & ovality g) Direction of lay h) Tensile Strength i) Elongation j) UTS a) Type of component b) Diameter of conductor / core Thickness c) Thickness d) Colour e) Identification Ridge f) Surface Finish g) Embossing h) Curing i) Hot set test j) Tensile Strength k) Elongation l) Volume Resistivity m) Spark Test
Stranding Phase/Messenger Wire
Major Major Major Major Major Major Major Major Major Major Major Major
Measurement Measurement Visual Visual Visual Visual Visual Test Test Test Electrical Test Electrical Test
do 100% do do do do do 1 spool do do do do
do do do do do do do do do do do do
V V V V V V V V V V V V
V V V V V V V V V V V V
Insulation
Page 2 of 4

MANUFACTURE'S NAME & ADDRESS: ITEM: 11 KV HT XLPE AERIAL BUNCHED CABLE (3X35+70) SUB-SYSTEM: Sl.No 1 Component & operation 2 Characteristics 3 a) Core Sequence 8 Laying Up b) Laid Up diameter c) Length a) Dimension of Tape 9 Copper Tape b) Surface finish c) Overlap in copper tape d) Continuity a) Type of component 10 Outer Sheath b) Colour of Sheath c) Embossing d) Surface finish Minor Major Major Major Major Minor Minor Visual Visual Electrical Test Visual Visual Visual Visual do do do 100% do do do do do do IS 7098 (part-II) & P.S do do do do do do IS 7098 (part-II) & A.D.S do do do do do do QC report do do do P P P P P P P M 100% do do Sample IS 7098 (part-II) & P.S do do IS 7098 (part-II) & P.S IS 7098 (part-II) & A.D.S do do IS 7098 (part-II) & A.D.S QC report do do Type Test Report P P P V V V V V V V V C V V V V V V V V V V V N V V V V Routine test certificate will be furnished for verificationduring final inspection do do Type Test Clearance from NESCL Engineering Minor Major Major Measurement Measurement Measurement do do 100% Class 4 Major Type of Check 5 Visual Quantum of Check 6 100% QP NO: REV.NO: DATE: No.of pages:5 Reference Document Acceptance Norms 7 IS 7098 (part-II) & P.S do do IS 7098 (part-II) & P.S 8 IS 7098 (part-II) & A.D.S do do IS 7098 (part-II) & A.D.S PROJECT/UTILITY: PACKAGE: CONTRACT NO: MAIN-CONTRACTOR: Format of Records 9 QC report do do QC report D P P P P Agency 10 V V V V V V V V Remarks 11 Review of manufacturers test certificates at the time of final inspection do do Review of manufacturers test certificates at the time of final inspection do do do Review of manufacturers test certificates at the time of final inspection do do do
SECTION: 3 Final Testing a) Conductor resistance 11 Routine test b) High Voltage c) Partial Discharge Test 12 All Type Tests as per NESCL Technical Specification Type Tests Major Major Major Electrical Test Electrical Test Electrical Test Major Electrical Test
a) Conductor resitance b) Test for thickness & Dimension of insulation including eccentricity & ovality c) Thickness of sheath
Major
Electrical Test
As per sampling As per IS 7098(Pt-II), Acceptance plan of IS As per IS 7098(Pt-II) A.D.S & NESCL test Certificate 7098(Pt-II) Specification do do do do
Major
Test
Major
Test
do
do
do
do
Page 3 of 4

MANUFACTURE'S NAME & ADDRESS: ITEM: 11 KV HT XLPE AERIAL BUNCHED CABLE (3X35+70) SUB-SYSTEM: Sl.No 1 Component & operation 2 Characteristics 3 d) Hot set test for insulation Class 4 Major Type of Check 5 Test Quantum of Check 6 do QP NO: REV.NO: DATE: No.of pages:5 Reference Document Acceptance Norms 7 do 8 do PROJECT/UTILITY: PACKAGE: CONTRACT NO: MAIN-CONTRACTOR: Format of Records 9 do D P Agency 10 W W Remarks 11
e) Partial discharge test 13 Acceptance test on Cable f) Tensile strength & elongation at break for insulation & sheath g) High voltage test
Major
Electrical Test
do
do
do
do
Major
Test
do
do
do
do
Major
Electrical Test
do
do
do
do
h) Insulation Resistance ( V. R)
Major
Electrical Test
do
do
do
do
k) Wrapping Test
Major
Test
do
do
do
do
l) Tensile Strength for Aluminum
Major
Test
do
do
do
do
a) Breaking Load Test Acceptance test on messenger b) Elonagtion wire c) Resistance Test 15 Packing & Marking
Major
Test
14
Major
Test
Major Major
Test Visual
As per sampling plan of IS 398(Pt- As per IS 398(Pt-II) II) As per sampling plan of IS 398(Pt- As per IS 398(Pt-II) II) As per sampling plan of IS 398(Pt- As per IS 398(Pt-II) II) Random
As per IS 398(Pt-II)
do
do
do do
P P
W V
W V
NESCL specification NESCL specification
*-All type tests to be carried out as per NESCL specification & Contract Agreement . - Record identified'' "tick mark" shall be essentially included by supplier in QA Documentations. Note: Manufacturing, inspection & testing as per IS 7098 (pt-II) P= Performed By V= Verified By W= Witness of test SIGNATURE OF THE CONTRACTOR M/A= Major P.S= Plant Standard A.D.S= Approved Data Sheet M/I=Minor SIGNATURE OF THE MANUFACTURER Page 4 of 4 M= Manufacturer N= Customer (NESCL) C = Contactor
MANUFACTUER'S NAME & ADDRESS:

ITEM: BUS POST INSULATORS UPTO 33 Kv SUB-SYSTEM: QP NO: REV.NO: DATE: PAGE:.OF.. Quantum of Check 6 Reference Document 7 Acceptance Norms 8 PROJECT/UTILITY: PACKAGE: CONTRACT NO: MAIN-CONTRACTOR: Format of Records 9 M White/off White, deep cream colour in raw form 4% Max. The residue shall be free from iron impurities white to cream, free from black specks. Supplier test certificate approx 30-40% 40-55% <4% <2% 16-19% 6% Max 18% Max white to deep cream/ yellow colour < 5% The residue shall be free from iron impurities White/off white to cream/Buff free from impurities. Supplier test certificate approx >25% 50-60% < 3% < 3% < 13% 6% Max 18% Max QC Report QC Report QC Report V P V Agency ** C V V V 10 N V V V Record review during final inspection Do Do Remarks 11
Sl.No 1
Characteristics 3
Class 4
Type of Check 5
SECTION: RAW MATERIALS INSPECTION a) Inspection b) Residue retained on 300 mesh (BSS) c) Fired colour d) Chemical analysis 1 China clays Al2 03 Sio2 Fe2 03 Tio2 LOI at 1220 c e) Dry shrinkage f) Total shrinkage a) Inspection b) Residue retained on 240 mesh c) fired colour d) Chemical analysis Al2 03 Sio2 Fe2 03 Tio2 LOI at 1220oc e) Dry shrinkage f) Total shrinkage Major Major Test Test Do Do Major Major Major Major Test Test Visual Test Do Do 0.01% in the total wt Do
o
Major Major Major
Visual Test Visual
0.01% in the total wt Do Do
IRM/CD/TP/2 Major Test Sampling Once in 250 MT
Supplier TC/ QC lab/TPL Supplier TC/ QC lab/TPL QC Report QC Report
P P V P
V V V V
V V V V
Record review during final inspection Do Record review during final inspection Do
Major
Visual
Do
QC Report
Do
Ball clays
IRM/CD/TP/2 Major Test Once in 250 MT
P P
V V
V V
Record review during final inspection Record review during final inspection
Sl.No 1
Characteristics 3 a) Inspection b) Residue retained on 240 mesh (BSS) c) fired colour
Class 4 Major
Quantum of Check 6 0.01% in the total wt Do
Acceptance Norms 8 White to off White raw colour < 3%Max The residue shall be free from iron particles and magnetic impurities Off white to White free from impurities Nil, No vitrification Supplier test certificate approx 98% Min 0.25% Max. 0.5% Max
Format of Records 9 QC Report V
Agency ** V 10 V
Remarks 11 Record review during final inspection Do
Major
Test
QC Report
Major Major
Visual Visual
Do Do IRM/CD/TP/1
QC Report QC Report
V V
V V
V V
Do Do
Quartz Powder
d) Sintering
e) Chemical analysis SiO2 Fe2 O3 LOI at 1000 c

o
Major
Test
Sampling Once in 250 MT
a) Inspection b) Residue retained on 240 mesh c) fired colour d) Firing behavior 4 Feldspar powder e) Chemical analysis K2O+Na2O K2O Na2O Fe2O3 LOI at 1000OC
Major
Visual
0.01% in the total wt Do Do Do IRM/CD/TP/1
White to light pink colour < 3% Max The residue shall be free from iron particles and magnetic impurities Grayish/off white to white Vitirified mass free from impurities Suppliertest certificate approx 13% Min 11% Min. 3.5% Max 0.2% Max 0.5% Max
QC Report
Record review during final inspection Do Do Do
Major Major Major
Test Visual Test
P V P
V V V
V V V
Major
Test
Once in 250 MT
a) Inspection b) Residue retained on 300 mesh 5 Iron oxide c) Fired colour d) Chemical analysis Fe2O3 content
Major Major Major
Visual Test Visual
500 gms/MT or part thereof Do Do IRM/CD/TP/1
Dark brown colour 0.5% Max Block/Greyish black free from impurities Supplier test certificate approx 85% Min
V P V
V V V
V V V
Record review during final inspection Do Do T/C review during final inspection
Major
Test
Once in 1 MT
Sl.No 1
Characteristics 3 a) Inspection b) Residue retained on 300 mesh
Class 4 Major Major Major
Type of Check 5 Visual Test Visual
Quantum of Check 6 500 gms/MT or part thereof Do Do
Acceptance Norms 8 Dark Grey to black colour free from impurities 0.5% Max
Format of Records 9 QC Report QC Report QC Report V P V
Agency ** V V V 10 V V V
Remarks 11 Record review during final inspection Do Do T/C review during final inspection Record review during final inspection Do Do T/C review during final inspection Record review during final inspection Do Do T/C review during final inspection
Manganese di-oxide
c) Fired colour d) Chemical analysis MnO2 content
IRM/CD/TP/1
Black/ balckish violet free from impurities Supplier Test certificate 85% Min Bottle Green colour 0.5% Max
Major
Test
Once in 10 MT 500 gms/MT or part thereof Do Do IRM/CD/TP/1
a) Inspection b) Residue retained on 300 mesh 7 Chromium oxide c) Fired colour d) Chemical analysis Cr2O3 content
Major Major Major
Visual Test Visual
V P V
V V V
V V V
Dark Green free from impurities Supplier Test certificate 85% Min White to cream raw colour. Free from impurities
Major
Test
Once in 10 MT
a) Inspection b) Residue retained on 300 mesh c) Fired colour d) Chemical analysis CaO content
Visual Test Visual Test
500 gms/MT or part thereof Do Do Once in 10 MT IRM/CD/TP/1
QC Report QC Report QC Report Supplier TC/ QC lab/TPL
V P V P M
V V V V C V V V C V
V V V V N V V V N V
Calcite powder
3% Max Light greenish Supplier Test certificate 50% Min
SECTION: ASSEMBLY MATERIALS INSPECTION a) Inspection 9 Cement b) Compressive strength c) Expansion Major Visual Major Major Test Test 0.01% of total quantity received Do Each consignment IS: 12269 IRM/CD/TP/3 QC Report
No lumpiness/solidification. 380 Kg/cm2 0.8% Max
V P P M
Record review during final inspection T/C review during final inspection Do
QC lab/TPL QC lab/TPL
SECTION: METAL PARTS INSPECTION a) Inspection Major Visual 100% Lot sample size size (nos) (nos) 1-500 4 501-1000 6 1001+ 10 Do As per IS:2486 part-II No sharp / rough edges. QC Report
11
Lead Thimble
b) Dimension
Major
Measurement
As per drawing
QC Report
Do
c) Gauge Checking
Major
Visual
QC Report
Do
Sl.No 1
Characteristics 3
Class 4
Type of Check 5
Quantum of Check 6
Acceptance Norms 8
Agency ** C V V V V V V V V V V V V V V V 10 N V V V V V V V V V V V V V V V
Remarks 11
SECTION: IN-PROCESS INSPECTION a) Inspection 12 Wet grinding of ceramic b) Residue retained on 300 body mesh c) Particle size Analysis 13 14 15 16 Slip's Litre Weight a) Moisture % Pug mill's clay blank b) De airing checking Major Major Major Major Major Major Major Major Major Major Major Major Major Major Major Visual Test Test Test Test Test Test Test Test Test Measurement Test Visual Test Test Each charge Do Once in week Daily once Twice in a shift Do Each charge Once in a day Once in week Once in a shift Do Once in a day Once in a day 3 samples per day Once in 3 month IP/CD/TP/1 IP/CD/TP/1 IP/CD/TP/1 Pale white to cream colour with no visual impurities < 30 grms/Ltrs <10 Microns-Min 70% < 30 Microns-Min 97% 1.40-1.50 Kg/litre 16.5-19% Min. 700mm of Hg vaccum Max. 2% Max. 2% 30 Kgs/cm Min As per drawing As per drawing 8 to 12% ( depending upon climate condition) Ambient-85oC 0.8% Max. Unglazed 750 Kgs/cm2 Min Glazed 850 gs/cm2 Min
2
QC Report QC Report QC Report QC Report QC Report QC Report QC Report QC Report QC Report QC Report QC Report QC Report QC Report QC Report QC Report
V P P P P P P P P P P P V P P
Record review during final inspection Do Do Do Do Do Do Do Do Do Do Do Do Do Do
Residue retained on 300 During glaze preparation mesh Properties of unfired porcelain a) Linear shrinkage b) Dry MOR a) Making cavity check b) Finishing dimension c) Moisture % before entry into dryer a) Hot rooms temperature
17
Shaping
18
Drying b) moisture content
a) Linear shrinkage 19 Properties of fired porcelain Fired MOR b) porosity c) Bulk density d) Water absorption
Major
Test Once in a day
< 14% 4 pieces from every unloaded car of Tunnel Kiln Daily once Daily once
QC Report
Major Major Major
Test Test Test
As per IS: 731
As per IS: 731 & 5300 2.38 Min 0.2% Max
P P P
V V V
V V V
Do Do Do
Sl.No 1
Class 4 Major Major Major Major
Type of Check 5 Visual Test Test Visual Visual
Quantum of Check 6 100% 3 samples per day Twice in a day. Hourly 100%
Acceptance Norms 8 Rose pink slip colour slurry with no visual impurities 2-3% Max 1.4-1.45 1220-1230 C depending on cycle As per IS:2544 As per NESCL approved specified drawings
o
Format of Records 9 QC Report QC Report QC Report QC Report QC Report V P P V V
Agency ** V V V V V 10 V V V V V
Remarks 11 Do Do
20
Glazing (Brown glaze) b) Moissture % c) Sp.gravity
20
Temperrature during firing of green wares a) Inspection
Do Do
Major
Sorting of fired insulator
b) Dimension & weight
Major
Measurement
3 Nos/day
QC Report
Do
c) Marking 21 a) Inspection
Major Major
Measurement Visual
100% 100% Lot sample size size (nos) (nos) 1-500 4 501-1000 6 1001+ 10
As per NESCL approved specified drawings/ NESCL Tech. Specs. No broken planks
QC Report QC Report
P V
V V
V V
Do Do
23
Packing ( wooden ) crate
b) Dimension
Major
Measurement
As per Approved Drawing
QC Report
Do
SECTION: FINAL INSPECTION a) Dimension checking b) Temperature cycle test 24 Acceptance Tests c) Mechanical strength test d) Porosity test e) Puncture Test f) Galvanising Test a) Visual Examination 25 Routine Tests b) Electrical Tests c) Mechanical tests All type test as per IS: 2544 & NESCL Tech. Specs. Major Major Major Major Major Major Major Major Major Measurement Test Test Test Test Test Test Test Test As per IS: 2544 As per IS: 2544 As per IS: 2544 As per IS: 2544 As per IS: 2544 As per IS: 2544 100% 100% 100% As per IS: 2544 As per IS: 2544 As per IS: 2544 As per IS: 2544 As per IS: 2544 As per IS: 2544 As per IS: 2544 As per IS: 2544 As per IS: 2544 As per IS: 2544 As per IS: 2544 As per IS: 2544 As per IS: 2544 As per IS: 2544 As per IS: 2544 As per IS: 2544 As per IS: 2544 As per IS: 2544 QC Report QC Report QC Report QC Report QC Report QC Report QC Report QC Report QC Report
M P P P P P P P P P
C W W W W W W V V V
N W W W W W W V V V Type Test Clearance from NESCL Engineering Department CHP CHP CHP CHP CHP CHP
26 Type Tests*
Major
Test
Sample
As per IS: 2544
As per IS: 2544
Type Test Certificate

Technical Specification Lohardaga

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NTPC ELECTRIC SUPPLY COMPANY LTD.

(A Wholly Owned Subsidiary of NTPC LTD.)

RURAL ELECTRIFICATION WORKS UNDER RGGVY SCHEME FOR

LOHARDAGA DISTRICT OF JHARKHAND

BID DOCUMENT NO. : NESCL/REC/CS-LH-808

RGGVY WORKS STANDARD TECHNICAL SPECIFICATION (REV.- 03)

RGGVY WORKS STANDARD TECHNICAL SPECIFICATION (REV.- 03)

33KV & 11KV COMPOSITE INSULATOR 11KV AERIAL BUNCHED CABLES

E2-REV.-03 E3-REV.-03 E4-REV.-03 E5-REV.-03 E6-REV.-03 E7-REV.-03 E8-REV.-03 E9-REV.-03

RGGVY WORKS STANDARD TECHNICAL SPECIFICATION (REV.- 03)

NESCL-RE-GEN-008 NESCL-RE-GEN-009 NESCL-RE-GEN-010 NESCL-RE-GEN-012

RGGVY WORKS STANDARD TECHNICAL SPECIFICATION (REV.- 03)

RGGVY WORKS STANDARD TECHNICAL SPECIFICATION (REV.- 03)

RGGVY WORKS STANDARD TECHNICAL SPECIFICATION (REV.- 03)

11 KV POLE TOP BRACKET GA OF LT HORIZONTAL FORMATION

RGGVY WORKS STANDARD TECHNICAL SPECIFICATION (REV.- 03)

REC CONSTRUCTION STANDARD: A-10

REC CONSTRUCTION STANDARD: A-12

REC CONSTRUCTION STANDARD : A-21

NESCL: ENGG: RGGVY: 11KV LINE:05 REC CONSTRUCTION STANDARD : A-23

RGGVY WORKS STANDARD TECHNICAL SPECIFICATION (REV.- 03)

RGGVY WORKS STANDARD TECHNICAL SPECIFICATION (REV.- 03)

REC CONSTRUCTION STANDARD : D-2

415/240 V SHACKLE INSULATORS

REC CONSTRUCTION STANDARD : D 3

REC CONSTRUCTION STANDARD : E-32

REC CONSTRUCTION STANDARD : E34,35 REC CONSTRUCTION STANDARD : E-36

REC CONSTRUCTION STANDARD : E-38 REC CONSTRUCTION STANDARD : G-2

RGGVY WORKS STANDARD TECHNICAL SPECIFICATION (REV.- 03)

REC CONSTRUCTION STANDARD : F-2

REC CONSTRUCTION STANDARD : F-3

REC CONSTRUCTION STANDARD : F-4

REC CONSTRUCTION STANDARD : F-5

RGGVY WORKS STANDARD TECHNICAL SPECIFICATION (REV.- 03)

REC CONSTRUCTION STANDARD : F-10

TERMINAL NESCL: ENGG: RGGVY: DT:24

TERMINAL NESCL: ENGG: RGGVY: DT:25

REC CONSTRUCTION STANDARD H-1

REC CONSTRUCTION STANDARD H-2

REC CONSTRUCTION STANDARD H-3

REC CONSTRUCTION STANDARD H-10

RGGVY WORKS STANDARD TECHNICAL SPECIFICATION (REV.- 03)

FQP-3 FQP-4 FQP-5 FQP-6 FQP-7

RGGVY WORKS STANDARD TECHNICAL SPECIFICATION (REV.- 03)

MQP-4 MQP-5 MQP-6 MQP-7

RGGVY WORKS STANDARD TECHNICAL SPECIFICATION (REV.- 03)

MQP-9 MQP-10 MQP-11

RGGVY WORKS STANDARD TECHNICAL SPECIFICATION (REV.- 03)

RGGVY WORKS LOHARDAGA-JSEB Bid Doc. No. : NESCL/REC/CS-LH-808

TECHNICAL SPECIFICATION VOL-II-A

CHAPTER-I SECTION-E1 Project Synopsis

3.00.00 3.01.00 4.00.00 4.01.00

RGGVY WORKS LOHARDAGA-JSEB Bid Doc. No. : NESCL/REC/CS-LH-808

RGGVY WORKS LOHARDAGA-JSEB Bid Doc. No. : NESCL/REC/CS-LH-808

TECHNICAL SPECIFICATION VOL-II-A

CHAPTER-I SECTION-E1 Project Synopsis

RGGVY WORKS LOHARDAGA-JSEB Bid Doc. No. : NESCL/REC/CS-LH-808

RGGVY WORKS LOHARDAGA-JSEB Bid Doc. No. : NESCL/REC/CS-LH-808

Anandpur Lawagain Nirhu

02634000 02634200 02634700

Block Name: KURU (0002) Village Name Census Code

RGGVY WORKS LOHARDAGA-JSEB Bid Doc. No. : NESCL/REC/CS-LH-808

RGGVY WORKS LOHARDAGA-JSEB Bid Doc. No. : NESCL/REC/CS-LH-808