DOCUMENT No PCPL-0532-4-407-04-10 1.0 1.

1 SCOPE

NON SEGRAGATED BUSDUCTS

SECTION - 4 PAGE: 1 of 9

This Specification covers the design, material, construction features, manufacture, inspection and testing at the VENDOR s!his S"#$VENDOR s %or&s, deliver' to Site and performance testing of segregated!non$segregated metal enclosed phase (us ducts. CODES & STANDARDS The design, material, construction, manufacture, inspection, testing and performance of segregated!non$segregated metal enclosed phase (us ducts shall compl' *ith all currentl' applica(le statutes, regulations and safet' codes in the localit' *here the E+uipment *ill (e installed. The E+uipment shall also conform to the latest applica(le standards. Nothing in this Specification shall (e construed to relieve the VENDOR of this responsi(ilit'. E+uipment shall conform to the latest applica(le standards as mentioned in Data Sheets. ,n case of conflict (et*een the standards - this Specification, this Specification shall govern. DEFINITION / Non$Segregated 0hase #us Duct is one in *hich all phase conductors *ith its associated connections, 1oints, accessories and insulating supports are enclosed in an earthed metal enclosure *ithout an' metal or insulation (arrier (et*een the phases.

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2.0 2.1

BUS ENCLOSURE 3aterial The enclosure shall (e made of sheet steel or aluminium allo' as specified in Data Sheet$ /. The grade of sheet steel or aluminium allo' shall (e indicated (' the #,DDER in his #id and shall (e su(1ect to the 0"R45/SER s approval.

2.)

Shape E6cept as noted other*ise in Data Sheet$/, the section of the (us duct enclosure shall (e s+uare or rectangular.

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3echanical Strength The design of the (us duct enclosure shall (e such that it *ill *ithstand the internal or e6ternal pressures resulting from the follo*ing7 a8 Normal operating conditions (8 3omentar' short$circuit currents 90ea&8 c8 Rigorous adverse *eather conditions, and d8 com(ination of the a(ove

2...) 2.2

The housings shall (e of sturd' construction to have inherent strength to *ithstand the a(ove forces. 4onstruction

DATE:22-0 -200 ISSUE No: P0

DOCUMENT No PCPL-0532-4-407-04-10

NON SEGRAGATED BUSDUCTS

SECTION - 4 PAGE: 2 of 9

The entire (us duct shall (e designed for indoor installation as specified in Data Sheet$/, *ith a dust and vermin$proof construction. #us duct installations meant for outdoor application shall (e of *eatherproof construction and shall have degree of protection (etter than or e+ual to ,0$:; and shall (e indicated (' the #,DDER in Data Sheet$#. 2.< 2.<.1 0ainting The inside of the (usduct enclosure shall (e treated *ith a matt finish paint of dar& colour, prefera(l' (lac& to facilitate efficient heat dissipation. The (are enclosure *ith a(ove painting shall (e designed so as not to e6ceed the temperature specified in 4lause 2.: *hen the conductor is carr'ing rated current. The #,DDER shall su(mit supporting test certificates. The outside of the enclosure shall (e given a finish as per the 0"R45/SER s re+uirement specified in Data Sheet$/. Temperature Rise "nder normal operating conditions, the hot spot temperature of the enclosure shall not e6ceed ;0O4. 2.; #ello* =oints =oints consisting of ru((er (ello*s shall (e provided on the (us enclosure at follo*ing points7 a8 Terminations at transformers (8Terminations at s*itchgear cu(icles 2.> ?le6i(le E6pansion =oints 2.>.1. ?le6i(le e6pansion 1oints for the enclosure shall (e provided *herever deemed necessar' (' the VENDOR. The fle6i(le 1oints shall ta&e care of e6pansion and contraction due to temperature variations on fault conditions. 2.@ #onding Necessar' (onding shall (e provided at the a(ove e6pansion 1oints if made of insulating material. 2.10 Terminal Enclosures and ?langes 2.10.1 Three$phase terminal enclosures shall (e provided *ith flanged ends *ith drilling dimensions to suit the flanges at e+uipment terminals. 2.10.) The flanges shall (e provided *ith gas&ets, nuts, (olts etc. 2.10.. ,t shall (e the responsi(ilit' of the VENDOR of the (us duct to co$ordinate *ith various e+uipment 9(' OT5ERS8 to *hich his (us duct has to (e terminated to ensure proper alignment of the (us duct *ith these e+uipment. 2.11 ,nspection 4overs 0rovision shall (e made for periodic inspection of insulators (' means of inspection covers. The inspection covers shall (e provided *ith +uic& acting stainless steel clamps and shall have gas&ets.

2.<.) 2.:

DATE:22-0 -200 ISSUE No: P0

DOCUMENT No PCPL-0532-4-407-04-10 2.1) Drain 0lugs and Vents

NON SEGRAGATED BUSDUCTS

SECTION - 4 PAGE: 3 of 9

?ilter t'pe drain plugs shall (e installed at lo* points along the run of the (us duct to drain out automaticall' an' moisture condensing *ithin the (us enclosure. The drain plugs shall (e fitted *ith porous filter elements, *hich *ill permit the escape of moisture (ut prevent the ingress of dust. The filter elements shall (e easil' remova(le for cleaning purposes. 2.1. Aas&ets 2.1..1 The gas&et material and thic&ness shall (e so selected as to satisf' the operating conditions imposed (' temperature, *eathering dura(ilit' etc. 4are shall (e e6ercised to ensure that covers fit easil', that the re+uired compression of the gas&ets can (e o(tained *ithout damage to the inspection covers (' (olts and that covers do not (end after this compression has (een applied. Over$compression of the gas&ets shall (e avoided. 2.1..) The material of the gas&et shall prefera(l' (e neoprene closed$cell sponge ru((er or e+uivalent. 2.1... ?langes gas&ets shall (e provided at the e+uipment terminal connections. 2.12 3iscellaneous 5ard*are The (us duct shall not have an' through (olts. /ll nuts and (olts shall (e mild steel hot dip galvanised. 3.S. spring *ashers shall (e provided for ma&ing satisfactor' 1oints. 4lamps, splice plates etc. shall (e provided *herever necessar'. 2.1< Earthing Necessar' earthing arrangement as applica(le shall (e provided *ith clamps to receive the 0"R45/SER s station earthing (us. /ll accessories and hard*are re+uired for the earthing arrangement should (e provided (' the VENDOR. <.0 <.1 BUS CONDUCTOR 3aterial The material of the conductor shall (e aluminium allo' or copper as specified in Data Sheet$/. The grade of aluminium allo' or copper shall (e indicated (' the #,DDER in his #id and shall (e su(1ect to the 0"R45/SER s approval. <.) Rating The (us conductor shall (e designed to carr' the rated current under normal Site operating conditions *ithout e6ceeding a hot spot temperature of >< O4. /lso, the temperature of the (us surface shall not e6ceed )<0O4 *hile carr'ing the specified short circuit current for one second *hen a fault occurs at the operating temperature. ?or a forced$cooled (us, the ratings under self$cooled and forced cooled conditions for same temperature rise shall (e given. <.. Shape E6cept as noted other*ise in Data Sheet$/, the section of the (us conductors used shall (e rectangular, tu(ular, hollo* s+uare, hollo* rectangular, dou(le channel or hollo* he6agonal!octagonal t'pe (ased on the current rating.

DATE:22-0 -200 ISSUE No: P0

DOCUMENT No PCPL-0532-4-407-04-10 <.2 3echanical Strength

NON SEGRAGATED BUSDUCTS

SECTION - 4 PAGE: 4 of 9

The (us conductors and insulated supports shall *ithstand *ithout permanent deformation, deterioration of conductor material and reduction in the #,B value of the (us duct, the stresses consistent *ith the momentar' short circuit current specified in this Specification. <.< 0ainting The (us conductor ma' (e given a coat of matt finish (lac& paint to facilitate heat dissipation. The (are conductor *ith a(ove painting shall (e designed to carr' the normal rated current *ithout e6ceeding temperature rise as specified in 4lause <.) a(ove. The VENDOR shall su(mit supporting test certificate. <.: Bosses The losses in the conductor shall (e limited to such a value that the temperature rise of the conductor does not e6ceed the specified values. The losses should (e such that an optimal operating cost is o(tained. <.; <.;.1 =oints /d1acent sections of the (us conductors shall (e (olted or *elded as specified in Data Sheet$/ to provide an efficient, electricall' continuous and mechanicall' strong connection. %elded Rigid =oints7 =oints shall (e highest +ualit' done as per the proven methods of *elding practice. Suita(le aluminium or copper connectors shall (e provided *herever the (us sections changes. <.;.. %elded E6pansion =oints7 ?le6i(le aluminium or copper connectors *elded to the main (us(ars shall (e provided *herever deemed necessar'. <.;.2 #olted Rigid =oints7 The connectors shall (e of the same material as the conductor and these shall (e silver$ plated for contact surface to ensure an efficient connection. The (olting schedule and contact pressures shall conform to accepted codes of practice. <.;.< #olted ?le6i(le =oints7 ?le6i(le (raided copper connections shall (e provided at the e+uipment terminal connections. #imetallic connectors shall (e provided (et*een the (us(ar and the copper fle6i(le if the (us conductor is of aluminium allo'. The 1oints shall (e capa(le of )<$mm settlement of the e+uipment mounting pads. The 1oints shall (e suita(l' designed to ta&e care of the vi(ration at the terminals as *ell as the e6pansion and contraction of the (us(ars. <.;.: #olted E6pansion =oints7

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DATE:22-0 -200 ISSUE No: P0

DOCUMENT No PCPL-0532-4-407-04-10

NON SEGRAGATED BUSDUCTS

SECTION - 4 PAGE: 5 of 9

E6pansion 1oints made of aluminium or copper strips shall (e provided *herever deemed necessar' (' the VENDOR, to ta&e care of e6pansion and contraction of the (us(ars under normal operating conditions. <.;.; /ll the a(ove 1oints shall (e tested for temperature rise to prove the ade+uac' of the design. The ma6imum temperature rise at the 1oints shall (e less than the specified temperature rise for the (us(ars. 4lamps and 5ard*are The (us(ar clamps at support insulators shall (e designed to *ithstand the forces due to momentar' short circuit current. The' shall permit free longitudinal movement of the (us(ars during e6pansion and contraction. The material of the clamps shall (e aluminium allo'. Suita(le copper or aluminium spacers shall (e provided *herever necessar'. /ll (olts, nuts and loc&ing *ashers used in the (us assem(l' shall (e of high tensile steel, plated for corrosion resistance. Spring *ashers of C#ellevilleD t'pe or e+uivalent shall (e used. Suita(le splice plates and (imetallic connectors shall (e provided *herever necessar'. Disconnecting Bin&s Disconnecting lin&s *ith rating same as that of the main (us(ars shall (e provided in the run of the (us duct at the points as specified in Data Sheet$/ to facilitate disconnection of the (us(ars during testing and maintenance. The separation of the (us(ar sections *ith the (olted lin&s removed shall (e sufficient to *ithstand the rated voltage of the (us duct. <.10 Shorting Bin&s <.10.1 Shorting 1umpers, for the purpose of dr'ing out the e+uipment (efore commissioning or for carr'ing out short circuit test on the e+uipment, rated for the main (us current shall (e supplied for shorting the (us duct at a location, ad1acent to the disconnecting lin&s or as specified in Data Sheet$/. <.10.) The shorting lin&s shall have drilling dimensions matching those of the main (us disconnecting lin&s. Suita(le supporting structures and supports insulators for the shorting lin&s if necessar' shall also (e offered. :.0 :.1 :.) :.).1 :.).) :.. BUS SUPPORT INSULATORS %ithin the (us duct the (us shall (e mounted and supported on insulators. The insulators shall (e mounted on resilient pads provided in the (us enclosure. 3aterial The insulators shall (e prefera(l' made of porcelain. ?or (us ducts *ith voltage rating up to 1100 volt, E0ER3/B, *ood or e+uivalent t'pe of non$h'groscopic insulating supports are accepta(le. 3echanical Strength The insulators shall possess sufficient mechanical strength to *ithstand the forces due to momentar' short circuit currents of magnitude detailed in this Specification. The spacing of the (us insulators shall (e decided giving due factor of safet'. DATE:22-0 -200 ISSUE No: P0

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DOCUMENT No PCPL-0532-4-407-04-10 :.2 Electrical Strength

NON SEGRAGATED BUSDUCTS

SECTION - 4 PAGE: of 9

/s a conse+uence of current loading and variation in e6ternal temperatures in the e6ternal sections of the (us duct, condensation of moisture ma' ta&e place on the surface of the insulators. 5ence the insulators shall have a high creepage distance and a *ithstand voltage rating sufficient to provide specified insulation under highl' humid conditions. ;.0 ;.1 !ALL FRAME ASSEMBL" & SEAL-OFF BUS#INGS %all ?rame /ssem(l' %herever the (us duct passes through the plant (uilding *all, from indoors to outdoors, a *all frame assem(l' *ith seal$off (ushings shall (e provided to prevent an' lea&age of rain *ater, infiltration of dust and air temperature variations from indoors to outdoors. The *all frame shall (e fa(ricated out of aluminium angles and sheet and shall (e suita(le for grouting in the *all. ,t shall (e provided *ith flanges on (oth sides to receive the (us duct flanges. ;.) Seal$off #ushings The (us duct shall (e e+uipped *herever necessar' *ith (affle or seal$off (ushings to prevent interchange of air at different temperatures. The seal$off (ushings shall (e flanged t'pe. ;.. 3aterial The insulator for *all frame assem(l' and seal$off (ushings shall (e of porcelain. /lso the (ushings shall (e designed for thermal e6pansion!contraction due to temperature differential for outdoor!indoor use. ;.2 3echanical Strength The insulator shall *ithstand the ma6imum short circuit forces under fault conditions specified in this specification. The insulator material shall not deteriorate under normal operating temperatures or due to temperature rise under fault conditions. ;.< >.0 >.1 @.0 @.1 Electrical Strength The electrical properties of the insulator shall (e in conformit' *ith this specification. P#ASE CLEARANCES The minimum phase to phase and phase to earth clearances of (us(ars *ithin the enclosures shall (e as specified in Data Sheet$/. BUS DUCT SUPPORTS 3aterial The supporting structure shall (e fa(ricated from standard steel sections and shall (e hot dip galvanised after fa(rication. The hot dip galvanising shall (e in accordance *ith standards listed in Data Sheet$/. @.) 3echanical Strength The supporting structures shall (e designed to *ithstand the dead *eight of the (us duct and also the short circuit forces under ma6imum fault conditions and also the *ind load DATE:22-0 -200 ISSUE No: P0

DOCUMENT No PCPL-0532-4-407-04-10

NON SEGRAGATED BUSDUCTS

SECTION - 4 PAGE: 7 of 9

and forces due to seismic accelerations *hich are specified in Data Sheet$/ and!or Section$# entitled E0ro1ect ,nformation . 4alculations shall (e furnished to su(stantiate the a(ove and shall (e su(1ect to the 0"R45/SER s approval. @.. /ccessories and 5ard*are The supporting structures shall include supporting mem(ers, (rac&ets, hangers, longitudinal (eams, channels, nuts, (olts, insulating pads, insulating *ashers and all other hard*are *hich are necessar' for the erection and support of the entire (us duct installation. /ll the accessories and hard*are of ferrous material shall (e hot dip galvanised. @.2 @.2.) @.2.. @.< 3ethods of Support ,ndoor portion of the (us duct ma' (e supported from the floor or ceiling (eams. Outdoor portion of the (us duct shall (e supported from ground (elo* on suita(le foundations in the ground. The foundations and structures in outdoor area shall clear the transformers, transformer foundations, ca(le trenches etc. Earthing Each supporting structure shall (e securel' - electricall' connected from t*o points to the 0"R45/SER s station earthing (us. /ll necessar' hard*are, such as clamps, connectors etc., Re+uired for this purpose shall (e furnished (' the VENDOR. 10.0 MAR$INGS /ll components of the (us duct along *ith the supporting structure shall (e distinctl' mar&ed for erection in accordance *ith the erection dra*ings to (e prepared - furnished (' the VENDOR. These mar&s shall (e made in a manner as not to (e o(literated and erased in transit or to damage the galvanising of the (us duct enclosure or the supporting structure. 11.0 11.1 11.) MISCELLANEOUS Studs, nuts, (olts and tapped holes shall conform to the relevant standards. Onl' he6agonal nuts shall (e used. /ll (olt holes shall (e spot faced for nuts. 4astings and forging shall conform to respective material specifications and shall (e free from fla*s. The' shall (e machined true as per good *or&shop practice. %elding shall (e performed in accordance *ith relevant esta(lished standards. /ll threaded pipe connections and fittings, pipe flanges and tu(e fittings shall compl' *ith relevant standards. DESIGN RE%UIREMENTS OF BUS DUCT T&' B() *&+,, -o./+(. )'*(0. -+,-1,+/(o. (. *122o3/ of the follo*ing parameters of the (us duct design7 a8 SiFing of the (us(ars, vis$G$vis thermal capa(ilit' to *ithstand rated continuous current and one second short time current.

11.. 1).0 1).1

DATE:22-0 -200 ISSUE No: P0

DOCUMENT No PCPL-0532-4-407-04-10

NON SEGRAGATED BUSDUCTS

SECTION - 4 PAGE: 4 of 9

(8 Spacing of the insulators vis$G$vis mechanical strength to *ithstand forces due to 3omentar' short$circuit current. c8 5eat loss and temperature rise calculations for conductor and enclosure. %herever Rain hood is provided the effects of solar radiation ma' (e neglected *hile calculating temperature rise. 1).) 1..0 1..1 T&' B() *&+,, 5' -o62,'/' 7(/& +,, &'+/ ,o** -+,-1,+/(o.* . /ll formulae and other information from *hich the heat losses have (een derived shall (e enlisted. SPACE #EATERS The (us duct shall (e provided *ith space heaters of ade+uate capacit' to maintain the internal temperature a(ove the de* point to prevent moisture condensation *ithin the (us duct. The space heaters shall (e rated for >0%, )20V single phase, <0 5F. /4 suppl'. The space heater shall (e automaticall' controlled (' differential thermometers. TESTS & TEST REPORTS The follo*ing t'pe and routine tests shall (e conducted on representative section of the (us assem(l'. The (us assem(l' tested shall include (olted connections and fle6i(le connections. The tests shall (e conducted as per standards indicated in these specifications. T'pe Tests

1480 12.1

12.)

12.).1 One$minute po*er fre+uenc' *ithstand voltage test. 12.).) ,mpulse voltage *ithstand test. 12.).. Temperature rise test of (are (lac& matt finish painted conductors and enclosures. 12.).2 D'namic *ithstand test. 12.).< %ater tightness test. 12.).: /ir tightness tests. 12.. Routine Tests 12...1 One$minute po*er fre+uenc' *ithstand voltage test. 12...) %ater tightness test 12.... /ir tightness test 12.2 Test Report for 4omponents 3anufacturer s t'pe and routine test certificates shall (e su(mitted for tests conducted as per relevant standards for the follo*ing components7 a8 ,nsulators (8 Seal$off (ushings c8 #olted and fle6i(le 1oints d8 #us(ars e8 Enclosure material DATE:22-0 -200 ISSUE No: P0

DOCUMENT No PCPL-0532-4-407-04-10

NON SEGRAGATED BUSDUCTS

SECTION - 4 PAGE: 9 of 9

f8 Aalvanising of support structures g8 ?uses if an'. 1580 SPARES %hether included in the #,DDER s recommendation or not, unit prices of the follo*ing items or the items recommended (' them shall (e +uoted together *ith their suggested +uantities and catalogue num(ers7 a8 #us support insulators (8 ?le6i(le connector c8 ,solating lin& d8 Different t'pe of gas&ets

DATE:22-0 -200 ISSUE No: P0