1

GUJARAT ELECTRICITY BOARD

SARDAR PATEL VIDYUT BHAVAN
RACE COURSE, VADODARA - 390 007
G
G
E
E
B
B
TENDER SPECIFICATION
FOR
22OKV AND 66KV SWITCHYARD WORK AT DHANERA
INCLUDING SUPPLY, INSTALLATION AND COMMISSIONING
OF ALL EQUIPMENTS, MATERIALS
PART III - A
TECHNICAL SPECIFICATION FOR
ELECTRICAL WORKS
(66kV, 11kV & GENERAL)
TENDER SPECIFICATION
NO. TR / EPC/DHANERA/0405
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INDEX
No. Description
Page
No.
Technical specification for
1 66kV Breaker 3
2 66kV Isolator 5
3 66kV LA 8
4 66kV CT 17
5 66kV PT 20
6 66kV C&R panel 23
7 66/11kV power transformer and automatic voltage regular. 29
8 Dist. Transformer. 40
9 11kV VCB. 41
10 11kV XLPE power cable 49
11 LT cable 57
12 Control cable 58
13 Station battery set 61
14 Battery charger 63
15 LT switch Board 69
16 Switchyard accessories. 77
17 66kV PI 79
18 Energy meter. 85
19 Insulator. 86
20 Illumination 94
21 Installation/erection specification 111
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TECHNICAL SPECIFICATION
6.1 66 KV SF6 CIRCUIT BREAKER
a) Application Strandard : IS 13118 IEC 56
b) Nominal System Voltage : 66 KV
c) Maximum Rated Voltage : 72.5 KV
d) Frequency : 50 Hz
e) No. of Phases : 3
1) No. of Poles
2) Rated nominal Current
3) Rated line charging current breaking
capacity
: 3
: 1600Amp.
: 10 Amp.
f) Closing coil : 220V DC
g) Tripping coil : 220 V DC
h) Symmetrical short circuit breaking
capacity at the highest System Voltage.
: 2500 MVA
i) Short time current rating for 3 sec. : 25.0 KA
j) Making capacity and dynamic stability
current
: 2.5 times of SC rating as per I.S.
k) I) Total break time for any current up
to the rated breaking current measured
from the instant of the trip
energization.
: 3 cycles
l) II) Closing time : Not more than 10 cycles
m) First pole to clear factor : 1.5
n) Whether circuit breaker is intended for
rapid re-closing
: Yes
o) Operating duty : 0.03 Sec.- CO 3 min. CO
p) Dead time of the breaker : Adjustable within 15- 20 cycles
q) Latching requirement : Trip free
r) System neutral : Solidity earthed
s) Insulation level of bushings
-at Rated one min. power frequency
withstand voltage
-at Rated lightning impulse withstand
voltage
: 140 KV rms.
: 350 KV peak
t) Min. creepage distance : 1800 mm.
u) Control supply voltage : 220V DC
v) Aux. contacts with each circuit breaker : 12 NO + 12 NC
interchangeable at site.
I) Rated characteristic for short Line
fault
: As per Cl. No. 4.10.5 of IS 13118 / IEC
56
II) Rated transient recovery Voltage for
transient fault
: As per Cl. No. 4.10.5 of
: IS 13118 / IEC 56
i) Type tests for performance : as per IEC
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verification
ii) Pole discrepancy control Trip and annunciation shall be provided.
iii) Accessories
ON/OFF indicator
Emergency tripping mechanism
termination suitability
conductor
with connectors
Anti-pumping relay operation counter,
local control panel, local/control panel,
local/remote selector switch.
: Mechanical as well as electrical
: Mechanical
: For ACSR Panther
: conductor
: Shall be provided
iv) i) Rated operating gas pressure (for
SF6 C.B.)
: 15Kg/Cm2 gm.
ii) Rated SF6 gas pressure at
20
o
C
: 5Kg/cm
2
g
v ) SF6 gas density monitor with alarm
& trip contact
: 1 No. per pole /phase
6.1.1 BUSHING
N Equalized electrical stress internally and over the bushings surface.
N From radio interference
N Provision for expansion over normal operating temperature range.
N Bushing with combination potential and power factor test cap.
6.1.2 OPERATING MECHANISM
N Shall be power operated by a motor compressed spring mechanism for both
closing and opening.
The mechanism shall be Trip free electrically and mechanically. It shall be
strong, quick in action and shall be removable without disturbing other parts
of the circuit breakers. All the parts of the mechanism shall be corrosion
resistant.
N The mechanism and Breakers shall be such that failure of spring shall not
prevent tripping and shall not cause tripping or closing.
N Shall be suitable for remote control from the electrical control room.
N A local control switch locking arrangement shall be provided for each
breaker for local operations i.e. tripping and closing during maintenance, test
etc.
N Local/Remote selector switch shall be provided in the mechanism cabinet.
N Interlocked to prevent remote operation when the selector switch is in the
local position.
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N Each breaker shall have ON/OFF indication lamp along with a mechanical
open/closed position indicator visible to a man standing on ground, with
the mechanism cabinet closed.
N Also facilities for remote indication of breaker open / close position in
the electrical control room.
N Cabinet for operating mechanism and its accessories shall be of IP55
protection with pad locking facility. In Cabinet all equipment shall be
mounted on front side and wiring shall be done on back side in proper wire
ways.
N Space heater shall be provided in the local cabinet with thermo-state control.
It shall house relays for control and interlocking as per scheme requirement.
N Wire-ways/cable ways shall be provided in open mechanism / cabinet to
ensure aesthetical, neat and orderly wiring. All the connection shall be at
back and equipment in front.
6.1.3 INTERLOCKS
Opening or closing of the isolator/disconnecting switch shall be prevented when the
breaker is in closed position.
6.1.4 TERMINAL CONNECTIONS
N Shall be suitable for twin ACSR Panther conductors. (Compression / 4 IPS Type )
N Suitable terminal earth connector for earthing connections shall also be supplied
having a bolt connection arrangement.
6.2 66KV ISOLATORS
6.2.1 APPLICATION
Normally these are to be used for:
N Breaker isolation
N Potential transformer connection to the bus systems.
N Line connection
N Grounding
6.2.2 TYPE AND CONSTRUCTION
N Three phase Tripe pole gang operated suitable for outdoor installation in open yard
under the specified site conditions.
N Center post rotating type with double break and with contacts coming in horizontal
plane.
N Common actuating mechanism for all three phases.
Single pole units shall be copper and of one solid piece construction.
N Minimum clearance between live parts and grounded structure shall be as per the
relevant standards & I.E. Rules.
N Interphase clearance shall be 1670 mm and mounting height not less than 3 meters.
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N Length of break in full open position shall be such that there is absolutely no
possibility of arc over from the live parts to the de-energized parts.
N Speed of operation during opening or closing shall ensure minimum arching.
6.2.3 TECHNICAL PARTICULARS
a. Nominal system voltage : 66 KV
b. Highest system voltage : 72.5 KV
c. Rated frequency : 50 Hz
d. Type : Triple pole, air break, off load,
double break outdoor, gang operated
type with & without earth switch.
e. Continuous current rating : 1250 A
6.2.4. MAKING AND INTERRUPTING CAPABILITY
Disconnecting blades shall be capable of carrying rated current continuously as well
as specified short circuit current for the specified duration without causing
mechanical damage to any part and without damaging the insulation, during
temperature rise.
6.2.5 CONTACTS
High pressure self aligning adjustable type.
Shall be well protected all round by a metal cover to provide not only electrostatic
screening but also to prevent coarse dust from entering between the contacts.
Contact pressure shall be released before any movement of the blades and the
opening takes place and shall be applied after the closing travel is completed.
Sufficient wiping action to make contacts self cleaning.
Contacts shall be of high conductivity, heat-resisting copper and shall be silver-
plated. The thickness of silver plating shall be adequate & shall be stated in the
tender / drawing.
Temperature rise of contacts shall not exceed 55
o
C over the ambient of 45
o
C.
6.2.6 OPERATING MECHANISM
Shall be suitable for remote electrical and local electrical and manual operation.
Operating mechanism and its controls shall be so designed that under no
circumstances the travel of the switch blades is interrupted before it reaches the
fully closed or open position.
Signaling device for all poles both for closed position and open position for remote
as well as local indication shall be provided.
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Provision for padlocking the mechanism in either the open or closed position.
Housing for the operating mechanism and its controls shall be of sheet steel weather
and dust proof construction with rubber gaskets conforming to enclosure protection
class IP-55.
6.2.7 EARTHING SWITCHES
Disconnecting switches shall be provided with earthing switches on one side (as per
single line diagram) forming integral part.
Rating of earthing switch shall be same as that of the isolator/disconnecting switch
with respect to rated short circuit time when the disconnecting switch is open and
vice-versa.
6.2.8 INTERLOCKS
To be interlocked with associated isolators and circuit breakers.
Earthing switches and isolator inter-locking :
N For closing of isolators, associated earthings switches, shall have to open and it
is to ensure that isolators are not used for on load closing.
N Final wiring or contact multiplication relays, blocking solenoid etc. shall have to
be provided as per approved logic diagram.
Earthing switch and circuit breaker interlocking:
N Breakers can be closed if associated earthing switches are open and isolators are
in closed position.
N Auxiliary relay and circuitory shall be such that interlocking cannot be bypassed
even in case of failure of control supply.
6.2.9 TERMINAL CONNECTIONS
Shall be provided with high conductivity terminal connectors suitable for twin/4
IPS Allum. bars ACSR panther conductors compression type.
6.3 LIGHTNING ARRESTERS
6.3.1 TYPE
N Station class, heavy duty, gapless lightning arrester
N Non linear resistor type.
N Self supporting type in single pole assembly.
N Suitable for pedestal mounting.
N Outdoor type suitable for installation in open yard. Shall be designed to provide
maximum protection against lightning and switching surges.
N
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6.3.2 TECHNICAL SPECIFICATION OF 66KV LIGHTNING ARRESTERS
6.3.2.1 SCOPE :
This specification covers the design, manufacture, assembly testing at manufacture's
works, and delivery of heavy duty station class lightning arresters alongwith surge
counter complete in all respects, conforming to modern design and practice for
protection of transformers, sub-station equipment's and overhead lines.
6.3.2.2 STANDARDS:
6.3.2.2.1 The lightning arresters covered by this specification shall comply with the
requirements of latest, edition of publication No. 99-I/1991, except specified,
otherwise in the specification.
6.3.2.2.2 Lightning Arresters, meeting the requirements of any other authoritative
standards which ensure equal /better quality than that as per the standards
mentioned above shall, also, be acceptable. When the lightning arrester
conforms to any other standards, the salient points of difference between the
standard adopted and standard given above shall be described.
6.3.2.3 DRAWINGS :
Drawings in duplicate, incorporating the following particulars shall be submitted by
each bidder with the offer for the purpose of preliminary Scrutiny.
1) G. A. Drawing, showing general outline of the complete lightning arrester with
clearances from grounded object and between adjacent poles of lightning arrester and
details of pressure relief class 'A' device, surge counter, insulating base, terminal
connector etc.
2) The tenderer may submit any other drawing found necessary in addition to the
drawings stated above.
6.3.2.4 TYPE :
The metal oxide lightning arresters shall be designed to provide maximum possible
protection against lightning and switching surges. Supporting insulators, terminal
connectors and other components as specified, hereafter, shall be provided with
arresters.
The metal oxide lightning arresters shall be of pressure relief class 'A' and long
duration Class-II.
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6.3.2.5 DESCRIPTION :
Design & Construction :
6.3.2.5.1 .Arresters shall be without series gaps as per the requirement along with
characteristic of elements.
The non-linear resistor blocks shall have non-ageing characteristic and stable
thermal properties. The blocks shall preferably be metalised on the flat surface for
ensuring good electrical contact.
The arresters shall be complete with suitable grading devices, wherever necessary
and shall be provided with an insulating base at the bottom and the supporting
structure to facilitate the use of a surge counter. Braided flexible copper samper
shall be provided for bypassing surge counter, whenever required.
Each individual component unit of the arrester stack shall have its arrester
elements hermetically sealed under dry inert air and fully protected against ingress
of moisture into the arrester.
The arrester, when energized at rated operating voltage, shall not exhibit any visible
corona, when viewed in complete darkness.
All arrester units shall be provided with pressure relief class 'A' devices, to limit the
internal arrester pressure to obviate explosion or violent shattering of porcelain housing.
Porcelain Housing:
All porcelain used in or with each arrester shall be manufactured by the wet
process, be free from lamination, cavities or other flaws, affecting mechanical &
dielectric strength and shall be vitrified property and non-porous. The leakage distance
alongwith external surface shall be large enough to ensure that surface contamination,
which is possible under site condition, will not adversely affect the performance of
arresters.
Pressure Relief Device:
The arresters shall be provided with efficient pressure relief device so as to check
bursting of lightning arresters, in case, excessive gas pressure is built up and in case, it
losses its ability to effectively dissipate the energy due to any operation. The tenderer
shall submit detailed information and literature on pressure relief class A device of
lighting arresters.
Terminal Connectors:
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Each lightning arrester shall be supplied with terminal connector suitable for ACSR
'PANTHER' Conductor or any other conductor or pipe as per final layout. Each
terminal connector shall be suitable for vertical / horizontal take-off. The GEB can
also cost for the connectors suitable 4 IPS Aluminum bus.
Galvanizing:
All metal parts exposed to weather and likely to be subjected to corrosion, shall be hot
dip galvanized as per IS: 2629 (latest edition). Bolts, Nuts and Washers shall be electro
zinc plated.
Name Plate :
Each arrester shall have non-corrosive nameplate, legibly and indelibly marked and
securely fixed to it. They shall be provided with the information as required by relevant
standard. The words 'GEB' shall, also, be punched on it after inspection of lightning
arrester is over.
Each lightning arresters shall be provided with a recording type surge counter with vertical
mounting. The installation of surge counter shall have practically no effect on the
operation. The number of discharges recorded by the counter shall be visible through
inspection window.
SYSTEM VOLTAGE:
Nominal system voltage Highest System Voltage
66 KV 72.5 KV
Rated Arresters Voltage:
The rated arrester voltage, shall be as under: -
Normal System Voltage Arrester Voltage
66 KV 60 KV
Nominal Discharge Current:
The arrester shall have a nominal discharge current of 10 KA (8/20 micro-sec) and
shall be of heavy-duty station class type with long duration Class II.
Maximum residual Voltage:
The maximum residual voltage @ nominal discharge current of 10 KA with 8/20 micro
Sec. current wave shall not exceed 190 KV (Peak).
System Neutral Connection:
All the lightning arresters shall be suitable for outdoor installation.
Altitude:
The lightning arresters covered in this specification will be installed at an altitude not
more than 1000 meters.
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Special Condition:
Maximum temperature for a few days, in a year, is likely to go to 50
0
C and humidity
during monsoon is likely to reach the value of 95%. The arresters offered must
withstand these climatic conditions without deteriorating effects.
The lightning ancestors shall be suitable for 1.2/50 micro-sec lightning impales voltage of
350 KV peak and one minutes power frequency withstand voltage of 140 KVrms.
Impulse withstand voltage of equipment's to be protected:
The basic insulation level of transformer and circuit breakers is 350 KV (Peak).
Overhead Earth wires:
Solidly grounded overhead Earth wires shall be provided for the sub-station and
Transmission Lines.
Physical data to be supplied for the Arrests:
Technical and guaranteed particulars in the Appendix 'A' shall be furnished with the
offer. Drawings showing, dimensions, (actual figures), arrangement and clearances
(actual figure) required should, also be furnished. Offer without details against
guaranteed particulars will be considered as incomplete offer. List of orders executed
for specified rating of, arrester along with performance reports for the same shall be
submitted.
Completeness of Equipments:
All fittings and accessories which may not be specifically mentioned in these
specifications but which are useful or necessary for lightning arresters shall be deemed
to be included in the specifications and shall be furnished by the tenderer without extra
charges.
Tests:
Copies of type test reports and routine test reports on complete arresters assembly
along with test reports for porcelain shells should be submitted with offer, failing
which, offer is liable to be evaluated accordingly. The type test report shall not be
older than 5 years as on the date of tender opening.
Creepage Distance:
The total minimum creepage distance shall be 1800mm.
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6.4 SURGE MONITOR
Surge monitor connected in series between the lightning arresters and ground shall
be provided to determine the service performance and on-line condition of the
lightning arresters. It shall include counter to record the number of operations
performed by the arrester. It shall be part of LA.
6.4.1 FITTING & ACCESSORIES:
This shall include pressure relief device, complete with supporting insulators,
Universal type terminal connectors suitable to receive ACSR Panther conductor,
standard fittings and accessories.
6.5 BUSBAR AND BUSBAR CONNECTION
6.5.1 TECHNICAL PARTICULARS
a) Nominal system voltage : 66 KV
b) Nominal current rating : 3500 Amp.
c) Bus conductor :114.3mm Allu. Pipe
d) Short time current rating for 3
(three) seconds.
: 40 KA for 3 Sec.
e) Dynamic current rating : 67 KA
6.5.2 CLEARANCES
The net clearances in air for busbar, jumpers etc., shall not be less than the
following.
a) Between phase : 2100 mm
b) Between one phase and : 1800 mm
earth for rigid connection
c) Minimum height of any bus-bar : 6096 mm
connection above ground level
or platform where person may
stand.
d) Center to center distance between : As per design
bays
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6.6 CURRENT TRANSFORMER
6.6.1 GENERAL DESIGN FEATURES OF CURRENT TRANSFORMERS:
6.6.1.1 The current transformers shall be of outdoor type single phase, 50 Hz, oil
immersed, self cooled suitable for operation in the climate conditions specified. The
current transformers shall be complete in all respects. The 66 KV CT shall be of dead
tank design for all ratio CTs.
6.6.1.2 The core shall be high grade, non ageing, silicon laminated steel of low hysteresis loss
and high permeability. The core material used in case of metering core shall be stated in the
tender.
6.6.1.3 The current transformers shall be hermitically sealed to eliminate breathing and entering
of air and moisture in the tank. Provision of pressure relieving device is not permitted
For compensation of variation in volume of oil due to temperature variation, stainless steel
bellows shall be provided. The successful bidder shall have to submit calculations of
volumetric expansion and contraction. These calculations shall be submitted along with the
basic parameters of SS bellow used in CT.
Rubber bellow or Nitrogen gas cushioning for above purpose shall not be permitted.
The current Transformers provided with stainless steel bellows for compensation of oil
volume variation shall be provided with a suitable oil level indicator at suitable location to
enable an observer to see the oil level of the C.T. from the ground level. Oil level indicator
shall be provided with fluorescent green coloured floating ball.
6.6.1.4 The core of current transformers to be used for metering and instrumentations shall have
saturation factor, low enough to avoid damage to the instruments, in the event of maximum
short circuit current.
6.6.1.5 a) The C.T. core, to be used for protective relays shall be of accuracy class, specified or
appropriate class suitable for back up, over current and earth fault, differential and bus bar
protection.
b) The bidder shall guarantee for trouble free and maintenance free performance for a
period of 60 months from the date of commissioning; during which period, the CTs shall be
replaced free of cost, immediately in case of any trouble. Therefore, the bidder shall ensure
that sealing of current transformer is properly achieved. In this connection the arrangement
provided by the bidder at various locations including the following ones shall be described
& supported by sectional drawings.
TECHNICAL SPECIFICATION FOR CURRENT TRANSFORMERS
AND VOLTAGE TRANSFORMERS:
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N Location of emergence of primary and secondary terminals. Interface between
porcelain housing and metal tank. Cover of the secondary terminal box.
G.A. drawing complete with details of primary and secondary windings overall
dimensions, weight, nameplate, porcelain insulator, primary & secondary terminals,
terminal connectors, etc.
c) Nuts and bolts (or screws used for fixation of interfacing porcelain bushings for taking
out terminals) shall be provided on flanges, cemented to the bushing and not on the
porcelain i.e. Flange type 66 KV bushing for CT, shall be provided.
d) For gasket joints, wherever used, nit rile butyl rubber gaskets shall be used. The gaskets
shall be fitted in properly machined groove with adequate space for accommodating the
gasket under compression.
e) The bolts required for fitting the dome shall be of stainless steel of minimum 6 mm dia.
f) The outer surface of metal tank shall be Hot Dip Galvanized, whereas, the inner portion
shall be painted with oil resistive, insoluble paint.
g) The tank of CT shall be provided with pressboard of 2 mm thickness inside and at
bottom.
h) The minimum thickness of flange & gasket provided on tank shall be as follow:
a) Flange thickness of tank - 8 mm
b) Top plate thickness - 5 mm
c) Gasket thickness - 6 mm
6.6.1.6 WINDING AND TERMINALS:
6.6.1.6.1 The rating of the secondary winding shall be as specified under Section II of this
specification. Ratio changing arrangement shall be provided on secondary winding for
multi ratio design, either a number of identical secondary winding may be provided to
achieve desired ratios by series / parallel connection for the secondary winding or the
secondary winding may be tapped. However, identical secondary for tapped secondary
winding shall meet requirement as specified.
6.6.1.6.2 Primary and secondary windings shall be of electrolytic grade copper and shall have
continuous thermal rating as specified for all ratios. However, the bidder may furnish the
additional cost adjustment if any, for primary winding to be designed for extended primary
current at 120% of rated primary current. (If so desired by the GEB). The secondary
winding wherever tapped, shall be adequately reinforced to withstand normal handling
without damage.
6.6.1.6.3 The primary terminals shall be of standard size of 30 mm dia x 100 mm length for all
CTs rated upto 1200 Amps. For higher values of primary current, each primary terminal
shall be made out of two such rods of 30mm dia x 100 mm length in parallel. The primary
terminals shall be of heavily tinned electrolytic copper. The maximum thickness of tinning
shall be 15 microns.
6.6.1.6.4 The secondary terminals shall be brought out in a compartment for easy access.
Secondary terminal studs shall be provided with at least three nuts and adequate plain and
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spring washers for fixing the leads. The studs, nuts and washers shall be of brass, duly
nickel-plated. The minimum outside diameter of the studs shall be 6mm. The length of at
least 15mm shall be available on the studs for inserting the leads. The horizontal spacing
between centers of the adjacent studs shall be at least 1.5 times the outside circum dia. of
the units.
6.6.1.6.5 The current transformer shall be provided with suitable test tap for measurement of
capacitance, tan delta as well as partial discharges, in factory as well as at site. Provision
shall be made of a screw on cap for solid and secured earthing of the test tap connection,
when not in use. A suitable caution plate shall be provided duly fixed on the cover of the
secondary terminal box, indicating the purpose of the test tap and necessity of its solid
earthing as per prescribed method, before energizing the CT.
6.6.1.7 TERMINAL BOX OF CURRENT TRANSFORMERS:
The exterior of the secondary terminal box shall be hot dip galvanized. A cable box along
with necessary glands for receiving control cables suitable for mounting on bottom plate of
the terminal box shall be included in the scope of supply. A door with locking arrangement
shall be provided on the front of the terminal box. The secondary terminals shall be taken
out through composite epoxy or FRP mould having single gasket packing & shall be
provided by suitable link with dummy secondary leads. For control cable connections,
separate terminal connector block to be provided. Secondary jumpers shall be terminated at
one side of this terminal connector block.
6.6.1.8 TEMPERATURE RISE:
The maximum temperature rise of the current transformer and its oil, winding and external
surface of the core and other parts shall be as specified in Table I of IS: 2705 (Part I) 1981.
6.6.1.9 BUSHING AND INSULATORS:
6.6.1.9.1 The porcelain insulator used in manufacturing the bushings shall be homogenous, free
from lamination cavities and other flaws or imperfection that might affect the mechanical or
dielectric qualities. All bushings of identical ratings shall be interchangeable. The bushing
shall conform to the latest edition of IS: 2099. The puncture strengths of the bushings shall
be entirely free from external and internal corona. The protected and total creepage
distance of the bushings shall be suitable for heavily polluted atmosphere i.e. the total
creepage distance shall be 1800 mm (minimum).
6.6.1.9.2 Apart from porcelain insulators polycrete or siliconrubber insulators moulded shall
also be acceptable conforming to latest relevant IEC or IS. The detailed specification for
the same shall be given by the bidder along with the bid.
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6.6.1.9.3 Suitable means shall be provided to accommodate conductor expansion and there
should not be any undue stress on any part of the equipment due to temperature changes.
The bidder may provide packing between insulator and tank. This packing shall be
preferably Nylon Bush of minimum 3 mm thickness. The exterior, upper and lower joints of
insulator bushing shall be sealed with suitable sealant.
6.6.1.9.4 The hollow porcelain bushings conforming to the latest edition of IS: 2099, shall be
used for current transformers. The insulation of bushings shall be coordinated,
with that of the instrument transformer such that the flashover, if any, will occur only
external to the current transformers. The bushings should not cause radio interference,
when operating at rated voltage.
6.6.1.9.5 The quantity of insulating oil for the first filling of oil in each CT and the complete
specifications of the oil shall be stated in the tender. The oil shall conform to the
requirements of latest edition of IS: 335. The actual oil to be used shall be of the following
approved make.
1 Apar, Mumbai
2 Madras petrolium, Chennai
3 Savita Chemicals,
4 Sarabati Petrochemical,
5 Raj Lubricants, Chennai
6 Rinki Petrochemical, Baroda
7 Amod Petrochem, Samiyala; Dist. Baroda
8 Raj Petrolium, Panoli
9 Tashkent Oil Co. ltd.
The manufacturer of CT shall measure the PPM/DGA value of oil before filling inside the CT
and shall keep record of the same.
6.6.1.10 TERMINAL CONNECTORS AND EARTHING TERMINALS:
Compression joint type bimetallic terminal connectors suitable for ACSR thin PANTHER
conductors or any other conductor and pipe as per final lay out and design (with 510 amps.)
shall be supplied. The terminal connectors shall be suitable for 31.5 KA for 3 secs. They
shall be suitable for vertical & horizontal connections of the transmission line conductors or
station bus bar. The bolt and nuts shall be of stainless steel and with 1 SS washer and 2 SS
nuts (including lock nut) for each bolt shall be supplied. Two grounding terminals suitable
for receiving connections for grounding shall be provided for the current transformers.
6.6.1.11 GALVANISING:
All ferrous parts of current transformers including bolts, nuts etc. shall be hot dip
galvanized as per IS : 2629 1966 with (latest edition).
6.6.1.12 TESTS AND TEST REPORTS :
6.6.1.12.1 Reports of all type tests as stipulated in the latest edition of IS: 2705 for current
transformers shall be submitted along with the tender.
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6.6.1.12.2 Routine tests as per the latest edition of IS: 2705 for current transformers shall be
carried out on each current transformer (in presence of GEBs representative, if
desired by the GEB).
6.6.1.13 ADDITIONAL ACCEPTANCE TEST:
6.6.1.13.1 In addition to the acceptance tests indicated in IS-2705 (with latest amendment), the
successful bidder has to conduct following tests on all offered lot of CTs during
inspection:
a) Tan Delta test (On all units)
b) Measurement of Capacitance test (On all units)
c) Temperature Rise test (On randomly selected one unit)
d) Partial Discharge test (On selected unit for (c), but to be
carried out before and after
Temperature Rise test)
e) Tests on Oil:
a) BDV test ]
b) Tan Delta test ]
c) Water PPM test ]
On randomly selected unit of very first lot
offered for inspection and to be conducted
after H V test only.
d) DGA test ] Copy of test report, received from the
power oil manufacturer, to be submitted.
(NOTE: If the supplier of oil is changed during execution of order, same test shall be
repeated for the oil of new supplier.
6.6.1.13.2 All the tests reports and oscillograms shall be submitted and got approved from the
GEB before dispatching the equipment in spiral bounded volumes.
6.6.1.14 QUALITY ASSURANCE PLAN :
6.6.1.14.1 The bidder shall invariably furnish following information alongwith his offer.
(i) Statement giving list of important raw materials, including but not limited to :
a) Conductor
b) Insulation
c) Core
d) Porcelain
e) Oil
f) Sealing material
g) Insulated wire
Names of sub-suppliers for the raw materials, list of standards; according to which the raw
materials are tested, list of tests normally carried out on raw materials in presence of
bidders representative, copies of test certificates.
ii) Information and copies of test certificates as in (i) above, in respect of bought out
accessories.
18
6.6.1.15 COMPLETENESS OF EQUIPMENTS:
Any fittings, accessories or apparatus which may not have been specifically
mentioned in these specifications, but which are usual or necessary for the
equipment of similar plant shall be deemed to be included in the contract and shall
be supplied by the contractor without extra charges. All plant and equipment shall
be complete in all details whether such details are mentioned in the specification or
not.
SECTION II
6.6.2.4 TYPE & RATING OF CURRENT TRANSFORMER:
6.6.2.4.1 The 66 KV Current transformer shall have the rating as given below:
1) CT Ratio a) 1200-600/1-1-1Amp.
b) 600-300/1-1-1Amp.
2) Core Three
3) Purpose Core 1 Metering
Core 2 Relaying
Core 3 Differential
4) Rated burden (VA)
(Lowest Ratio)
(at minimum tap)
30 (Core 1)
30 (Core 2)
--- (Core 3)
5) Class of accuracy 0.5 (Core 1)
5 P (Core 2)
P S (Core 3)
6) i) Rated accuracy / limit factor
ii) Instrument security factor.
10 at minimum ratio for all 66 KV
CTS
5 or less at minimum ratio for all 66
KV CTS.
7) Minimum knee point voltage (at
highest ratio)
600V for (a)
650V for (b) & (c)
8) Exciting current at knee point voltage As per IS : 2705 (latest edition)
9) Resistance of secondary winding - do -
10) 1.2 / 50 microsecond lightning impulse
withstand voltage (KV peak)
350
11) Power frequency withstand voltage for one
minute (KV rams)
140
12) Short time withstands current KA 31.5
19
(corresponding to fault level in MVA for
3.0 secs.
13) Minimum total creepage distance mmfor
heavily polluted atmosphere: 1800
6.6.2.4.2 The ratings specified shall be guaranteed at all primary connections. Any changes
in the particulars of the CTs which may be required for the protective relays
(protective relays being procured separately) actually ordered shall have to be met
by the supplier of CTs without any extra cost.
6.6.2.4.3 All current transformers shall meet the requirements of this specification for H 3%
variation in rated system frequency of 50 Hz.
"6.6.2.5 EARTH QUAKE & WIND DESIGN LOADS:
Each CT, including its supporting structure shall be designed to withstand repeated
earthquake acceleration of 0.08 x 2g with wind loads of 150 kg/m
2
on the projected area
(non-simultaneous) without damage to component parts and without impairment of
operation.
6.6.3.1 SCOPE:
This specifications is intended to cover the design, manufacturing, assembly, testing at
manufacturers works, supply and delivery of voltage transformers for metering and relaying
service in 66 KV phase system.
6.6.3.2 TYPE AND RATING:
The voltage transformers shall be of outdoor type, single phase, oil immersed, self cooled
suitable for operation in 3 phase, 66 KV solidly grounded system as per system details (cl. 2.3
of Section II of CT) under the climatic conditions specified at clause 2.2 under Section II of
CT.
The voltage transformers shall have the following ratings :
i) Nominal system voltage 66 KV
ii) Highest system voltage 72.5 KV
iii) Frequency 50 Hz
iv) Earthing Effective
v) Number of Windings Two
a)Ratio : Winding I 38.1 KV/63.5V
b) - do - - II 38.1 KV/220V
vi) a) Rated Burden, Winding I 100VA
b) - do - - II 200 VA
vii) a) Class of accuracy windings I 0.5 (Metering)
b) - do - - II 3 P (Protection)
6.6.3 DETAILED TECHNICAL SPECIFICATIONS FOR 66KV VOLTAGE
TRANSFORMERS
20
viii) Over voltage factor : 1.2 continuous
ix) 1.2/50 micro second lightning impulse withstand voltage 350 KVP
x) P.F. withstand voltage for one minute 140 KV rms
xi) Total Creepage (Min) Distance 1810 mm
The manufacturers nearest standard rating shall be offered.
6.6.3.3 STANDARDS:
The voltage transformers shall conform in all respects to the latest issue of IEC,
recommendations publication No. 44 or British Standards No. 81 & 2046 and IS:3156 (latest
issue) except wherein specified otherwise, where the equipment conforms to any other
standard, the salient points, differences between the standards adopted and the British
Standards shall be clearly brought out in the tender.
Equipment meeting any other authoritative standard, which ensures an equal or better quality
than the standard mentioned above is also acceptable.
6.6.3.4 GENERAL:
6.6.3.4.1 The voltage transformers shall be outdoor, oil immersed and self cooled type suitable
for the services indicated conforming to the modern practice of design and
manufacture.
6.6.3.4.2 The core shall be of high grade, non ageing, electrical silicon laminated steel of low
hysteresis loss and high permeability to ensure high accuracy at both normal and over
voltage.
The potential transformer shall be hermetically sealed to eliminate breathing and to
prevent air and moisture from entering the tank. Provision of pressure relieving
device is not permitted. The P.T. shall be provided with stainless steel bellows for
compensation of oil volume variation due to temperature variation. The successful
bidder shall have to submit calculations of volumetric expansion and contraction.
These calculations shall be submitted alongwith the basic parameters of SS bellow
used in PT.
6.6.3.4.3 Rubber bellows or Nitrogen Gas cushioning shall not be permitted for above purpose.
The potential transformer provided with stainless steel bellows shall be provided with
oil level indicator at suitable location to enable an observer to see the oil level of the
P.T. from the ground level. Oil level indicator shall be provided with fluorescent
green coloured floating ball.
6.6.3.5 WINDINGS:
The primary winding shall be of electrolytic grade copper. All primaries of
potential transformers will be connected in phase to neutral with the neutral point
solidly earthed. The neutral of the system is also solidly earthed.
The primary terminal shall be of heavily tinned electrolytic grade copper and shall
be of standard size 30 mm dia. x 100 mm long and tinning shall be adequate.
21
The secondary winding shall be of electrolytic grade copper. Secondary terminal
shall be nickel plated brass.
All potential transformers for phase to ground connection shall be provided with
two separate windings rated for 220 V and 63.5 V for connection in star and delta
winding respectively. The star winding, to be used for metering and relaying
(distance relays) shall be of accuracy class specified or appropriate class. The rated
burden of this winding shall not be less than that specified above.
The delta winding to be used for synchronizing and relaying (directional relays)
shall be of accuracy class specified or appropriate class and its rated burden shall
not be less than that specified above.
6.6.3.6 INSULATION:
a) The potential transformer shall withstand 1.2/50 microsecond lightning impulse withstand
voltage of 350 KV(P).
b) They shall withstand power frequency withstand voltage of 140 KV(rms) (dry & wet) for
one minute.
6.6.3.7 TEMPERATURE RISE:
The potential transformers shall be designed to limit the temperature of windings and other
parts as specified in the British Standards / relevant standards when corrected or the
differences between the temperature prevailing at site and temperature specified by the
standards. The temperature rise, at 1.2 times rated primary voltage when applied continuously
at rated frequency and at rated burden, shall not exceed the limits specified above and the
temperature rise at 1.5 times rated primary voltage when applied for 30 seconds, starting from
previous stable operating condition at rated frequency and rated burden shall not exceed the
above temperature limits by more than 10
o
C.
6.6.3.8 INSULATING OIL:
Insulated oil shall be purchased from the standard suppliers listed below:
6.6.3.9 TERMINAL CONNECTIONS:
The compression joint type terminal connector suitable for ACSR PANTHER or any other
conductor or aluminium pipe conductor shall be supplied. Suitable terminal earth connector
for connections for earthing shall also be supplied.
6.6.3.10 TESTS:
The type test reports for all the type tests as stipulated in IS: 3156 (Part I latest edition) but
not older than five years prior to the date of Bid operating shall be submitted. The type test
reports for offered terminal connectors (confirming to IS: 5561 (latest edition), but not older
than five years prior to the date of bid opening and those for offered insulators confirming to
the applicable standard shall also be submitted along with the offer.
22
Each voltage transformer shall be subject to routine tests as stipulated in IS ; 3156 (latest
edition) in presence of GEBs representative, if so desired, by the GEB. All the type test
reports shall be submitted and got approved from the GEB before the dispatch of potential
transformer.
6.6.3.11 GUARANTEED AND TECHNICAL PARTICULARS:
Guaranteed and technical particulars as called for in attached Annexure I shall be furnished
along with the tender. Particulars, which are subject to guarantee, shall be clearly marked.
6.6.3.12 COMPLETENESS OF EQUIPMENTS:
Any fittings, accessories or apparatus which may not have been specifically mentioned in
these specifications, but which are usual or necessary for the equipment of similar plant shall
be deemed to be included in the contract and
shall be supplied by the bidder without extra charges. All plant and equipment shall be
complete in all details, whether such details are mentioned in the specification or not.
6.7.1 TECHNICAL PARTICULARS OF SOLID CORE POST INSULATORS
a) Type : Cap and base type
b) Nominal system voltage : 66 KV
c) Highest system voltage : 72.5 KV
d) Rated frequency : 50 Hz
e) Insulation level
- Rated one minute power frequency
wet and dry withstand voltage
- Rated lightning impulse withstand
voltage
: 140 KV rms
: 350 KV Peak
f) Minimum creepage distance
Total
Protected
: 1800 mm
: 900 mm
g) Top Metal fitting PCD : 127 0.2 mm
h) Bottom Metal fitting PCD : 127 0.3 mm
i) PI structure : Lattice/ Pedastal/ Tubular shall be acceptable.
6.7.2 EARTHING AND LIGHTNING PROTECTION
6.8. 66 KV CONTROL AND RELAY PANEL
6.8.1. PANEL CONSTRUCTION FEATURE
N Panels shall be arranged to form a continuous board with the mimics and control
equipment. Panels shall be vertical, free standing, with rear hinged door, side
terminal blocks, control signaling circuit breakers, restores, fuses, links, isolating
switches etc. Flush mounted meters, relays, switches, signal lamps etc. on front of
the panel. Made of cold rolled pressed sheet steel of thickness Front side- 3 mm,
Rear side 2 mm. Should be provided with 102 mm base channel. Will have
23
bottom cable entry Provided with space heater and interior illumination lamp with
switches. Final painting shall be done with light Grey paint as per the shade 631 of
IS 5 after proper degreasing, pickling and chemical phosphatising.
6.8.2 WIRING
Fully wired with grade wire. Should be Multi-strand copper wire having area 2.5/1.5
sq. mm. with PVC insulation. Wire shall not be joined or tied between the terminal
points and no bunch should contain more than 12 wires.
Wire end shall be fitted with moisture and oil resistant insulating material having
glass finish with identification number clearly engraved in black.
6.8.3 TERMINAL BLOCKS
N Stud or insertion type terminal blocks vertically mounted.
N Stud type terminal blocks shall be provided with brass studs of less than 6 mm
diameter.
N Insertion type & shall have pressure plates.
N 20% spare terminals shall be provided, in each terminal block.
6.8.4 CONTROL SUPPLY
N The control voltage shall be 220V DC
N For switching off supply disconnecting devices, auxiliary contacts for indication
of control supply.
6.8.5 ANNUNCIATORS
N Static type alarm annunciators having 12 windows shall be provided, for
transformer panel it should be 18 windows.
N Test, accept and reset facilities shall be provided.
N Hooter and bell for trip and non-trip alarm indications.
N Microprocessor based with computer interfacing facility.
6.8.6 TECHNICAL PARTICULARS
a) Panel thickness : Steel sheet thickness front side-3 mm,
rear side-2 mm extendable on both
sides.
b) Enclosure : IP 54 Protection
c) Illumination with door switch : To be provided having CFL tube
light.
d) Provisions of cable glands : To be Provided
e) Inscription : Both sides, front and rear.
f) Control supply : 220 V DC
g) Signaling supply isolation : Semaphore Indication with LED
provision.
h) Relays:
Drawout feature
- Protective relays
- Auxiliary relays
:
:
Draw out type
Non-draw out
24
i) Hand reset contact with mechanical
flag
- Master trip relay
- Auxiliary relays
:
:
To be provided
As per circuit requirement.
j) Test on relays : To be carried out
k) Instrument size : 144 mm square
l) Provision of test block for CT and
PT circuit
: Yes
m) PT secondary voltage : 110 V
n) CT secondary current
- 66 KV
- 11 KV
:
:
1 amp
5 amp for metering and relaying For
Diff. core 0.577 Amp.
o) Base channel : To be provided at 102 mm Height
6.8.7 SCHEDULE OF COMPONENTS
List of components of main protections and indicative control circuitry arrangement
shall be furnished. However, all the relays and accessories required to complete the
scheme shall fall within the scope.
6.9 66KV TRANSFORMER CONTROL & RELAY PANEL
All the relays should be of numerical type .
6.9.1 TYPE 1 66KV TRANSFORMER C & R PANEL
INSTRUMENTS:
a) 1 - Static KWH meter to be connected with CTs and PTs secondary for
export/import energy measurement and other parameters compatible and
communicable with Sub-Stations SCADA/DA for report generation in
Sub-Station PC
b) 1 - Section of no fluorescent mimic diagram to represent bus bars,
connections etc. and comprising the following switches, push button,
semaphore indicators and indicating lamps.
c) 1 - Pistol Grip spring return type 3 position control switch with lost motion
device for 1-66KV circuit breakers.
d) 2 - Automatic semaphore indicators for position indication of the breaker
and the isolator with LED indication
e) 2 - One red and one green ON and OFF indicating lamps for the circuit
breaker working on 220V D.C.
f) 1 - Indicating lamp (white) for 66KV breaker for Trip Circuit healthy
indication with on demand push button.
g) 2 - Blue indicating lamp (Spring charge) to show spring in charge position
for the breaker and SF6 gas pressure normal.
h) 1 - Amber indicating lamp for auto tripping indication of breaker.
Note : All indicating lamps shall be of LED type.
25
6.9.2 ANNUNCIATION :
a) 1 - Microprocessor based annunciator with minimum of 12 facia for
feeder panel and 18 facia for Tr. panel window for alarm annunciation
for indication of individual type of faults. The unit shall be complete
with necessary logics and auxiliary devices, push key units for alarm
reset, alarm acknowledge and lamp test and shall be suitable for
operation on 220/220 V D.C. It shall be mounted on the front of the
panel.
b) 1 - Set of alarm accept, reset and lamp test push buttons.
6.9.3 PROTECTION :
a) 1 - 3 Pole differential relay with percentage bias and harmonic restraint
Siemens /Alstom / Easun / ABB or any other approved make on HV
side of 66KV Transformer. Suitable interposing ratio matching CTs
shall be supplied and mounted in the panel by the bidder.
b) 1 - 3 Pole IDMT over current non directional relay with high set suitable
for 1 Amp. secondary CTs and contacts rated for 220V D.C. control
supply and having a setting range of 50 - 200% for over current and
10 - 40% for earth fault of 1 Amp., with operation time of 3 seconds at
10 times setting for back up protection. Siemens / Alsom / Easun /
ABB relays shall be considered.
c) 1 - Trip circuit supervision relay for pre and post close supervision.
d) 1 - Inter tripping relay.
e) 1 - Master Trip relay of type equivalent to VAJH of Alstom for
differential as well as backup protection trip function along with
transformer auxiliary relays trip functions viz. buchholz, oil temp.
high, winding temp. high, PRV etc. The Nos. of elements for extending
trip alarm functions shall be 10 (Ten).
f) 1 - Directional IDMT o/c relay ( 2 Nos. ) having a setting range of 50 -
200% and IDMT Directional E/F relay (1No) having 10 - 40%setting.
g) 1 - Restricted E/F relay- A single pole instantaneous high impedance
high stability circulating current differential relay with stabilizing
register shall be provided for this purpose. Non-linear resistances to
limit peak voltage less than 1 KV shall also be supplied. The relay
shall be tuned to fundamental frequency. The relay shall be connected
across phase and neutral CTs provided on transformer HVor LV as the
case may be, side with control voltage 220/220 VDC.
h) 1 - Over flux relay - The relay operating on voltage/ frequency ration shall
be continuously adjustable between 110% to 130% based on the
normal transformer voltage and frequency conditions shall be
provided. The relay shall have necessary time delay relays
incorporated for alarm and tripping with independent time settings.
6.9.4 TYPE II- 66KV FEEDERCONTROL& RELAY PANEL :
6.9.4.1 Instruments
a) 1 - Static KWH meter as in 6.9.1 (a) above to record the import and export
26
energy shall also be equipped with RX 485 port for polling the data to
computer provided in control room .
b) 1 - Section of mimic diagram as in 6.9.1 (b) above.
c) 1 - Pistol grip, spring return type 3 position control switch as in 6.9.1 (c)
above
d) 3 - Automatic semaphore indicators as in 6.9.1 (d) above for breaker ,
isolator earth switch position indication.
e) 2 - One red and one green indicating lamps as working on 220V D.C. to
show circuit breaker ON and OFF position.
f) 1 - White trip circuit healthy indicating lamps with on demand push
button.
g) 2 - Blue indicating lamp for spring charge position of breaker and SF6 gas
pressure normal as in C. 6.9.1 (g) above.
h) 1 - Amber indicating lamp for auto tripping of breaker as in 6.9.1 (h)
above.
6.9.4.2 Annunciation
a) 1 - Microprocessor based annunciator for annunciation as in 6.9.2 (a)
above.
b) 1 - Set of alarm accept, reset and lamp push buttons.
6.9.4.3 Protection
a) 1 - 3 Pole IDMT relay suitable for 1 amp. Secondary CTs and contacts
rated for 220 V DC control supply having a setting range of 50-200%
for over current and 10-40% for earth fault with operating time of 3
seconds at 10 times current setting for single feeder protection.
6.9.4.4 Indicating lamp, instruments and vector group of power transformer
1. Series resistors shall be provided with all indicating lamps to prevent short
circuiting of D.C. supply in the event of fusing of the lamps.
2. All auxiliary CTs and PTs required for matching the instrument transformer
ratio with that of any instrument / relay device specified shall be furnished,
mounted and wired by bidder.
4. Coloured mimic diagram shall be painted 10 mm vide for main bus and 5
mm for remaining. Colour shade shall be as under :
Earth Green
66KV - Golden brown shade 414 of IS:5
27
STATEMENT-II
66 KV CONTROLAND RELAY PANELS- SPECIFIC REQUIREMENT PER PANELS
# Particulars Unit Transformer
Panel
With differential
protection
Feeder Panels
Type II
1 2 3 4 6
1 Semaphore for breaker
automatic
No. 01 01
2 Semaphore for isolator
automatic
No. 01 03
3 Indication lamp (closed,
open, trip circuit healthy,
spring charged, auto trip,
SF6 gas pressure normal).
No. 06 06
4 Breaker control switch
(Pistol grip 3 position spring
return to neutral with lost
motion device and bell
alarm contacts).
No. 01 01
Isolator control switch
(Pistol grip 3 position ).
No. 02 02
5 Static KWH meter for
EXPORT/ IMPORT type as
per cl. 6.9.3
No. 01 01
6(a) IDMT Dir O/c(2) + E/F (1)
relay Set as specified in
6.9.3.
No. 01 01
6(b) IDMT Non Dir. O/C (3) +
E/F (1) relay Set as specified
in 6.9.3.
No 01 -
6(c) Restricted E/F relay as
specified in 6.9.3
No 01 -
6(d) Over flux relay as specified
in 6.9.3.
No 01 -
7 Differential relay as
specified in Specification
No. 01 -
8 Directional relay type No. - -
9 IVTs for polarization of
relay in 14 above.
No. - -
10 Trip circuit supervision
relay (type Vax31 of Alstom
Or equivalent.
No. 01 01
11 Auxiliary relay for
buchholz, oil temp. and
winding temp. as specified at
No. 01 01
28
# Particulars Unit Transformer
Panel
With differential
protection
Feeder Panels
Type II
6.9.3(b)
12 Inter trip relay as specified
at 6.9.3(b)
No. 01 -
13 6 way facia annunciation
complete set with 3 nos.
push buttons for accept,
Reset and lamp test with
Aux. Relay (type VAA 121
of Alstom Or Specified make
equivalent) with bell, hooter,
alarm relay and flasher
relay.
Set. 01 01
14 Cable glands (2 core-2.5
sq.mm. To 19 core-2.5
sq.mm.)
No. 09 09
15 Panel illumination CFL 22
W with door operated
switch
No. Provided for each panel
16 Space heater with
thermostat control ON/OFF
switch and required fuses.
No. Provided for each panel
17 Mimic diagram. No. Provided for each panel
18 Car type locable handle. No. Provided for each panel
19 3.0/2.00 mm thick sheets
steel for front/all sides resp.
No. Provided for each panel
20 Circuit wiring to comply to
specification with required
fuses, links, terminal
No. Provided for each panel
21 Push buttons for trip ckt.
Health.
No. Provided for each panel
22 Test terminal block No. 01 01
23 M.S. Foundation bolts/nuts,
size 18 mm dia x120 mm
long.
No. 04 04
Note:-
Indicating lamps shall be as under:( LED type )
a) C.B. Closed : Red colour.
b) C.B. open : Green colour.
29
c) Trip circuit healthy : White colour.
d) Spring charged : Blue colour.
e) Auto trip. : Amber colour
f) SF6 gas pressure normal : Blue colour
6.10 POWER TRANSFORMER
6.10.1 Vector Group of 10 MVA Dyn11
66/11.55KV Power Transformer
1. The bidders shall have to confirm :
Sr.
No.
Particulars Confirmation
(i) That they shall offer the core for inspection and approval
by the GEB during the manufacturing stage. Bidders
call notice for this purpose should be accompanied with
the following documents as applicable as a proof towards
the use of prime core material:
(a) Invoice of the supplier
(b) Mills Test Certificate.
(c) Packing List.
(d) Bill of landing
(e) Bill of entry Certificate to customs.
YES/NO
(ii) that the core material shall be directly procured either
from the manufacturer or through their accredited
marketing organization of repute and not through any
agent.
YES/NO
(iii) that they have in-house core cutting facilities for better
control of quality and to avoid possibility of mixing
prime core material from second grade core material. In
the event if the bidder is sending the core to their sub-
vendor for cutting purpose, in that case, they shall have
to confirm that they will provide documentary evidence
and other means (manufacturers original seals provided
to the CRGO rolled sheet) to prove that the prime core
material is not being mixed with second grade core
material or second grade core material is not used by
their sub-vendor during the cutting process of the core
material.
YES/NO
(iv) that they have in-house facility for drawing out the
required cross section of copper winding material. They
also have to confirm that they will furnish the details
such as name, address, contact persons, phone number
etc. of their sub-supplier from where they procure the
required cross section of the copper winding materials.
YES/NO
30
Also, the sub-supplier must be authorised by the original
manufacturer for supply of such copper winding
materials.
(v) that they agree to submit copy of test certificate of
copper winding material purchased from the original
manufacturer.
YES/NO
(vi) that the EHV grade transformer oil to be used in the
power transformers will be Nepthenic based.
YES/NO
B) STATEMENT OF RAW MATERIALS :
The bidder should submit the statement of raw materials to be utilised during
manufacturing of specified power transformers as per following format. The raw materials
should be procured directly from the manufacturer or through accredited marketing
organisation of repute.
The raw materials shall include crgo, Copper, Insulating Paper, Power Oil, Steel, HV, LV
and Neutral Bushings, OLTC, Radiators etc. to be utilised in offered power transformer.
Sr.
No.
Item Make Grade / Type
1 CRGO silicon steel laminations (Core
material)
2 Electric grade-copper used for
(a) HV winding.
(b) MV winding.
(c) LV winding.
3 Insulating Paper
4 Power oil.
5 Steel used for
(a) Yoke
(b) Main Tank
(c) Other accessories.
6 HV Bushings
(i) Complete bushing.
(ii) Hollow insulator.
7 LV & Neutral bushings.
8 OLTC
9 Radiators.
The bidder may mention various reputed make of raw material, but the test certificates will
have to be submitted for the exact make at the time of drawing approval. The bidder will not be
permitted to use any other make material at later date without approval, once make is
indicated/confirmed.
31
6.10.5 POWER TRANSFORMER PRINCIPLE PARAMETERS
The transformer requirements shall confirm to the following specific parameters.
Sr.
No.
Item Specification
1. Type of Power transformer 3 ph, Double copper wound, Core type,
Transformer, suitable for outdoor
installation.
2. Rated capacity 10 MVA
3. Type of mounting On wheels, mounted on rails
4. System Frequency 50 HZ
5. Rated voltage Ratio 66/11.55 KV
6. Type of cooling ONAN
7. Method of connection HV-Delta
LV-Star
8. Connection Symbol Dyn11
9. System earthing Neutral solidly grounded
10. Transformer Neutral earthing Directly earthed
11. Percentage impedance at rated
MVA and normal tap.
9.4%
12. Tap changing gear
(i) Type
(ii) Class (KV)
(iii) Provide on
(iv) Tap range
(v) Tap Steps
(vi)Control
(vii) Tolerance in voltage
ratio @ all taps.
(viii) Current rating of
OLTC (Amp)
(ix) Control cubicle to be
supplied
On LOAD
66
HV winding for LV variation
-5%+15% (looking from LV side)
1.25%
Manual with Local & Remote Selection
+ 0.5%
200
By bidder
13 Over voltage operating capability 10% over voltage of max. voltage.
14 Over Fluxing Required Yes
15 Max. flux density at normal voltage,
rated MVA and frequency (Tesla)
1.6
16 Insulation level of winding tests HV (72.5 KV) LV 12 KV
(a) 1.2/50 Microsecond wave
impulse withstand voltage
(KVP) 350 90
(b) Power Frequency withstand
voltage (KV rms)
140 30
(c) Separate source voltage test
(i) HV (KV)
32
(ii) LV (KV) 140
30
(d) Induced over voltage Test at twice the rated voltage (KV) of the
winding & double the rated frequency.
17 Type of winding HV LV
interleaved Continuous disc
type / Disc type type/Layer Type
with static end rings at both ends
18 (a) HV winding insulated Uniformly
(b) LV winding insulated Uniformly
19 System short circuit level 25.0 KA for 66 KV for 3 sec.
20 Noise level at rated voltage &
frequency
As per NEMA Tr 1
21 Permissible temp. rise over ambient
temperature specified in C 1.1(ii_
(a) under section B
(i) of top oil measured by
thermometer (C
o
) 35
(ii) of winding measured by
resistance (C
o
) 45
22 (A) Bushing (suitable for heavily
polluted atmosphere)
For HV (66
KV Wdg)
For LV
(11.55 KV
Wdg.)
For LV
Neutral
Details
same as
(i) Rated Voltage Class (72.5 KV) (24KV) as those of
LV Bushing
of resp.
transformer
(ii) Current rating (AMP) 400 400
(iii) Insulation level
(a) Lightning Impulse withstand
voltage (KVP)
350 90
(b) 1 minute power frequency 140 30
(c) Creepage distance (mm) 1810 380
(B) VOLTAGE CLASS OF BUSHINGS & THEIR TYPES
(a) HV winding line end 72.5 KV OIP condenser Bushing
(b) LV winding (11.55 KV) 24 KV Solid Porcelain type Bushing
(c) LV Winding neutral of
66/11.55 KV Transformer
24 KV Solid porcelain Bushing
NOTE : Bare terminals on transformer bushing stem for connection to rigid bus
bars or over head conductor.
(d) Minimum clearance (mm)
33
(i) PH to PH
(ii) PH to E
HV 790
HV 690
LV(11.55) 270
LV(11.55) 270
23 Terminal connectors HV LV
Bimetalic terminal
connectors suitable
for twin ACSR
panther conductor
and the rated current
of HV winding
terminal
Copper terminal
connectors suitable
for connecting 2 or
3 No. 11 KV / 240
Sq. mm. XLPE
cable and the rated
current of LV
winding terminals.
(Connectors must withstand all short circuit currents, when bus fault occurs. They shall
be duly tested at 25 KA currents. Type test certificate of connectors should be enclosed
with relevant detailed drawings, as stated in data sheet A1 of section D(i)A
Clamps & connectors).
24 Earthing Conductor
Material / size
Copper strip
size 2x50x6 mm
25 a) Type Test Required (a) Impulse test full wave and with
chopped wave on HV & LV Phases
(b) Heat Run Test
b) Special Test Short Circuit Test
* These tests will have to be carried out only if GEB desired after placing the order.
26 Transformers to be transported Filled with oil or that filled with inert gas
along with reducer connection, pressure
gauge is preferred.
6.10.6 APPLICABLE STANDARDS
1. POWER TRANSFORMER * IS 2026 BS 171 IEC 76
2. FITTING & ACCESSORIES * IS 3639
3. CLIMATE PROOFING * IS 3202 BS-CP-1014 IEC 296
4. LOADING OF OIL IMMERSED
TRANSFORMER
* IS 6600 BS-CP-1010 IEC-354
5. TRANSFORMER OIL * IS 335 BS-148 IEC 296
6. BUSHING * IS 2099 BS 223 IEC 137
7. DEGREE OF PROTECTION * IS 2147
8. TESTS * IS 2020 BS 171 IEC 76
9. TOLERANCE ON GUARANTEED
PARTICULARS
* IS 2026 BS 171 IEC 76
10. BUCHHOLZ RELAY * IS 3637
11. ELECTRICAL INSULATION BY
THERMAL STABILITY
* IS 1271 BS 2727 IEC 85
NOTES:-
34
1. EQUIPMENT, ACCESSORIES, COMPONENTS / PARTS, RAW
MATERIALS AND TEST SHALL IN GENERAL CONFORM TO IS/ BS/
IEC
2. APPLICABLE STANDARD.
6.10.7 CONTROL CABINET
6.10.7.1 LOCAL OLTC CONTROL CABINET & REMOTE OLTC PANEL
a) i) Each three phase transformer unit shall be provided with Local OLTC control
cabinet and with automatic voltage regulating relay as per specification at
6.10.15.7 to be mounted in Transformer control and relay panel.
ii) The cabinet shall be provided with non disconnecting stud type terminal
blocks. Each of the terminal blocks in the above panels should have 20% spare
terminals exclusively for owners/GEBs use. Necessary scheme of wiring
shall be designed to co-ordinate with voltage regulating relay for remote
operation and parallel running of transformers.
iii) The Local OLTC control cabinet shall house all necessary devices meant for
OLTC control and indication.
iv) Following cablings are specifically included in the scope of the Bidder. and
interconnection drawings for the same are to be submitted by the Bidder.
i) Cabling between remote voltage regulator mounted in transformer
panel to local OLTC cabinet for remote control and parallel operation.
iii) Cabling between Local OLTC Cabinet to GEBs / owners panel.
b) The sheet steel used shall be at least 3 mm thick for outdoor use. The degree of
protection shall be IP 55 (For OLTC cabinet & Marshaling Box) in accordance with
IS 13947.
GEB reserves the right to ask for tests of degree of protection for the panels.
c) The temperature indicators shall be so mounted that the dials are not at height more
than 1600 mm from ground level. Glass door of suitable size shall be provided for
convenience of reading.
d) A space heater and cubicle lighting with ON-OFF switch shall be provided.
e) TERMINAL BLOCKS
i) The terminal blocks to be provided shall be fully enclosed with removable
covers and made of moulded non inflammable plastic material with block and
barriers moulded integrally. Such block shall have washer and binding nut
bolts for external circuit wire connections. A white marking strip for circuit
identification and moulded plastic cover.
All terminals shall be clearly marked with identification numbers or letters to
facilitate connection to external wiring.
35
ii) All internal wiring to be connected to the external equipment shall be
terminated on terminal blocks, preferably vertically mounted on the side of
each panel. The terminal blocks shall be 1100 V grade and have 10 amps
continuous rating, moulded piece complete with insulated barriers, non-
disconnecting stud type terminals, washers, nuts and lock nuts. Terminal block
design shall include a white fiber marking strip with clear plastic, slip on / clip
on terminal cover. Markings on the terminal strips shall correspond to wire
number and terminal numbers on the wiring diagrams. The communication
cables between voltage regulating relay and OLTC cabinet and transformer
shall be in scope of bidder and shall be as recommended by voltage regulating
relay supplier.
iii) At least 20% spare terminals shall be provided on each panel. These spare
terminals shall be uniformly distributed on all terminal blocks.
iv) Unless otherwise specified, terminal blocks shall be suitable for connecting the
following conductors on each side.
a) For all circuits, minimum of one no. 2.5 sq.mm. copper.
v) There shall be a minimum edge to edge clearance of 250 mm between the first
raw of terminal blocks and the associated cable gland plate. Also, the clearance
between two rows of terminal blocks shall be a minimum of 150 mm.
vi) Arrangement of the terminal block assemblies and the wiring channel within
the enclosure shall be such that a row of terminal blocks is run parallel and in
close proximity along each side of the wiring duct to provide for convenient
attachment of internal panel wiring. The side of the terminal block, opposite
the wiring duct shall be reserved for the GEBs/owners external cable
connection. All adjacent terminal blocks shall also share this field wiring
corridor. A steel strip shall be connected between adjacent terminal block rows
at 450 mm intervals for support of incoming cables.
vii) The number and sizes of the multi core incoming cable will be decided by
Bidder as per requirement.
(f) The gaskets shall be of neoprene rubber.
6.10.7.2 BOLTS & NUTS
All bolts and nuts exposed to weather shall be hot dip galvanized/cadmium plated.
6.10.7.3 WIRING AND CABLING
(a) All external cabling will be carried out by bidder based on wiring diagram &
interconnection schedule to be supplied by the bidder. Cable box / sealing end shall
be suitable for following types of cables :-
(i) 415 Volt power : 1100 Volt grade PVC insulated aluminium
conductor cable with armour.
(ii) Control : 1100 Volt grade PVC insulated 7/0.737mm
stranded copper conductor cable with armour.
36
(b) Compression type cable connector shall be provided for termination of power and
control cables.
(c) Not more than 2 wires shall be connected to one terminal. Each terminal shall be
suitable for connecting two 7/0.737mm stranded copper conductors from each side.
(d) All internal wiring shall be securely supported, neatly arranged, readily accessible
and connected to equipment terminals and terminal blocks.
(e) Engraved code identification plastic ferruls marked to correspond with schematic
diagrams shall be fitted at both ends of wires. Ferruls shall fit tightly on wires and
shall not fall off when the wire is disconnected from terminal block.
6.10.7.4 Local OLTC Control Cabinet
The auxiliary devices for electrical control of the OLTC shall be housed in a weather proof
cabinet. It shall be completed with the following :
(i) A contactor with thermal overload devices for controlling the AC auxiliary supply
to the OLTC motor.
(ii) Cubicle light with door switch.
(iii) Space heaters to prevent condensation of moisture.
(iv) Padlocking arrangement for hinged door of cabinet.
(v) Cable terminal glands for power and control cables to the OLTC gear.
6.10.7.5 Remote OLTC Control Equipment (Voltage regulating relay equivalent to a -
ehorte as specified below ).
(a) Loose equipment mounted on Control Panel : Control and signal devices required to
be included in voltage regulating relay minimum for remote OLTC operation
(i) Actuator for electrical raise / lower control
(ii) Remote tap position indicator.
(iii) Signal lamps for change in tap position
(a) Tap changer in progress
(b) Tap changer out of step
(c) Tap changer motor trip
37
6.10.7.6 CONTROL CABINET
SPECIFIC REQUIREMENT
SR.
NO. PARTICULARS
(A) General
(i) Designation Marshalling box, OLTC local cabinet,.
(ii) Location & Degree of Protection IP 55 for OLTC cabinet & marshalling
box (as per IS 13947)
(iii) Type of mounting See Note 1
(iv) Finishing colour Outside Hot dip galvanizing for marshalling box
and D.M. for OLTC.
- Inside Glossy white .
(v) Cable entry Bottom
(vi) Short circuit level KA 25
(vii) Thickness (mm) 2.6 For indoor & 3.0 for outdoor
(B) Main Bus Bar & Associated
equipment
(i) Design ambient temperature 50
o
C
(ii) Continuous current rating (AMP) By bidder
(iii) a) Short time current duration (Sec) Three
b) Short time current (KA rms) 25
(C) Auxiliary power supply 430 V, 3 PH, 50 HZ
(i) For power devices, drive motors Duplicate feed provided.
(ii) Space heater/Lighting supply 240 V, 1 PH, 50 HZ
(iii) Control supply voltage 220 V, Single phase AC and 220 V, DC
for annunciation.
(D) Control schematic for control cabinet Not enclosed
(E) GEBs earthing control material size Galvanized steel strip 25 x 4
(F) Control switches with NAC Required/ Nat contacts
(G) No. of control switches & No. of
contacts
To suit control scheme.
(H) Annunciator Required for OLTC
NOTE
1. OLTC LOCAL CABINET, MARSHALING BOX TO BE TANK MOUNTED.
38
APPLICABLE STANDARD
============================================================
SR.
NO. EQUIPMENT
============================================================
1 Switchgear general
Requirements * IS-4237 BS-162 IEC
2 Air break switches * IS-4047 BS-3185 IEC-408
3 Fuses * IS-2208 BS-3185 IEC-259-1
4 Contactors * IS-2959 BS-775 IEC-158-1
5 Starters * IS-1822 BS-4941 IEC-292
6 Indicating instruments * IS-1248 BS-89 IEC-51
7 Panel wiring * IS-375 BS-158 IEC
8 Degree of Protection * IS-13947 BS- IEC-529
NOTES
1 EQUIPMENT, ACCESSORIES, COMPONENTS / PARTS, RAW MATERIALS AND
TESTS SHALL, IN GENERAL, CONFORM TO IS / BS / IEC
2* APPLICABLE STANDARD
6.10.7.7 Automatic Voltage regulating relay
1. Automatic voltage control shall be initiated by a voltage regulating relay of an approved
make and suitable for flush and/or wall mounting / DIN-rail mounting.
2. The relay shall operate from the nominal reference voltage derived form a circuit mounted
1 phase / 3 phase Voltage transformer (VT).
3. The AVR relay shall Microprocessor based Numerical relay having large LCD display
128x128.
4. The relay shall have 4 selectable set point voltages.
5. The AVR relay shall have the following methods as option for the compensation of voltage.
Apparent Current (Z-Comp.)
Line drop compensation (LDC)
Active Current
Reactive current
6. The relay bandwidth shall be adjustable between 5 to +15 of set point voltage.
7. The relay shall have following options regarding time behavior with Time factor selectable
from 0.1 to 30.
Linear
Integral
Fast integral
8. The relay shall incorporate an under voltage / over voltage blocking facility which shall
make the control inoperative if voltage falls / rises by percentage value of set point value
(as mentioned in Guaranteed technical particulars) with automatic restoration of control
when nominal voltage rises / falls to value as mentioned in the Guaranteed technical
particulars.
39
9. The AVR relay shall have integrated features for the display of following parameters
Integrated tap changer position display
Nominal Voltage
Load current
Bandwidth
Measuring values V. I. Active power, Reactive power, Apparent power, phase
angle, Power factor, Reactive current and frequency
10. The AVR relay shall have facility to compensate the VT and CT-errors.
11. The AVR relay shall have facility to register the tapchanger statistics. In the statistics mode,
the relay shall display the no. of tap changing operations occurred on each tap.
12. The AVR relay shall have facility to recode the voltage and current with respect to time.
Each of voltage value shall be measured for 100ms and averaged for 1 second. The
recorded values shall be presented in graphical format on the device.
13. The AVR relay shall have integrated feature to make the parallel operation of 10
transformer working in parallel. The relay shall be self sufficient and shall not require any
additional devices like parallel balancing module etc. The following principal shall be
available in the relay as standard.
Master Follower
Master Slave
I Sin (Circulating current)
I Sin (S) (circulating current principal for different KVA/MVA ratings of
transformer)
Cos
14. The AVR relay shall have facility to monitor or control the following parameters
Monitoring of life time consumption of transformer
Monitoring of operating hours of Tapchanger, Fans and Pump
Control of cooling levels of transformer
Recording of Hot spot temperature
15. The AVR relay shall have facility to record specific events (Event-Recorder) like under
voltage, over voltage, Over current, Auto/Manual, local/remote etc. with date and time
stamping.
16. The AVR relay shall have facility to make selection of Auto/Manual and Local/Remote.
17. The AVR relay shall have different LEDs to indicate Service and Blocked condition.
18. It is preferred that 12 nos of freely programmable LEDs shall be available to indicate
different Operations / Alarm / Faults condition.
19. The AVR relay shall have freely programmable Binary Inputs, Binary outputs, Analog
Inputs and Analog Outputs.
20. The AVR relay shall have software to make the parameter settings of the device and it shall
also be possible to do the parameter setting through keyboard of relay.
21. The AVR relay shall have suitable interface to make communication with higher level
SCADA system. The following ports a minimum shall be available on the device.
a. Rs 232 port (COM 1) for doing the parameter setting and local
communication with device.
40
b. RS 232 port (COM 2) for communication with higher level SCADA with
optional protocols like MODBUS, SPABUS, PROFIBUS DP, LON, IEC
60870-5-101, -103 and 104, IEC 61850 in preparation.
22. It shall be possible to communicate via bus with all similar devices located at different
location by making communication link with any one device through its RS 485- port (E-
LAN) meant for local communication.
23. It shall have facility by which a customer specific software programme can be written and
incorporated as feature in the relay.
7.0 DISTRIBUTION TRANSFORMER
Distribution Transformers (11.0 KV/0.443 KV)
- Specification : IS 2026
Part I - 1977
Part II - 1977
Part III - 1981
Part IV - 1977
- Type : Out door use, mineral oil immersed,
natural cooling type (Installed in open
yard)
- Capacity : 200 KVA
- Voltage : Primary- 11 KV
Secondary 433 V
- Frequency : 50 HZ
- No. of phases : 3
- Insulation class : Class A
- Cooling : ONAN
- Winding : Delta/ Star
- Vector group : Dyn 11
- Neutral impedance : LV- Solidly grounded
- Percentage impedance : 4.5%
- Insulation Class : Class A
- Termination : Primary 11 KV XLPE Cable Secondary
1.1 KV PVC Cable
41
8.0 11 KV VACCUM CIRCUIT BREAKER
8.1 11 KV Switchgear
N The switchgear shall be of metal clad, single busbar, self standing, dust proof construction,
indoor cubicle type fitted with vacuum circuit breakers, in fully draw out execution.
N The circuit breakers shall be suitable for following duties :
i To withstand in rush magnetizing currents of transformers, and capacitor bank ON
and OFF operation.
ii Transients surge produced by one CB due to server chopping during rapid
interruption of inductive currents.
N The controls, indicating lamps, relays and meters shall be mounted on breaker cubicle itself.
N Operating counter, close/open mechanical indications spring charged / discharged
indication shall provided.
N All circuit breakers shall have motor operated spring charged independent closing and shunt
tripping from 220V DC. Closing coil shall be suitable to operate between 85- 110% of
voltage and tripping coil between 70 to 110% of rated voltage. Spring charging motor shall
operate between 85-110%.
N A manually operated device to enable charging of closing springs.
N All circuit breaker trucks shall have service test and draw out positions.
N Test position shall engage only the auxiliary (control) contacts to close the CB during
testing.
N Anti pumping features shall be provided.
N All live parts shall be insulated by tapping supported by suitably designed insulators. Proper
insulation of bus bars, upper and lower contacts of breakers, vacuum bottles (for VCB) and
sealing of opening of bushings, shall be provided to eliminate accidental contacts.
Switchboard busbars shall be tapped by proper grade of insulating tape. In the design of the
switchgear the following positive interlocking shall be provided.
N It shall not be possible to move the truck from the isolated to the Service Position unless
low voltage plug and socket connections have been made.
N It shall not be possible to disconnect the low voltage plug and socket as long as the circuit
breaker truck is in service position.
N It shall not be possible to withdraw the truck past the Isolated Position without
disconnecting the low voltage plug and socket.
N It shall not be possible to move the truck from the service to the Isolated position or vice
versa with the circuit breaker in the ON position.
N It shall not be possible to switch on the circuit breaker when the trucks is in between the
Isolated and the service positions (except in Test position).
N Shutters shall be lockable in closed position.
N Where local/remote selector switches are called for, it shall be ensured that:
' The breaker can be closed locally only if the breaker truck is in the test position and
the local/remote selector switch is in local position.
' The breaker can be operated from remote panel (in shop) only when the breaker
truck is in service position and the local/remote selector switch is in remote position.
' The breaker can be tripped locally regardless of the position of the breaker truck.
42
N Each cubicle shall be of compartmentalized construction and shall have separate
compartments for busbars, CTs and outgoing cables, metering protection devices.
N All circuits breaker trucks of same rating shall be identical in all respects (except metering
and protective devices) and shall be interchangeable with similar breaker panel.
N Continuous earth bus shall be provided throughout the board.
8.2 Operating Mechanism
N The operating mechanism parts shall be designed to give longer life trouble free operation,
and minimum maintenance.
N The material and components used shall have chopping current limited to minimum.
Insulation Level
N Corresponding to the rated voltage as below.
N Nominal voltage (KV) : 11.0
N Highest system voltage (KV) : 12.0
N One minute power frequency : 28.0
withstand voltage (KV)
N 1.2/50 micro second impulse : 75.0
withstand voltage (KV)
Clearance in Air : As per relevant IS
8.3 Short Circuit Strength
N Rated short time withstand current not less than the system short circuit level specified for
the stipulated duration i.e. normally specified as 25 KA for 3 sec.
N Each cubicle shall be of compartmentalized construction and shall have separate
compartments for busbars, CTs and outgoing cables, metering protection devices.
N All circuits breaker trucks of same rating shall be identical in all respects (except metering
and protective devices) and shall be interchangeable with similar breaker panel.
N Continuous earth bus shall be provided throughout the board.
N Rated peak withstand current not less than 2.5 times the system short circuit level.
8.4 Auxiliary buses for control & protection
N Buses shall be formed by wore looping.
N Control supply buses for AC and DC
N Signaling supply
N PT secondary voltage
8.5 Provision of surge suppressor
N In case of breakers like VCB that give rise to over voltage surges due to current chopping
phenomenon, surge suppressors to be provided at the load side terminals of the breakers to
limit the switching surges to value limited for as per IEC.
43
8.6 Alarm Scheme
1 Trip Bell (on D.C. supply)
1 Hooter for D.C. fail (A.C. supply)
1 Bell for A.C. fail (D.C. supply)
8.7 Busbar and connections
N Power buses of 1600 Amp Current rating suitably insulated shall be of electrolytic high
grade copper and shall be rectangular rates.
N PVC Sleeves or Tap of suitable thickness shall be provided on busbars and jumpers except
at the joints. The joints shall be separately tapped.
N Suitable insulated shutters shall be provided such that the Busbar shall be in accessible
when the Breakers is drawn out for maintenance.
N All connections external to a feeder, all the auxiliary contacts of the HV breaker and at least
1 No + 1 NC spare contacts for the relays, brought on to terminal block.
N Not more than two connections on any one terminal.
N All telemetering signals wired to terminal strips.
8.8 External Terminations
N Control Terminations
- 1100 grade multi-way terminal blocks of non-tracking molded plastic complete with
insulated barriers, stud type terminals, washers, nuts and lock nuts and identification
strips.
- Control terminals of minimum rating 10 amps and suitable to receive 2.5 sq. mm
copper conductor.
- 20% spare terminals in each control terminal block.
8.9 Power Terminations
N Suitable for accepting cable as specified.
N Sufficient space and support arrangement inside each panel to accommodate HT cable
termination kits, and sealing kits suitable for the type, size and number of cables to be
terminated.
N Dummy panels to be provided adjacent to the switch panel, where the required number of
cable terminations cannot be accommodated in the cabling chamber of the main panel.
N Where more than one cable has to be terminated per unit, the arrangement shall permit
connection and disconnection of cables separately without disturbing other cables.
N All connections external to a feeder, all the auxiliary contacts of the HV breaker and at
least 1 No + 1 NC spare contacts for the relays, brought on to terminal blocks.
N Interconnection between panels of adjacent shipping sections to be brought out to a
separate terminal block.
N Not more than two connections on any one terminal.
N All telemetering signals wired to terminal strips.
44
b) Type and Connection 1 Unit 3 Phase,
11KV/220V
Class 1.0 accuracy PTS
OR
Alternatively.
3 Nos. 1-0, 11KV / 110 PTS
Connected in Star/Star With
Neutral grounded.
8.10 The PTS shall be cast resin insulated and draw out type with necessary plug and
socket type connection to enable easy withdrawal of PTS. The secondary lead shall
be brought out to the terminate Board. Fuses shall be provided on Both 11 KV and
LV sides and limiting resistance if required shall be provided.
The PTS shall be easily withdraw able independently of the Breaker.
8.11 Relays
N All relays shall be flush mounted in dust proof cases and shall be mounted on front sided of
cubicle.
N All protective relays shall be draw out type and rest type with Auxiliary contacts.
N All timers and protection relays shall have flag indicators.
N Triple pole IDMT O/C and E/F relays of JVS / ALSTOME / ABB / ASHIDA / ER / Jyoti
are in draw out Flush pattern with setting range of O.C. 50% to 200% and E/F 20% to 80%.
DMT 0.3 sec at 10 times plug setting.
N Double element auxiliary relay for Buchholze, Alarm and Trip house in non draw out
flush pattern case for transformer panel. Makes shall be as stated for IDMT Triple Pole
relay stated above.
N Alarm cancellation and set of potential selection relays shall also be provided for
transformer panel.
N
8.12 Indicating instruments
8.12.1
N All indicating instruments shall confirm to IS:1248-1983 and IS:2419-973.
N Shall be capable of withstanding system fault current taking account CT saturation.
N Shall be black connected.
N Shall be located in the upper part of the panel.
N Shall have 144 sq. mm. square flush case, clearly divided and indelibly marked scales,
sharply out lined pointer and zero adjusting device.
N The full load reading of each ammeter shall occur at the most prominent part of the scale.
N Each volmeter shall be calibrated.
45
8.12.2 ENERGY METER (STATIC)
N Static energy meter of high precision of accuracy 0.5 capable of performing function of
recording / storing in memory half hourly units sent out. The meter shall be 3-0, 3 wire
Balanced load type.
N 220 V D.C. voltage for closing and Tripping coils.
8.13 Control Supply
N Sub circuits shall be protected with HRC fuses, wherever required.
N 240 V AC supply shall be taken from a substation aux. board
N For spring charging motors 240 V AC 50Hz with voltage variation of + 10% and 15% of
normal value and frequency variation 3%.
8.14 Voltage Selection Circuit
N Voltage selection circuit shall be formed to ensure that only one PT feeds the entire load PT
consumers. This shall be necessary to avoid paralling of PTs, when more than one voltage
source is ON.
8.15 Terminal Blocks
N Stud type suitable to accommodate minimum 2 cores of 2.5 sq. mm copper control cables.
N Size of terminals for bus wires AC/DC incoming supplies shall be a per requirements.
N 20% spare terminals shall be provided in each panel.
N All terminals going out of the switchboard shall be brought to a separate terminal board
marked External Connections.
8.16 Small wiring and ferrules
N All small wiring shall be carried out with 1100 V grade single core cable having copper
conductor, preferably stranded, of not less than 1.5 sq. mm cross section.
N Wiring across the hinges shall be through flexible cables.
N The wires shall be identifies by numbered ferrules at each end, all in accordance with
connection diagram.
N All ferrules shall be made of non-deteriorating materials.
N The ferrules shall be firmly located on each wire so that they cannot move freely on the
wire.
8.17 Indicating Lamps
N 7 watts, screw type filament lamps with series connected resistors, preferably built in the
lamp assembly.
N Colour: ON - RED
OFF - GREEN
CIRCUIT HEALTHY- WHITE
FAULT/WIRING - AMBER
8.18 Control and selector switches
N Control switches for circuit breaker ON/OFF control-3 position spring return to neutral with
lost motion device and pistol grip handle.
N Other control and selector switches stay put type.
N Ammeter selector switches 4 position, make before break
N Volmeter selector switches 4 positions.
N Rating: Continuous - 10 amps
46
AC - 4 amps, 240V
DC110- 0.5A
8.19 Push Buttons
N Rating:Suitable rating as per IS as per bill of materials.
8.20 Control Circuit Protection
N Preferably with MCBs, alternatively HRC link type fuses.
8.21 Protective Earthing
N Continuous earth bus of minimum size 30 x 6 mm copper or designed to carry the peak
short circuit and short time fault current as specified.
N Provided at the bottom extending throughout the length of the board, bolted/brazed to the
framework of each panel, with an earthing terminal at each and, for terminal at each end for
terminating external earth conductor.
N Vertical earth bus for earthing individual functional units.
N All non-current carrying metal work (including metallic casses of instruments and other
panel mounted components) effectively bonded to the earth bus.
N Hinged doors earthed through flexible earthing braid.
N Looping of earth connection resulting in loss of earth connection to other devices when the
loop is broken, not permitted.
N Withdraw able units provided with self aligning, spring loaded, silver plated copper,
scrapping earth contacts, of make before/break after type, ensuring earth continuity form
service to the test position.
8.22 Test And maintenance equipment
N Each board to be supplied with
N 1 set of test plugs
N 1 common transport trolley for interchanging withdraw able units, height of the trolley
lifting arm adjustable for raising/lowering the units.
N Any other special purpose tools for maintenance.
8.23 Construction features : Mechanical Design
N Sheet steel clad, floor mounted, freestanding design.
N Minimum sheet steel thickness: doors & covers 3 mm cold rolled, other members 2.5
mm
N Degree of protection IP53
N Assembled on base channel of structural steel of minimum height 75 mm, painted black.
N Earthed metallic barriers between compartments and between vertical sections.
N Seal-off bashing wherever bus bars pass through metallic partitions.
N Zinc bichromated and passivated hardwares.
N Transport unit not larger than 3.2 meters.
N Removable lifting arrangement for each transport unit.
N Lockable front doors with connected hinges with the door not forming part of the draw out
truck.
N Extensibility on both sides of the panel.
N Screwed wire mesh for bus bar and CT chambers to prevent accidental contact with live
parts.
47
N Removable sheet steel covers at rear.
N Explosion vents for different chambers.
N Pressure relief flaps which can not be opened from outside to release pressure that built up
in the event of arcing faults inside the cubicle
N All similar units should be electrically and mechanically interchangeable.
8.24 Labels
N Switchboard designation name plate at the centre of the board with letters not less than 25
mm high.
N Panel designation number on each panel, both in front and rear
N Inscription plate for each feeder on the door.
N Door/Front mounted devices to have labels directly below them.
N Labels made on non-rusting metal.
N Label designation and size of lettering subject to approval.
N Bus side and cable side shutters labeled for identification.
8.25 Surface Treatment
N All metal parts of the panel to undergo surface treatment that includes derusting, cleaning,
chemically degreasing, picking in acid, cold rinsing, phosphating and passivating followed
by spraying with two coats of zinc oxide primer and baking in oven.
N Shade of paint :
Panel interior and
Exterior : 2 coats of enameled paint of shade 631
of IS-5 (unless otherwise specified) and further
stoved.
8.26 Technical particulars and design parameters
1. Type : Indoor, metal clad.
2. Enclosure : IP-52
3. Nominal system voltage : 11 KV
4. Highest system voltage : 12.0 KV
5. No. of phases and frequency : Three Phase 50 Hz
6. System earthing : solid earthed
7. Circuit breaker rating
a) Continuous current rating at 45 C : 1250A
b) Short circuit rating : 2.5 KA per 3 sec.
c) Dynamic system : 2.5 times of short circuit
rating
8. Busbar rating : 1600 A
9. Power frequency with voltage : 28 KV rms for 1 min.
48
stand
10. Impulse withstand voltage : 75 KV
11. Control voltage : 220V DC/240V AC
12. Termination : 3 core 185 mm2 x LPE
Aluminium power added
With complete accessories
i.e. lugs glands etc. For
transformer panel and 2
Nos. cables for Feeder
panel.
8.27 Power transformer control switchboard panel
The circuit breakers (vacuum) switchboard panels shall be complete with the following
equipments:
1. Vacuum circuit breaker of 11 KV, 500 MVA, 1250 Amp current rating and having S.T.C.
rating specifications.
2. 1-true trip free manually charged, manually released spring closing mechanism fitted with
220 V DC shunt trip coil and, a hand trip device.
3. 1-set of vertically / horizontally isolated secondary plugs and sockets with automatic safety
shutters with locking arrangement.
4. 3 nos., epoxy cast resin type cable termination kits, suitable for 3 core 300 MM2 / 240
MM2 XLPE aluminium power cable, with complete accessories i.e. lugs, glands etc. The
cable entry shall be from the bottom (240 MM2 cable for 1250 Amp VCB).
5. 3-cast resin insulated current transformer having ratio 900-600/5-5-0. 577 Amp for
instrumentation, protection and differential as per detailed technical particulars, furnished
under clause no 1.3.2.2 of this specification.
6. 1-voltage transformer, cast resin insulated, withdrawable carriage type independent of
breaker 3 phase and having ratio 11000/220 Volts, class I accuracy to IS:3156, complete
with current limiting resistors and HT and LT fuses. Alternatively 3 nos. 1-phase
3
110
3
11 V KV
PTs connected in star-star may be offered.
7. 1-80 watts/230 volt AC tubular heater, with thermostat set at required setting.
8. 1-instrument panel mounted on the front comprising:
a) 1-Ammeter, 144 mm2 flush pattern case, with selector switch and scaled suitably.
b) 1-Volmeter, 144 mm2 flush pattern case, with selector switch and scaled suitably.
c) 1-KW meter, suitable for 3-phase 3-wire unbalanced load.
d) 1-Double element auxiliary relay for buchholz alarm and trip housed in non drawout
flush pattern case.
e) 1- Power factor meter suitable for 3-phase 3-wire unbalance load.
f) 1-Triple pole IDMT over current and earth fault relay of Alstome / ABB / Ashida /
ER / Jyoti make mounted in drawout flush pattern case with setting range for O/C
50-200% and E/F 20-80%, DMT 0.3 secs at 10 times p.s.
g) 1-alarm cancellation relay
h) 1-set of potential selection relays of makes (stated at g above) shall be provided
for automatic selection of voltage supplied to a volmeter, KW and KVA meters in a
49
definite sequence (provision shall also be made for two future transformer
connection sets at each sub-stations).
i) (1) 1-CB TNC control switch.
(2) One each local manual close and trip push buttons.
j) 2-Indicating lamp working on 220 V DC supply to indicate circuit breaker ON/OFF
position.
k) 1-Trip circuit healthy amber lamp with push button and working on 220 V DC
supply.
l) 1-Mechanical ON/OFF indicator.
m) 1 Set of suitable mechanical interlocks.
n) 1-Test terminal block having 1100 V grade insulation, dully wired for testing of
relays and meters.
o) Complete internal wiring with 1100 volt grade single core multi-stranded wires
conforming to modern standard practice. All necessary cable glands and minor
accessories shall be supplied.
p) Internal earthing of all parts of the panel as per standard practice and providing for
earthing of panel.
q) 1-Circuit breaker operating handle, if applicable (two for each panel board set or 1
no. for each single phase transformer or 0 / G feeder panel).
r) 1- Truck or trolley for easy drawl of the breaker from its panel, if applicable (two
for each panel board set).
s) Alarm scheme consisting of
1-Trip bell (on DC supply)
1-Hooter for DC failure (on AC supply)
1-Bell for AC failure (on DC supply)
t) 1-Panel label set.
8.280 Feeder control switchboard panels
These panels will be similar to the transformer control, switchboard panels, but with the
following changes:
1. Item Nos. 6, 8(b), 8(e), 8(f), 8(h), 8(i), 8(t) shall not be provided.
2. 3 Cast resin insulated current transformer having ratio 300-150/5-5A for instrumentation as
per detailed technical particulars furnished enclosed 1.3.2.2 of these specifications.
3. The set of indicating lamps shall work on 240 V AC supply instead of 220 V DC supply, as
in item 8(k).
2 Nos. epoxy resin type, cable termination kits suitable for three core 150 mm2/185 mm2 XLPE
aluminium power cable, with complete accessories i.e. lugs etc. The cable entry shall be from
bottom.
50
9 SPECIFICATION FOR 11KV (E)XLPE (CROSS LINKED
POLYETHELENE) DRY GAS CURED INSULATED POWER CABLE
9.1 SCOPE
9.1.1 This Section of the Specification covers design; manufacturing, testing, packing,
supply & delivery of 11KV XLPE Dry gas cured insulated power cable for
effectively earthed specification system.
9.1.2 STANDARDS :
9.1.2.1 Unless otherwise specified, the cable shall conform in all respect to IS:7098
(Part-II)-1985 with latest amendment thereof.
9.1.3 PRINCIPAL PARAMETERS:
9.1.4.1. 11 KV (E) Grade XLPE, 3-Core, power cable shall be of high conductivity,
stranded compacted, H.D. aluminium circular shaped conductor with XLPE
(cross linked Poly Ethelene) Dry/Gas cured insulation provided with shielding
of extruded semi-conducting materials over conductor and XLPE insulation.
Each insulated core shall have copper tape screen, laid together and provided
with common covering of PVC Inner Sheath (Extruded). Overall galvanized
steel strip armour and PVC outer sheath shall be provided. The specification for
manufacture of cable shall be conforming to IS : 7098 (Part-II) 1985 (latest
edition) for 11 KV , 3-phase, 50 Hzs. Earthed system.
9.1.4.2. Outer sheath shall be designed to afford high degree of mechanical protection
and shall also be heat, oil, chemical and weather resistant, Common acid,
alkalies and sealing solution shall not have adverse erection material of PVC
sheath.
9.1.4.3. Cable shall be suitable for laying in covered trenches and/or buried under-
ground in outdoor.
51
9.1.4.4. Cable Parameters:
(i) Voltage grade (Uo/U) : 6.35/11
(ii) Cores Nos : 3
(iii) Nominal system voltage KV : 11
(iv) Highest system voltage KV : 12
(v) System frequency Hz : 50
(vi) Variation in frequency % : H 3
(vii) (a) Maximum allowable temp. of
conductor during continuous
normal operation at rated full
load current.
(b) Maximum allowable
temperature under short circuit
condition
:
:
90
0
C
250
0
C
(vii) 1.2/50 microsecond lightning impulse
withstand voltage wave value.
: 75 KVP
(ix) 5 Min, Power frequency withstand
voltage
: 17 KV rms
(x) System earthling : Effectively earthed.
52
9.1.5 GENERAL TECHNICAL REQUIREMENTS:
9.1.5.1 Conductor:
The cable conductor shall be made from high conductivity stranded High capacity
aluminum to form complete circular shaped conductor having resistance within
limits specified in IS:8130/1984 and any latest amendment to it.
9.1.5.2 Conductor shield:
The conductor having semi-conducting screen shall ensure perfectly smooth profile
& avoid concentration of stress. The conductor screen shall be extruded in the same
operation as the insulation. The semi-conducting polymer shall be cross-linked.
Insulation:
The XLPE insulation shall be suitable for 11 KV system voltage and should be
manufactured with Dry/Gas curing. The bidder shall submit the description of dry
gas airing process, with the clear inclusion of equipments / parameters involved.
The manufacturing process shall ensure that the insulation shall be free of voids.
The insulation shall withstand mechanical and thermal stress under steady state and
transient operating conditions. The extrusion method should give very smooth
interface between semi-conducting screen and insulation. The insulation of the cable
shall be of high standard quality generally confirming to IS: 7098 (Part-II)-1985 and
any latest amendment to it.
9.1.5.3 Insulation shield:
Non-metallic semi-conducting shield shall be provided over the insulation to
confine electrical field to the insulation. The insulation shield shall be extruded in
the same operation as the conductor shield and the insulation by suitable extrusion
process. The XLPE insulation shield shall be of tended type. The copper metallic
overlapped tape shield shall be provided.
9.1.5.4 Filler and Inner-Sheath:
The sheath shall be suitable to withstand the site conditions and the desired
temperature. It shall be of adequate thickness, condiment quality and free from all
defects. The PVC sheath shall be extruded. The material of fillers and inner-sheath
shall be compatible with the temperature ratings of the cable and shall have no
53
deleterious effect on any other component of the cable. Central PVC filler shall also,
be provided with other peripheral PVC fillers to have proper circular section.
9.1.5.5 Armour:
Armouring of galvanized steel strip shall be provided. The dimensions of steel strips
shall be as per latest edition of IS:3975/1979.
9.1.5.6 Outer-Sheath:
Extruded type SF2 PVC outer-sheath, confirming to IS:5831-(1984) (latest edition)
over armouring with suitable additives (to prevent attack by redents &termites),
shall be provided.
9.1.5.7 Construction:
9.1.5.8.1. The cable shall have suitable PVC fillers laid up with insulation cores to have
subsequently circular cross-section before the inner sheath is applied. The fillers
shall be suitable for operating temperature of the cable.
9.1.5.8.2. All materials used in manufacturing of cable shall be new, unused and of finest
quality. All materials should comply with the requirements/ tests as per applicable
IS., IEC specification, Indian Electricity Rules and any other statutory provision of
rules & regulations.
9.1.5.8.3. The PVC material used in the manufacture of cable shall be of reputed
manufacturer. No recycling of PVC is permitted. The GEB reserves the right to ask
for documentary evidence of the purchase of various materials, (to be used for the
manufacture of cable) quality control. Quality Assurance plans shall be submitted.
9.1.5.8 Current Rating: The indicative value of continuous current carrying capacities at
Maxi. Conductor temp. of 90
0
C (for design purpose by field ) of the various sizes of
the cables are given below.
Cont. Current carrying capacity in Amps. Sr.
No.
Size of 3 Core
cable (Sq.mm) In Ground In Air
1 95 185 200
2 150 235 265
3 185 270 310
54
4 240 305 345
5 300 340 396
9.1.5.8.1. Short circuit ratings of various sizes of 3 core cable calculated for duration of one
second at maximum temperature of 250
0
C, are given below:
Sr. No. Size of 3 Core Cable (Sq.mm)
Conductor short circuit rating
in KA (rms)
1 95 8.93
2 150 14.1
3 185 17.4
4 240 22.6
5 300 28.2
9.1.5.8.2. The current rating shall be based on maximum conductor temperature of 90
0
with
ambient site condition specified for continuous operation at the rated current.
9.1.5.9 Operation:
9.1.5.9.1. Cable shall be suitable for operation under frequency variation of 3% and voltage
variation of 10% -15% and combined frequency-voltage variation of 10% (absolute
sum).
9.1.5.10 Length:
The cable shall be supplied in standard drum length of 300 mtrs. H 5% tolerance
for all the sizes of cable except for 3 C x 240 mm
2
and 3 C x 300mm
2
size cable.
The drum length for 3 C x 240mm
2
and 3C x 300mm
2
cable shall be 200 mtrs. H
5%.
Over all tolerance in total quantity of ordered cables shall be 2%.
9.1.5.11 Identification Mark:
(i) The cable drum shall be printed with information as per cl; 21;2 of IS and
ISI Certification mark. Bidder shall submit xerox copy of valid ISI Licenses
with technical bid.
55
(ii) For identification of cores, coloured strip of Red, Yellow and Blue colours
shall be used for identification of phases. Following details of identification
shall be embossed at intervals of length of one meter of cable outer sheath.
9.1.6. TESTS:
9.1.8.1 (A) Type Tests
The power cable offered should have been fully type tested as per the relevant
standards at any Govt. recognized Laboratory. The bidder shall furnish three sets of
type test reports if required by GEB These type tests must have been conducted
within last five years prior to Bid opening.
9.1.6.1(B) Type tests certificates for following type tests shall be invariably with the
offer :
(a) Tests on conductor:
(i) Tensile test
(ii) Wrapping test
(iii) Resistance test
(b) Tests for armouring strips / wires. :
(c) Tests for thickness of insulation and sheath. :
(d) Physical tests for insulation. :
(i) Tensile strength and elongation at break.
(ii) Ageing in air oven
(iii) Hot set
(iv) Shrinkage test
(v) Water absorption
(e) Physical tests on outer sheath:
(i) Tensile strength and elongation at break.
(ii) Ageing in air oven
56
(iii) Shrinkage test
(iv) Hot deformation
(v) Bleeding and blooming test
(f) Partial discharge test
(g) Bending test
(h) Dielectric power factor test
i) as a function of voltage
ii) as a function of temperature
(i) Insulation resistance test (volume resistivity)
(j) Heating cycle test
(k) Impulse withstand test
(l) High voltage test
(m) Flammability test
9.1.6.2 Acceptance Test:
9.1.6.2.1. The selection of samples for acceptance test shall be 10% of each lot offered for
inspection or part thereof or minimum one drum.
9.1.6.2.2. The following acceptance tests may be carried out on the selected samples as per
IS:7098 (Part-II) 1985
(a) Annealing test (for copper)
(b) Tensile test (for aluminum)
(c) Wrapping test (for aluminium)
(d) Conductor resistance test.
(e) Test for thickness of insulation and sheath
(f) Hot set test for insulation
(g) Tensile strength and elongation at break test for insulation and sheath.
(h) Partial discharge test (for screened cables only)
(i) High voltage test for 4 hours (as per cl. No. 19.7.1)
57
(j) Insulation resistance (volume resistivity) test.
9.1.6.2.3. All the acceptance tests shall be carried out by the firm, in the presence of GEBs
representative at their works. The firm shall give atleast 15 days advance notice
to the GEB to enable him to depute the engineer for witnessing the tests. The test
certificates for acceptance tests witnessed by inspecting officer/ engineer shall be
submitted for approval before dispatch of material from works.
9.1.6.3 Routine Tests:
9.1.6.3.1. The bidder shall have to submit well in advance the following test certificate for
following routine for approval prior to inspection of the materials for the
complete lot offered for inspection at a time.
(a) Conductor resistance test
(b) Partial discharge test
High-voltage test for 5 minutes (as per Clause 19.7.2 of IS:7098 / (Part-II) / 1985)
9.1.7. DOCUMENTATION:
The bidder shall furnish following documents alongwith his offer.
9.1.8.1. Sectional view, showing the General constructional feature with conductor /
conductor screen / insulation / armouring / inner and outer sheath etc.
9.1.8.2. Drawing of cable drum with details of material dimension and paint etc. shall be
submitted.
9.1.8.3 All the required type test reports for offered items tested at any Government
recognized Laboratory as stated under Cl. 1.6.1(b).
10.0 TECHNICAL SPECIFICATION OF UNARMOURED 1100 VOLTS ALUMINIUM
L.T. PVC INSULATED AND PVC SHEATHED CABLES 3 CORE 25 mm
2
, 50
mm
2
, 70 mm
2
and 150 mm
2
(to be supplied by bidder)
I. APPLICABLE STANDARD:
(1) IS:1554 (Part-D/1988 (For Cable)
(2) IS:10462 (Part-I)/1983 (For Cable diameters)
(3) IS: 5831/1984 (For PVC Insulation / Sheath)
(4) IS : 8130/1984 (For Aluminium Conductor)
(5) IS: 10418/1982 (For Wooden Drums)
(6) IS: 10810/1984 (Methods of test for Cables)
58
(7) IS: 10462 (Part-I)/1983 (Factitious calculation
method for determination
of dimensions of protective
covering of Cables.)
The IS applicable shall be latest amended / revised IS in force on date of tender for tender
submission. The acceptance test are to be carried as per latest amended / revised IS in force
on date of inviting tender for supplies against the order.
II. TECHNICAL PARTICULARS:
(a) The LT PVC cables shall be unarmored PVC insulated and sheathed with shaped stranded
aluminium conductor for earthed neutral system conforming to IS:1554 (Part-l) / 1988 with latest
amendment or revision if any. The cable shall be ISI marked and shall have characteristics suitable
for voltage rating of 1100V in standard length as mentioned below.
(b) Insulation and Sheath:
The type of insulation shall be type A as per IS:5831 of 1984 with latest amendment
/ revision if any. The type of sheath shall be type ST-I as per IS:5831 of 1984 with
latest amendment / revision if any.
(c) Colour of insulation of each core as specified in IS.
(d) Colour of outer sheath shall be yellow only.
(e) Colour of inner sheath shall be black.
11.0 TECHNICAL SPECIFICATION OF 1100 VOLTS COPPER / ALLUMINIUM
CONTROL / L.T. PVC - INSULATED AND P.V.C. SHEATHED CABLES OF
DIFFERENT CORE AND SIZES. (To be supplied by Bidder)
I. SCOPE:
This specification covers manufacture, testing at works, supply and delivery at any place in Gujarat
of armoured 1100 Volt grade P.V.C. Insulated and P.V.C. Sheathed Cables with Copper Conductor
for Control Cables and aluminium conductor for L.T. Power Cable.
II. APPLICABLE STANDARD (WITH LATEST AMENDMENTS)
(a) IS: 1554 (Part-I) 1988: For Cable
(b) IS : 5831 / 1984 : For Insulation / Sheath
(c) IS : 8130 / 1984 : For Copper & Aluminium
(d) IS : 10418 / 1972 : For Wooden Drums
(e) IS : 3975 / 1979 : For Armouring
(f) IS : 3961 : For Current rating
The design, manufacture and performance of the Cables shall comply with the above
applicable standards.
59
IV. PARTICULARS:
(a) The Cables shall be armoured PVC insulated and sheathed with circular / shaped,
copper / aluminium conductor for earthed neutral system conforming over-all to IS :
1554 (Part - I) 1988 with latest amendments. The cable shall be ISI marked and
shall have characteristics suitable for voltage rating of 1100V in a specified standard
lengths, prescribed under Cl No VI hereunder:
(b) Insulation & Sheath:
(i) The Insulation of each core shall comply with Type A of IS : 5831 / 1984.
(ii) The outer and inner sheath shall comply with Type STI of IS: 5831 / 1984.
(c) (i) Colour scheme for core identification shall be followed as per
relevant IS Specification
(ii) Colour of outer and Inner Sheath shall be black only.
(d) Armouring:
The type of armoring for all sizes of Cable shall comply with the requirements of relevant
IS Specification. Hot dipped galvanized armoring strips/round wire shall comply with
relevant IS Specification and should bear I SI certification mark.
(e) Conductor:
Copper / Aluminium Conductor should comply with IS : 8130 1984 and should bear ISI
mark.
Copper Conductor should be made of electrolytic grade annealed, stranded, high
conductivity copper comply with IS : 8130 Class 2.
The Grade of aluminium shall be (a) H2 & Class l / Class 2, for sizes up to 10 sq. mm
and (b) H4 & Class 2, for sizes 16 sq. mm. and above conforming to IS : 8130 84 with
latest amendments if any.
VI. STANDARD & NON-STANDARD LENGTH:
(i) All Copper Cables shall be supplied in standard length of 500 meters.
(ii) All aluminium Cables up to the size of 50 sq. mm shall be supplied in standard
length of 500 mtrs.
(iii) All aluminium Cables above 50 sq. mm size may be supplied in standard length of
250 meters.
(iv) + 5% Tolerance in standard length for all types and sizes will be
acceptable.
VII. Type A: Acceptance Routine Tests:
The following shall constitute the Type Tests for each offered sizes of cable.
(a) Test for Conductor:
(i) Annealing Test (for copper)
(ii) Tensile test (for aluminium)
(iii) Wrapping test (for aluminium)
(iv) Conductor resistance test (for both)
(b) Test for armouring wires / strips (for both)
(c) Test for thickness of Insulation and Sheath (for both)
60
(d) Physical tests for insulation and outer sheath (for both)
(i) Tensile strength and elongation at break.
(ii) Ageing in air oven.
(iii) Shrinkage test.
(iv) Hot deformation.
(v) Loss of mass in air oven.
(vi) Heat shock test.
(vii) Thermal stability
(e) Insulation resistance test (for both)
(f) High voltage test (Water impression test) (for both)
(g) High voltage test at room temperature (for both)
(h) Flammability test (for both)
The following shall constitute the acceptance tests for specification, number of samples
recommended in relevant specification of entire quantity, offered in a lot, as per discretion
of the inspection authority:
(a) Annealing Test (for copper)
(b) Tensile test (for aluminium)
(c) Wrapping test (for aluminium)
(d) Conductor resistance test (for both)
(e) Test for thickness of Insulation and Sheath (for both)
(f) Tensile strength and elongation at break of insulation and sheath (for both)
(g) Insulation resistance test (for both)
(h) High voltage test at room temperature (for both)
(i) Optional tests if any described in relevant standard (for both)
The following shall constitute the routine tests:
(a) Conductor resistance test.
(b) High Voltage test at room temperature.
SCHEDULE A
Sr.
No.
Description of Materials Quantity Required /
KMs
(A) 1100 Volts Grade multi core control cable with
annealed stranded high conductivity copper conductor,
colour coded PVC inner sheathed, hot dip galvanized
armoured PVC Jacketed overall confirms to IS : 1554
(Part I) 1988 latest edition and should bear ISI
Marking in following size :
(1) 2 core x 2.5 mm
2
(2) 4 core x 2.5 mm
2
(3) 7 core x 2.5 mm
2
(4) 12 core x 2.5 mm
2
(5) 19 core x 2.5 mm
2
(6) 27 core x 2.5 mm
2
(7) 4 core x 4 mm
2
61
(8) 12 core x 4 mm
2
(B) PVC 1100 Volt grade stranded sector shaped circular
aluminium conductors PVC Insulated cores laid up,
PVC extruded inner sheathed with single layer of hot
dip galvanized steel strip armoured and overall PVC
sheathed Power Cable conforming to IS : 1554 / 1988
(latest edition).
(1) 2 core x 10 mm
2
(2) 3 core x 25 mm
2
(3) 3 core x 50 mm
2
(4) 3 core x 150 mm
2
IMPORTANT NOTES:
(1) Standard length of 500 mtrs. + 5% shall only be acceptable for items up to 50 sq.
mm size. Above 50 sq. mm. Standard length of 250 meters + 5% may be supplied.
(2) Non-standard length will not be acceptable.
(3) Type of armouring for all sizes of cable shall comply with the requirements of I. S.
specification.
(4) All cable shall bear ISI Marking as per I.S. Standard.
(5) Wooden drum shall be supplied as per IS : 10418 / 1972.
(6) In Schedule A (B) Item No.1 shall comply with IS : 1554 / 1988 with latest
amendment and the Conductor shall be solid aluminium of H2 grade Class I,
Circular in shape, complying with IS : 8130 of 1984.
(7) In Schedule A (B), Item No. 2, 3 & 4 the conductor shall be H4 Grade / Class
2 as per RECs specification, shape stranded (not solid) aluminium conductor.
12.0 TECHNICAL SPECIFICATION OF BATTERY CELLS 220V, 250 AH ( SEALED
MAINTENANCE FREE TYPE /Ni Cd TYPE ) :
12.1.1 The DC battery shall be stationary Lead Acid sealed maintenance free type (with plate or
Tubular Positive plates) for standby duty. Tubular type batteries shall be Normal
Discharge type and plate type batteries shall be high discharge type. These Batteries shall
be suitable for a long life under continuous float operations at 2.15 to 2.25 volts per cell
and occasional discharges.
OR
Alternatively bidder can offer stationary Ni-Cd type battery. The battery should conform
to international standard and IEC requirements for construction, installation and
performance.
62
12.1.2 GENERAL REQUIREMENT:
(i) The batteries shall be of the capacity 220 Volts, 250 AH
(ii) Battery of 220V, 250 AH rating shall consist of 55 numbers of series connected
HDP sealed lead acid cells of 2 volts 250 Ampere hours capacity at 10 hours
discharge rate.
(iii) The battery offered as per Cl. 3.1 shall be stationary lead acid sealed type with high
discharge performance (HDP) confirming to IS: 1651 and other relevant IS for
sealed lead acid type, suitable for Indoor operation.
12.1.3 CHARGE RATE:
Fully discharged batteries should get recharged at 10 Amps. Rate for 10 hours at
room temperature. The trickle charge rate shall be 50 100 mA.
12.2 All materials used shall be free from flaws and defects and the battery assembly shall be
complete in all respects.
12.3 All cell terminals shall have adequate current carrying capacity and shall be of lead
alloy or lead alloy reinforced with copper core inserts. Cell terminals post shall be
equipped with connection bolts having acid resisting nuts.
12.4 Containers shall be made of glass or hard rubber or suitable plastics. Containers shall
be robust, heat resistant, leak proof, non-absorbent, acid resistant, and free from
flaws. Glass containers shall be transparent. Electrolyte level lines shall be marked
on container in case of transparent containers. Float type level indicator shall be
provided in case of opaque containers. The marking for the electrolyte level should
be for the upper, normal and lower limits. The materials of level indicator shall be
acid-proof and oxidation proof.
12.5 Vent plugs shall be provided in sealed type cells. They shall be of anti-splash type
having more than one exit hole and shall allow the gases to escape freely but shall
prevent acid from coming out. Open type cells shall be provided with suitable
arresters to prevent spilling of electrolyte.
12.6 The plates shall be designed for maximum durability during all service conditions
including high rate of discharge and rapid fluctuations of load. The construction of
plates shall confirm to latest revision of IS : 1651 or IS : 1652 as applicable. The
separators shall maintain the electrical insulation between the plates and shall allow
the electrolyte to flow freely. The positive and negative terminal posts shall be
clearly marked.
12.7 Sufficient sediment space shall be provided so that cells will not have to be cleaned
out during normal life.
12.8 Each cell shall be separately supported on porcelain or hard rubber insulators fixed
on to the racks with adequate clearance between adjacent cells.
63
12.9 The electrolyte shall be prepared from battery grade sulphuric acid confirming to IS :
226 and distilled water confirming to IS 1069. The cells shall be shipped dry and
uncharged. The electrolyte for the initial filling shall be furnished separately. A
minimum of 10% extra electrolyte shall be provided for the initial filling.
12.10 The name plate on the battery shall indicate the following :
i) Serial number along with year of manufacture.
ii) Manufacturers type designation.
iii) AH capacity at 10 Hours discharge rate.
iv) Upper and lower electrolyte level in case of transparent containers.
12.11 Lead or lead coated connectors shall be used for connecting up adjacent cells, rows
and end take off. Bolts. nuts and washers shall be effectively lead coated to prevent
corrosion. End take off connectors shall be provided for end connections from
positive and negative poles of the batteries to the cable. The cable will be single
core having standard aluminium conductor and PVC insulated. Necessary wooden
supports and lugs for termination of these cables on batteries shall also to be
provided. All connectors and lugs shall be capable of continuously carrying the 30
Minutes discharge current of the respective batteries.
12.12 Battery racks shall be made of FRP and shall be freestanding type mounted on
porcelain/hard rubber insulators. The racks shall be rigidly supported and anchored.
Numbering tags for each cell shall be attached on to the battery racks.
12.13 ACCESSORIES:
The bidder shall supply the battery with accessories and devices as stated here
under:
(i) Battery stands constructed out of FRP. The construction of the stand shall be
suitable for mounting on a flat concrete floor. The stand shall be rigid, freestanding
type and free from wrap and twist.
(ii) Set of inter cell and inter tier connectors as required for the complete installation.
(iii) Set of stand insulators and cell insulators.
(iv) Hydrometer syringe capable of indicating specific gravity reading in steps of 0.005.
The hydrometer shall be complete with wall mounting teak wood holder.
(v) One 3 0 3 V DC voltmeter with suitable leads for measuring cell voltage.
(vi)One filler hole thermometer (Gravity correcting scale).
(vii) Electrolyte for first filling + 10% extra in non-returnable containers.
(viii) Cell number plates and fixing pins.
64
(ix) Rubber syringe.
(x) Two acid resisting jugs of adequate capacity
(xi) Two acid resisting funnels.
(xii) Five nos. of dry uncharged extra cells.
(xiii) Any item not specified above but which is needed for maintenance and efficient
working of batteries may be quoted separately as optional / extra.
12.14 The bidder shall state the following values (in Guaranteed Technical Particulars
Appendix - I of the Specification), which shall be guaranteed.
1) Normal charging rate
2) Starting charging rate
3) Finishing charging rate
4) Trickle charging rate
5) Discharging rate on 3 minutes basis in Amp. at end voltage 1.85 V / Cell must be
specified by supplier
13.0 TECHNICAL SPECIFICATION OF 220V BATTERY CHARGER ANDLV PANEL.
13.1 BATTERY CHARGER: SCOPE :
13.1.1 This specification provides for Design, Manufacture, Testing at works and Supply
of the complete Battery Charger for :
(i) Single phase charger for 220V, 250 AH, Batteries
13.2 APPLICABLE STANDARDS:
13.2.1 The design, manufacture and performance of the equipment shall comply with all
currently applicable standards, regulations and safety codes. Nothing in this
Specification shall be construed to relieve the Bidder of their responsibility.
13.2.2 Unless otherwise specified, the battery charger shall confirm to the latest applicable
Indian / IEC standards and in particulars to the following standards.
a) IS-3895 - Specification for rectifier equipment in
general
b) IS-2208 - Specification for HRC fuses.
c) IS-1248 - Specification for Indicating Instruments.
d) IS-2147 - Degree of protection for cubicles
e) IS-375- - Specification for wiring
f) IS-4540 - Mono crystalline semiconductor rectifier
Assemblies and equipment
g) IS-6619 - Safety code for semi conductor rectifier
equipment.
h) IS-2026 - Transformers
65
i) IS-2959 - A.C contactor for voltages not
exceeding 1000V
j) IS-6005 - Code of practice for phosphating of Iron
and Steel.
k) IS-5921 - Printed circuit boards.
l) IS-249 - Printed circuit boards
13.2.3 The bidder shall clearly state the Standards to which the equipment offered by him
conforms.
13.3 CONSTRUCTION:
i) It will be indoor, freestanding, floor mounting and naturally air cooled type,
designed for continuous operation in the ambient temperature of 50
o
C. A
good ventilation shall be made through side louvers.
ii) Each charging equipment offered shall be housed in a sheet steel cubicle
reinforced by angle iron frame and shall be mechanically strong. The cubicle
shall be dust and vermin proof. The rear and front door cover of the cubicle
shall be hinged and shall have locking arrangement. Thickness of sheet steel
shall be 2 mm for load bearing members and 1.60 mm for other sides.
iii) All the accessories and equipment shall be of adequate rating to suit the
above requirements.
iv) Gland plate : Gland plate for incoming / outgoing cables shall be provided.
Earthing with two separate earthing terminals shall also be provided.
v) Dimensions of the charger shall be as near as possible of the following:
N Width 1200 mm x Depth 450 mm x Height 1400 mm for 220V, 250 AH
Battery charger (Single phase).
vi) All the door mounted equipment as well as equipment mounted inside the
cabinet shall be provided with individual labels with equipment description
engraved.
vii) Electrical indicating instruments shall be flush mounted on the panel with only
flange projecting. The dial shall be white with black numbers and lettering.
viii) The electronic control circuitry should have built in feature of soft start so that
whenever the charger is switched on, the output voltage should increase gradually.
13.3.1 FINISH:
Each cubicle will undergo a through process of de-rusting, cleaning, application of
red oxide primer paint followed by the coats of light grey synthetic enamel paint
shade 631 of IS: 5.
66
13.3.2 WIRING:
All chargers will be complete with internal wiring and input and output terminals.
The components shall be liberally rated. Standard colour code practice shall be
followed, with the use of ferrule for numbering and identification of wires. PVC
copper conductor of suitable size shall be used. All hardware such as screws nuts,
studs, washers shall be of brass and no ferrous parts shall be used in electrical
circuitry control / power.
13.4 RATINGS:
13.4.1 The charger for 220V batteries (consisting of 110 Nos., 2 Volts Nicad cells) shall
have following output ratings.
(a) 220 V, 250 AH Battery charger (Three phase):
(i) Trickle charge and load current ratings:
10/30 Amp. Between 234 V to 252 V D.C.
(ii) Boost charging current rating :
50 Amps. Between 198 V to 296 V D.C.
13.5 DUTY:
13.5.1 The composite charger shall consist of two separate chargers, viz. The float charger
and the boost charger. The charger shall be required to cater the following
requirements.
13.5.2 The float section of the charger shall be of fully automatic type during operation on
Auto mode. However necessary provisions of manual operation control shall also be
provided in addition to auto control with required auto / manual selector switch and
circuit etc., in the event of failure of auto control.
13.5.2.1 Normally the float charger shall operate in parallel with the 220 Volts, battery and
the load. The float charger shall supply the DC loads of the sub-station and also
provide the trickle charge for keeping the battery floating totaling up to full
capacity. For this condition, the float charger shall be designed to float charge the
110 cells between 234 V to 296 V and supply DC load of the sub-station, keeping
the load bus-bar voltage between 220 V to 252 V. Hence the float charger shall have
adequate capacity to meet the above demand at constant voltage.
13.5.2.2 The float charger shall supply the DC output voltage as specified in Cl. 13.5.2.1
with + / - 1% stability of adjusted value for AC fluctuations as specified at Cl. 6 of
the Specification and for DC load variation from zero to 100% load.
13.5.3 During emergency, when the AC supply fails, the battery shall meet the DC load of
the sub-station and in doing so, will get discharged gradually. The battery will need
boost charging, for which, a separate charger, called the boost charger shall be
required.
67
13.5.3.1 Boost charger shall have adequate rating to quick charge the battery fully within 10
hrs. after an emergency during which the complete DC load is met by the battery.
13.5.3.2 While boost charging the battery, the charger may also be called upon to supply the
DC load of the sub-station incase of float charger failure. Based on the condition of
the battery, it shall be possible to set the boost charging voltage between 198 V to
296 V for 110 cells with a total output current between zeros to full load capacity of
the charger with the voltage on the load bus bar not exceeding 252 volts. The
required dropper diodes shall be provided to restrict load bus bar voltage not
exceeding 252.0 volts DC.
13.5.3.3 Boost charger shall incorporate static components comprising silicon-controlled
rectifiers with necessary protection. Boost charger, apart from normal constant
current operation shall also be capable of constant voltage operation which shall
enable it to operate as a float charger delivering stabilized DC output voltage within
+ / - 1 % from no load to full load in case of float charger failure. Suitable electrical
circuitry shall be provided for this purpose. In the constant current mode it shall
have a current stability of +2% of the set value. The constant current setting shall
have step less range from 10 % to 100 % of full rated current. Further, the boost
charger shall have a provision for manual mode of operation, over and above auto
mode of operation. Required circuitry arrangement with auto / manual selector
switch etc. shall also be provided for the purpose.
13.5.3.4 The boost charger and the float charger shall be so interlocked electrically that
during boost charging of the battery, the float charger will supply the DC constant
load without supplying to the battery, and at the same time will be in parallel with
the battery through a reverse current blocking diode at a suitable tapping. One DC
contactor may be incorporated which shall get engaged through N/C contact of the
contactor on AC side of the boost charger. In case of failure of AC supply, this
contactor shall connect the entire battery supply to the load through one of its N/O
contacts automatically without any interruption of DC supply even of a momentary
nature. Under no circumstances the voltage across lower tapped terminals shall
exceed (+) 10% or fall below (-) 15% of the rated voltage.
13.5.4 LOAD LIMITING:
13.5.4.1 The charger shall be provided with load limiting feature for protection against over
load. The load limiting curves shall be submitted with the offer. The SCRs /
thyristors shall be protected against voltage surges by providing voltage suppressor
devices.
13.6 INCOMING SUPPLY:
13.6.1 220 V, 250 AH Battery Charger (Three Phase) :
Incoming AC supply of 440 Volts, 50 Hz, Three phase for float and boost charger
shall be available.
13.6.2 The variation in the incoming AC supply shall be + 10% and - 15% for voltage and
3% in frequency, which may occur simultaneously.
68
13.7 CHARGER OUTPUT:
13.7.1 Suitable ripple filtering circuits shall be provided to give a smooth DC output. The
ripple content, without the battery connected shall be limited to less than 5% on
resistive load. The DC output shall be free from switching surges, transients, etc.
13.8 SPECIFIC PROVISIONS:
As specified in Clause - 4, the composite charging equipment shall have a separate
float charger and a boost charger. Each charger shall consist of the following
components and components shall be of the best quality and bill of materials along
with rating of the same shall be submitted invariably with the offer.
13.8.1. Float Charger (Single Phase) :
1) Three phase AC input on / off main switch (rotary type)
2) AC input HRC fuse of required capacity
3) Indicating lamp for AC supply ON indication (after main AC fuse) with
series resistor.
4) Double wound impregnated naturally air cooled single phase transformer
with taps at normal, -15% and +10 % on primary side with necessary
secondary tapes for achieving required control of DC output voltage.
5) Full wave half controlled rectifier bridge comprising of silicon diodes and
silicon controlled rectifiers (SCR) with R/C surge suppressor net work and
suitable heat sink along with free wheeling diodes and semi conductor fuse
protection.
6) Ammeter for measuring DC output current of float charger (0 30 Amps.).
7) Auto / manual mode selector switch.
8) Potentiometer for controlling DC output voltage in auto and manual modes.
9) Suitable filter circuit comprising filter choke, filter condenser with HRC fuse
protection and bleeder resistor.
10) Blocking diode with suitable heat sink.
11) DC output ON / OFF switch.
12) DC output fuse (HRC).
13) DC ON indicating lamp with series resistor.
14) Any item not specifically mentioned, but which is needed basically for
efficient working of the equipment.
13.8.2 Boost Charger (Single Phase)
1) Three phase AC input ON / OFF main switch.
2) AC input HRC fuse of required capacity
3) Indicating lamp for AC supply ON indication (after main AC fuse) with
series resistor.
4) Double wound impregnated naturally air cooled single phase transformer
with taps at normal, -15% and +10% on primary side with necessary
secondary tapes for achieving required control of DC output voltage.
5) Full wave half controlled rectifier bridge comprising of silicon diodes and
silicon controlled rectifiers (SCR) with R/C surge suppressor net work and
69
suitable heat sink along with free wheeling diodes and semi conductor fuse
protection.
6) Ammeter for measuring DC output current of float charger (0 - 50 Amps.).
7) Auto / manual mode selector switch.
8) Constant current constant voltage mode selector switch.
9) Potentiometer for adjustment of constant current in boost mode.
10) Potentiometer for controlling DC output voltage in float mode (auto and
manual modes).
11) Suitable filter circuit comprising filter choke, filter condenser with HRC fuse
protection and bleeder resistor.
12) Thermal relay for overload protection.
13) Blocking diode with suitable heat sink.
14) Double pole DC output ON / OFF switch.
15) DC output fuse (HRC).
16) DC ON indicating lamp with series resistor.
17) Dropper diode scheme ON / OFF switch.
18) Dropper diode selector switch with minimum four position.
19) Diodes for diode dropper scheme (minimum 28 nos.).
20) Any item not specifically mentioned, but which is needed basically for
efficient working of the equipment.
13.8.3 Common Components (Three Phase Charger)
1) DC Voltmeter, double pole 4 position rotary type to measure DC voltage
across float section, boost section, load and battery with HRC fuse
protection.
2) AC voltmeter to measure the AC input voltage with suitable fuse link and
selector switch arrangement.
a) Range 0 - 500V for Three phase charger.
3) DC charge / discharge ammeter with suitable shunt to read discharge /
charge current of the battery.
a) Range 50 0 50 A for single phase charger.
4) Ammeter (range 100 0 100 mA) showing the earth leakage current of the
charger & out going circuit (load side).
5) Space heater with thermostat and lamp for internal lighting with ON / OFF
switch for each separately and required fuses.
6) Detachable cable gland plate for cable entry from bottom.
7) DC contactor interlocked with boost charger AC contactor.
8) Silicon blocker diode with suitable heat sink to be connected to a suitable
tapping of battery to maintain DC continuity during power failure while
batteries are on boost charge.
9) Three pin socket with switch and fuse.
70
13.9 OUT GOING CIRCUITS:
The following out going circuits comprising of a double pole ON OFF rotary
switch, HRC fuses and indicating lamps with series resistor shall be provided. The
separate DCDB shall be provided with battery charger which shall include all Dc
distribution feeders stated below.
Three phase charger
1) 30 Amps. Feeder : 4 Nos.
2) 20 Amps. Feeders : 6 Nos.
3) 10 Amps. Feeders : 4 Nos.
13.10 PROTECTION:
Following protections with alarm indicating lamps and alarm accept push button
and lamp test push button shall be included in the scope of supply.
a) Three Phase Charger
1) Load under voltage relay.
2) Earth leakage relay
3) Float charger failure
4) AC mains failure
5) DC over voltage relay for battery protection.
6) Single phasing preventor
13.11 Looking to the detailed description of duty requirements of both the charger and the
battery, the manufacturer shall design a circuit which shall be capable of providing
complete protection to various components of the unit and automatic i.e. with
automatic voltage regulator in the float circuit operation of the unit without
interruption.
13.12 Necessary product information booklet, drawings, circuit diagrams, operation and
maintenance manuals, type test certificates, experience certificate etc. should be
submitted along with the offer.
13.13 TESTING:
13.13.1 The following test shall be carried out by the manufacturer on each battery charger,
in the presence of the Boards Representative.
1) Visual inspection and dimensions.
2) Checking of wiring and continuity of circuits.
3) Insulation resistance.
4) H. V. break down test.
5) Ripple content measurement.
6) No load test.
7) Load test.
8) Operational test for protection, alarm, indication.
9) Auto / manual operation test.
71
13.14 Three sets of each of the detailed dimensional drawings, commissioning and
operating instructions manual, literature, write up and test certificates of the
manufacturer shall be supplied with each of the battery charger.
13.15 PACKING AND MARKING:
13.15.1 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.
13.15.2 Specifications for 350AH 52 V battery set for PLCC will be same as 250AH battery set
except total cell requited will be 26 of 2.0Vand that of 30A charger for PLCC will be
same as 220 V chargers except out put voltage will be 52V DC and 30A rating.
13. 16 TECHNICAL SPECIFICATION FOR L.T. SWITCH BOARD:
13.16.1 SCOPE:
This specification covers the design, manufacture, assembly, testing at
manufacturers works, supply and delivery of L.T. distribution boards, as detailed in
Schedule of Requirements with all accessories required for complete installation.
13.17 STANDARDS:
The design, manufacture, identification, installation, testing and commissioning of
the equipment and materials covered by this specification shall confirm to the latest
editions (amended upto date) of the following standards unless otherwise stated in
this specification.
1.
IS : 3043
- Code of practice for earthing.
2. IS : 4237 - General requirements for switchgear and
control gear for voltage not exceeding
1000 volts.
3. IS : 2147 - Degree of protection provided by
enclosures for L.V. switchgear.
4. IS : 375 - Marking and arrangements for switchgear
bus-bars, main connections and auxiliary
wiring.
5. IS : 2208 - H.R.C. Cartridge fuses.
6. IS : 1554
Part-I
- PVC Insulated cables.
7. IS : 3016 - Code of practice for selection installation
72
and maintenance of fuses (voltage not
exceeding 650 volts).
8. IS : 732 - Code of practice for electrical wiring
installation (system voltage not
exceeding 650 volts).
9. IS : 3646 - Code of practice for interior illumination
Part-I and II.
10. IS : 694 - Specification for PVC Cables and codes
for electrical power and lighting for
working voltages upto and including 65
volts to earth.
11. IS : 1567 - Specification for metal clad switches
(current rating not exceeding 100 Amps.)
12. IS : 1913 - General and Safety requirements.
13. IS : 4047 - Specification for heavy duty air-break
switches and composite units of Air-
break switches and fuses for voltages not
exceeding 1000 volts.
In addition to the above, the L.T. switchboard cubical shall meet all applicable
Indian Electricity Rules. Fire Insurance regulations and other local statutory codes.
All requirement and its components shall be new and of superior quality in all
respects. All works shall be done with a neat workmanship acceptable to the GEB.
13.18 GENERAL DESIGN OF SWITCH BOARD CUBICLE:
13.18.1 The L.T. Switch board cubicle shall be of metal clad, totally enclosed, sheet steel
cubicle, indoor floor mounting and freestanding type. It shall be completely dust-
tight, weather and vermin proof and highly corrosion-resistive. Effective rubber
gasketting shall be provided between adjoining surfaces of the doors and covers to
make the switchboard dust-tight and vermin proof.
13.18.2 The sheet steel parts shall be subjected to finishing process of chemical degreasing,
pickling, phosphate coating, a primer coat and finally a two tone finishing shall be
73
given by using two shades of synthetic enamel i.e. light battle shed gray paints of
Narolac. The finishing shall be elegant and enduring. The colour scheme shall be
subject to GEBs approval.
13.18.3 The L.T. Switch board shall be of unit type in construction compact in size and neat
in appearance. They shall be capable of being easily extended an either side and
shall have a high degree of flexibility. The design of feeder units shall be such as to
minimise the floor area required. The overall dimensions of the L.T. Switchboard
cubicle shall be as near as possible but not less than the following width-1600mm,
Height 2000mm and width 350 mm, with H 10mm tolerance.
13.18.4 The feeder units shall be arranged individual compartments in vertical section and a
vertical wire way shall be provided to accommodate all control cables. Wire way
shall be so designed that even if the doors of wire way is opened, there is no access
to the bus bars. The wiring layout shall be planned for easy screw and quick circuit
tracing. Wiring shall be properly bunched and arranged in such 3 way that there
shall be no sag. Each compartment shall be covered with sheet steel hinged door
having rounded edges and maintenance to be carried out from the front. Inspection
as well as maintenance shall be done safely and easily without effecting the other
feeders. All switches and switch fuse units shall be front operated type and shall be
interlocked with the hinged doors. The sheet steel used shall be not less than 2mm
thick for all sides.
13.18.5 The bus-bars shall be of copper arranged vertically supported by liberally designed
non hygroscopic insulating plates. The manufacturer shall describe in details, the
merits of arrangement of bus-bars proposed by him.
13.18.6 The cable box chamber shall have adequate space to accommodate cable boxes,
glands packing glands and incoming and outgoing power and control cables.
Outgoing feeder terminals shall be brought out into the cable box chamber for easy
connection of cables. Rose courtn any copper lugs type terminal arrangement
according to the rating at the feeders and associated cable shall be provided. Cable
entries shall be arranged from bottom.
13.18.7 Earthing bus-bars of copper of adequate size shall be provided running through the
entire length at the bottom of each control center. Two clamps type terminals one at
each end of the panel shall be provided on the ground bus suitable for connection
125mm2 stranded copper cable for grounding.
74
13.18.8 Adequate illumination shall be provided for interior of the cubicle however it is
necessary.
13.18.9 Indicating instruments (viz. Voltmeter Ammeter) lamps (for supply ON
indication) shall be mounted on the front, on the outgoing side of the main incoming
switch. Ammeters and voltmeters shall be of flush mounting type and preferably of
96x96mm size. The switchboard panel shall be completely factory wired ready for
connecting to the GEBs equipment. Nameplate with required details shall also, be
provided on the front.
13.18.10 Wiring shall be done with PVC copper conductors suitable size.
13.18.11 KWH:
Static KWH meters shall be 31, 4W, 415V, 50Hz suitable for unbalanced load shall
be as per Annexure - I. It shall be provided with five digital type dial arrangement.
The meters are required for colony supply and station supply 1 No. each.
...1 Current Transformers: Ring Type tap insulated.
i) C.T. shall be ring type, tap insulated as per IS-2705 of latest version.
ii) C.T. shall have a short circuit current 3.0 KA (RMS) for 1.0 second and
dynamic peak current 7.5 KAP (shall not be less than 2.5 times rated thermal
current).
iii) The C.Ts. shall have following characteristics:
a)
No. of core
: One for metering.
b) Class of Accuracy : 0.5
c) Burden : 10 W
d) ISF : 5
e) C.T. Ratio
(Primary/secondary
current).
: 400/5 Amp.
f) Rated service voltage : 660 volts
75
g) Frequency : 50 Hz
h) One minute P.F. voltage
withstand test on winding
: 3KV (RMS) for 1.0 minute
i) Tests : All routine and type tests as
per IS-2705 of latest version
(Manufacturers test
certificates are required to
be submitted by successful
tenderers).
...2 C.Ts. : Required formetering and instrumentation shall be within the scope of
supply. All wiring required for current and potential terminals of the C.T.
operated KWH meter.
Note : Each C.Ts. shall have sleeved secondary heads with tinned copper
crimpling pins of required length for connecting directly to KWH meter
of the L.T. Panel.
13.18.12 MAIN BUS:
The main bus-bar shall be rated for 600 Amps. continuous current. The short circuit
and short time current ratings shall correspond to that of the associated switch fuse
units. All bus-bar connections shall be silver plated and the bus-bar high
conductivity copper. Bus-Bar shall be suitably insulated by means of insulating
tapes / compound. The chemical and electrical characteristics of the insulating tap
compound shall be clearly brought out in the tender. The temperature of bus-bar and
bus-bar connections when carrying rated current at rated frequency shall not exceed
90
0
C for a maximum ambient temperature of 50
0
C.
13.18.13 SWITCH FUSES:
Switch fuses shall be 3 pole units for A.C. capable of breaking of the associated
circuit. Switches shall be quick make and quick break design. Switch contacts shall
be silver plated and contact spring shall be of stainless steel. Compartment doors
shall be interlocked with the operating handle of the switch so as to prevent opening
of the door when the switch is closed. Switch handles shall have provision for
locking in both fully open and fully closed position.
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Fuses shall be H.R.C. type. The shall be provided with visible indicators to show
that they have operated the final steady state temperature of the fuse link contacts
when carrying their rated current shall not exceed 100
0
C. The fuse rating shall be
according to the load of the circuit.
13.19 TESTS:
13.19.1 Routine tests shall be performed in compendia of relevant ISS to ensure that the
equipment comply with the requirements of this specification and type tests shall
also, be carried out if so desired, by the GEB.
13.19.2 The test certificates shall be submitted to the GEB for his approval prior to the
dispatch of the equipment.
13.20 DRAWINGS:
13.20,1 Drawings in triplicate incorporating the following particulars shall be submitted by
each tenderer with the tender to the GEB for preliminary study.
a) General outline drawing showing dimensions, weights etc. of L.T. Switchboard.
13.20,2 The tenderer may submit any other drawings found necessary in addition to the
drawings stated above.
13.20.3 On receipt of order the supplier shall have to get approval on the following
drawings.
1) G.A.D. showing front, elevation and plain of the switchboard with detailed
dimensions (Dimensions shall be in metric units).
2) Detailed drawing of mounting arrangement.
3) Outline drawing of internal wiring and cabling arrangement.
13.21 FEEDERS:
13.21.1 The switch board
Panel suitable for A.C. system voltage off 500V, 3-1, 50 Hz. shall comprise of the
following feeders:
i) 400 Amps. Rated incoming switch fuse unit feeder having 400 Amps. Quick
make quick break switch unit with 3 Nos. 400 Amps. H.R.C. fuses and a
77
neutral link complete with cable box suitable for 3 cores, 300mm
2
PVC
cable lamps indicating supply (ON) position shall also be provided.
ii) 100 Amps. rated 2-outgoing switch fuse unit feeders (T.P.) each having 100
Amps. quick make quick break switch fuse unit equipped with 3 Nos.
100Amps. H.R.C. fuses and complete with glands suitable for PVC cable.
iii) do- but 200 Amp. rated 1-outgoing switch fuse unit feeder (TP), having 200
Amp. switch fuse unit with glands, HRC fuses etc.
iv) 60 Amps. rated 6 outgoing switch fuse unit feeders (TP) each having
60Amps. quick make quick break switch fuse unit equipped with 3 Nos. of
60 Amps. H.R.C. fuses and complete with glands suitable for PVC cable.
v) 60 Amps rated, 2 outgoing switch fuse unit feeder (TPN) each having 60
Amps. quick (make quick break switch fuse unit with 3 Nos. of 60 Amps.
H.R.C. fuses and a neutral link complete with glands.
vi) 30 Amps. rated 6 outgoing single phase neutral feeders each having
30Amps. switch fuse units equipped with suitable H.R.C. fuses and complete
with glands for PVC cable.
15 Amps. rated, 4 outgoing single phase neutral feeders each having 15 Amps.
switch fuse units equipped with suitable H.R.C. fuses and complete with glands for
PVC cable.
SCHEDULE OF REQUIREMENT
Sr.
No.
Description of equipment
Quantity
1. Metal clad, sheet steel L.T. Switch Board,
cubicle, indoor floor mounting totally
enclosed dust and vermin proof, suitable
for 31-4wire, 500 volts, 50Hz A.C.
equipped with 600 Amps. bus bars
chamber comprising of following :
2. INCOMING :
i) 400 Amps. Rated incoming TPN
78
feeder unit with 500Amp. rated
quick make, quick break switch
fuse unit equipped with 400Amps.
H.R.C. fuses natural links and
complete with suitable cable box
and glands.
3. OUTGOING:
i) 200 Amps. Rated outgoing switch
fuse unit feeder (TP) having 200
Amp. quick make quick break
switch fuse unit equipped with 3
Nos. 200Amp. HRC fuses and
complete with glands for PVC
cable.
ii) dobut 2-100Amps. rated
outgoing switch fuse unit feeder
(TP)
iii) 60 Amps. rated outgoing TP feeder
unit with quick make, quick make,
quick break front operated switch
equipped with 3 Nos. 60Amps.
H.R.C. fuses and complete with
glands suitable for PVC cable.
iv) dobut 2-60Amps. rated switch
fuse unit feeder (TPN) with gland,
neutral link and HRC fuses etc.
v) 30 Amps. rated, single phase
neutral outgoing (SPN) feeder unit
equipped with 30Amps. suitable
H.R.C. fuses and complete with
glands suitable for PVC cable.
79
vi) 15Amps. rated single phase neutral
outgoing (SPM) feeder unit
equipped with 15A H.R.C. fuses
and a gland suitable for PVC Cable.
14.0 SWITCHYARD ACCESSORIES AND HARDWARE
GENERAL SPECIFICATION
(To be supplied and erected by the bidder)
14.1 SCOPE:
This specification covers the supply of 66KV switchyard accessories and hardware
to site by the Bidder.
14.1.1 Creepage of each insulator : 465 mm (min.)
14.1.2 Electromechanical strength of : 8200 Kg.
Insulators and hardware
14.1.3 Accessories to be provided : D-shackles
Ball clevis / Ball eye
Socket eye
Strain Clamp
(Compression type)
Any other accessories
Like cotter pin, split pin,
Locking pins etc.,
Shall be supplied.
14.1.4 Electrical withstand characteristics of: As per IS 731 for BIL
complete string. of 350 KV (PEAK)
14.1.5 D shackles shall be of forged steel. All other ferrous parts shall be forged steel
depending on the strength. Locking and split pins shall be of stainless steel.
14.1.6 All ferrous parts shall be hot dip galvanized conforming to IS-2629.
14.1.7 Hardware shall be corona free up to a falling power frequency visible discharge test
voltage of 1.1 times the maximum system voltage.
14.1.8 All hardware components shall be smooth and as far as possible have round exposed
surface.
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14.4.2 SUSPENSION STRING ASSEMBLY:
14.4.2.1 Nominal Voltage : 66 KV
14.4.2.2 Applicable Standards : IS 731
14.4.2.3 Highest system voltage : 72.5 KV
14.4.2.4 No. of conductor, material and size : One (1) No.
Conductor, ACSR
PANTHER, 37/3 mm
(Overall dia. = 21 mm)
14.4.2.5 No. of insulators per string : 6 Nos.
14.4.2.6 Type of insulators : Fog type, 11 KV disc.
of 280 mm x 155 mm
14.4.2.7 Creepage of each insulator : 465 mm (Min.)
14.4.2.8 Electromechanical strength of : 8200 Kg.
Insulators and hardware
14.4.2.9 Accessories to be provided : (a) D-shackles
(b) Ball clevis / Ball eye
(c) Socket eye
(d) Strain Clamp
(Compression type)
(e) any other accessories
like cotter pin, split
pin, locking pins etc.
shall be supplied.
14.4.2.10 Electrical withstand characteristics of : As per IS 731 for BIL
complete string. of 350 KV (PEAK)
14.4.2.11 D shackles shall be forged steel. All other ferrous parts shall be forged steel
depending on the strength. Locking and split pins shall be of stainless steel.
14.4.2.12 All ferrous parts shall be hot dip galvanized conforming to IS-2629.
14.4.2.13 Hardware shall be corona free up to a falling power frequency visible discharge test
voltage of 1.1 times the maximum system voltage.
14.4.2.14 All hardware components shall be smooth and as far as possible have round exposed
surface.
14.4.3 BUS POST INSULATOR ASSEMBLY :
14.4.3.1 Nominal Voltage of the system : 66 KV
14.4.3.2 Applicable Standards : IS 3544
14.4.3.3 Highest system voltage : 72.5 KV
14.4.3.4 Type of post insulator assembly : Stack type / Solid
Core
14.4.3.5 No. of insulators in each stack : 1 No. Solid core
14.4.3.6 Rating of each insulator in stack : 72.5 KV
14.4.3.7 Height of each insulator in stack. : 368 mm with a PCD
of 127 mm / 770 mm
per insulator
14.4.3.8 Height of the complete stack : 736 mm / 770 mm
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14.4.3.9 Electrical characteristics of the : As per IS 731 for BIL
Insulators and the complete stack of 350 KV (PEAK)
14.4.3.10 Creepage distance of the compete : 1810 mm (min.)
Stack
14.4.3.11 Torsional strength of the stack : 460 Kg. (min.)
14.4.3.12 Tensile strength of the stack : 9100 Kg. (min.)
14.4.3.13 Compression strength of the stack : 12240 Kg. (min.)
14.4.3.14 Breaking strength (upright) : 545 Kg (min.)
14.4.3.15 Details of the conductor supported on : ACSR Panther
bus post insulator Conductor : Conductor
14.4.3.16 All ferrous parts shall be hot dip galvanized. The cap and the base shall be of forged
steel or malleable iron.
14.4.3.17 The type of insulators used in the stack shall be of BHEL / NGK / IEC / Modern.
14.4.4 ACSR CONDUCTOR
14.4.4.1 Type : ACSR (Aluminium
Conductor, steel
Reinforced) as per IS
398.
14.4.4.2 Code Name : PANTHER
14.4.4.3 Details of conductor : 30 strands of 3 mm
dia aluminium plus
seven strands of 3 mm
dia steel
14.4.4.4 Ultimate Tensile Strength : 9500 Kg.
14.4.5 G. I. SHIELD WIRE :
14.4.5.1 Type : G. I. Stranded wire
14.4.5.2 Details of the wire : 7 strands of 3.65 mm
G. I. wire
14.4.5.3 Ultimate Tensile Strength : 7000 Kg.
14.4.6 Corona Bells
14.4.6.1 Material : Aluminium, grade 91
E as per IS 5082
14.4.6.2 Shape and Details Standard
14.4.6.3 Inside diameter (I. D.) of the bus : 62.7 mm
tube (D1)
14.4.6.4 Outside diameter (O.D.) of the bus : 73 mm
tube (D2)
14.4.6.5 Material of the bus tube : Aluminium, grade 91E
14.4.7 CLAMPS AND CONNECTORS :
14.4.7.1 Transformer Terminal Clamps
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14.4.7.1.1 Type : Rigid - Bimettalic
14.4.7.1.2 Details of terminal provided by the : Universal for
transformer supplier horizontal / vertical
take off 30 mm dia for
66 kV
14.4.7.1.3 Material of clamp : Aluminium alloy LM6
with a cast copper
alloy liner for mating
with the copper pad.
14.4.7.1.4 Details of the conductor connecting : 0.2 sq. inch copper
the stud equivalent ACSR
PANTHER conductor
14.4.7.1.5 Current rating :
(a) Continuous : 600 A
(b) Short time : 25 KA for three sec.
On 66 kV
14.4.7.1.6 Clamp shall be corona free up to : 80 KV rms
14.4.7.1.7 Temperature rise over an ambient : As per IS 5561
of 50
o
C
14.4.7.2 P.G. CLAMPS ( Bolt less )
1. Details of conductor 1 : 0.2 sq. inch copper
equivalent ACSR
PANTHER conductor
2. Details of conductor 2 : 0.2 sq. inch copper
equivalent ACSR
PANTHER conductor
3. Material of clamp :Galvanized malleable
iron / forged steel
galvanized.
14.4.7.3 Shield wire Strain Clamp (if required)
14.4.7.3.1 Materials of clamps : Malleable iron casting
Hot dip galvanized /
Forged Steel galvanized
14.4.7.3.2 All steel parts shall be hot dip
galvanized.
14.4.7.3.3 Minimum slip strength shall be
3500 kgs.
14.4.7.3.4 Details of conductor to be held in : G.I. Wire 7/3.65 mm
Strain Clamp of ultimate tensile
Strength = 7000 Kgs.
14.4.7.3.5 Accessories to be supplied with the : a) D-Shackle with
strain clamps rivert
: b) Bolted type
Tension clamps
With Keeper
: c) U-Bolts with nuts
83
and washers of
forged steel
d) Split pin of brass
e) Any other
accessories
required for
completing the
installation.
14.4.7.4 Bus Post Clamps
14.4.7.4.1 Details of conductor supported by : ACSR PANTHER
the clamp
14.4.7.4.2 Details of the post insulator : PCD of insulator top
supporting the conductor with the 127 mm
clamp Material of } Malleable
Insulator } iron or
Metallic } cast iron
Short circuit force = 8
Kg/M wind loading
equivalent to wind
velocity of 150 Km/Hr.
14.4.7.4.3 Self tapping screws to fix the clamps on the insulator shall be supplied along with
the clamp.
14.4.7.4.4 No. of bolts shall be provided depending on dynamic force to which clamp is
designed.
14.4.7.4.5 All bolts, nuts and washers shall be Stainless Steel.
14.4.7.5 Tee Clamps - Conductor run and tap
14.4.7.5.1 Details of Run and Tap conductor : ACSR Panther and
ACSR Panther Tap
14.4.7.5.2 Minimum thickness of current : 12 mm
carrying part.
14.4.7.5.3 Continuous current rating : 600 Amp.
14.4.7.5.4 Short time current rating : 21.8 KA for one sec.
14.4.7.5.5 Material of clamps : Al. alloy LM6
14.4.7.5.6 Temperature rise over an ambient : As per IS-5561
of 50
o
C.
14.4.7.5.7 Connector shall be corona free up : 80 KV (rms).
to
14.4.7.6 Flexible clamp for connecting pad type terminal of circuit breaker / isolator to Bus
Conductor.
14.4.7.6.1 Type : Flexible
14.4.7.6.2 Details of terminal pad of : As per manufacturers
equipment drawing which will be
made available to the
bidder later.
14.4.7.6.3 Material of the clamp : Aluminium alloy LM6
with a cast copper
alloy liner for mating
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with the copper.
14.4.7.6.4 Details of the Bus conductor : ACSR Panther
connecting the pad Conductor
14.4.7.6.5 Current ratings
(a) Continuous : 600 A
(b) Short time : 21.8 KA for one sec.
14.4.7.6.6 Clamps shall be corona free up to : 80 KV rms
14.4.7.6.7 Temperature rise over an ambient : As per IS 5561
of 50
o
C.
14.4.7.6.8 All hardware such as nuts, bolts, washers shall be of stainless steel
14.4.7.7 Straight end connector for CT stud and tube.
14.4.7.7.1 Type : Straight jointing type
and rigid
14.4.7.7.2 Details of terminals provided by the : Horizontal take off by
CT supplier 30 mm dia, 80 mm
long (approx.) copper,
cylindrical stud
14.4.7.7.3 Material of the clam : Aluminium alloy LM6
with a cast copper
alloy for mating with
copper stud
14.4.7.7.4 Details of the bus conductor : ACSR Panther
connecting the stud Conductor
14.4.7.7.5 Current ratings :
(a) Continuous : 600 A
(b) Short time : 25 KA for three sec.
14.4.7.7.6 Clamp shall be corona free up to : 80 KV rms
14.4.7.7.7 Temp. rise over an ambient of 50
o
C : As per IS 5561
14.4.7.7.8 All nuts, bolts, washers shall be of stainless steel:
14.4.7.8 Clamp for connecting pad type terminal of isolator / lightning arrester to ACSR
Conductor.
14.4.7.8.1 Details of terminal pad : will be furnished later
14.4.7.8.2 Details of conductor : 0.2 sq. in copper
Equivalent ACSR
Panther conductor
14.4.7.8.3 Continuous current rating : 600 A
14.4.7.8.4 Short time current rating : 25 KA for Three sec.
14.4.7.8.5 Material of the clamp : Al. alloy (LM-6)
14.4.7.8.6 All hardware such as nuts, bolts, shall be stainless steel.
14.4.7.9 Notes
14.4.7.9.1 All current carrying clamps / connectors shall be suitable for carrying 800 amps
continuous current
14.4.7.9.2 All mating surfaces between steel and copper or aluminium and copper shall be by
using a cast copper alloy liner (of minimum 4 mm thickness) between copper and
steel / aluminium surfaces. This liner shall be cast internal so that no voids are left
between dissimilar metal surfaces.
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14.4.7.9.3 The following are the tolerances allowed on external dimensions of the clamps /
connectors.
(a) up to 50 mm - 5 %
(b) 51 to 100 mm - 4 %
(c) above 100 mm - 3 %
14.4.7.9.4 All sharp edges and corners shall be burred and rounded off.
14.4.7.9.5 No part of a clamp or connector shall be less than 10 mm thick.
14.4.7.9.6 Bolts and nuts shall have hexagonal heads and threads as per standards.
14.4.7.9.7 Flexible connectors, braids or laminated straps shall be made from tinned copper
sheets or aluminium laminates depending on the clamps / connectors.
14.4.7.9.8 Adequate quantity of contact paste shall be supplied with the clamps / connectors
which when applied at site will prevent corrosion occurring on the contact surfaces
between aluminium and copper, this paste shall be non-poisonous and non-
inflammable.
14.4.7.9.10 Size of the terminal / conductor for which the clamp / connector is suitable, shall be
embossed / punched (i.e., indelibly marked ) on each component of the clamp /
connector, except on the hardware.
14.4.7.9.11 The temperature rise while carrying the rated current shall be equal or less than that
of the conductor at the specified ambient temperature. The rated current for which
the clamp 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.
14.4.7.9.12 Bolted type of parallel connector design comprising the same run and tap stranded
conductor material shall be made with a common base plate and a common cap.
14.4.7.9.13 Bolts shall have M 10 or M 12 thread. Tightening torque shall be 45 Nm for M 10
and M 12 respectively.
14.4.7.9.14 Clamps shall be designed such that the support insulators are not subjected to extra
stresses by butt torsional action from the tubular conductor during vibration, wind,
ice load and short circuits.
14.4.7.9.15 The clamps shall be light in weight and easy to handle. Suspension clamp shall have
ease of oscillation around horizontal axis and small moment of inertia enabling it to
follow freely the movement of the conductor.
14.4.7.9.16 The natural frequency of mechanical vibration of clamps shall be different from that
of the conductor, to avoid any effect of resonance. The clamp shall be designed,
manufactured and finished to give it a suitable shape without sharp angles at the
ends and radius of curvature so as to avoid any possibility of hammering between
the clamp and conductor due to vibrations.
86
14.4.7.9.17 Connectors used for copper to ACSR conductor connections shall be aluminium
alloy clamps with necessary cast in copper liners.
14.4.7.9.18. Clamps shall be corona free.
14.4.7.9.19 Connectors shall be designed to withstand stresses in service due to wind, ice,
vibrations, fluctuations in temperature and short-circuits, without suffering
permanent deformation or breakages. In addition, connectors shall withstand short-
circuit inertia forces.
14.4.7.9.20 Connector design shall be such that tensile, bending and wrenching stresses
transmitted to the equipment terminals are minimum possible. Flexible connectors
shall permit axial movement of the tubular conductor.
14.4.7.9.21 Flexible connectors shall be designed so that electric current during both normal
load and short circuit is not transferred through mechanical support.
14.4.7.9.22 Current carrying connectors shall be designed so that hysteresis and eddy current
losses are small.
14.4.7.9.23 The shape of current carrying connectors shall be such that water collection is
eliminated. If this is not possible, the connector shall be supplied with drainage
holes of at least 6 mm.
14.4.7.9.24 Tubes in flexible connector shall not rattle.
14.4.7.9.25 Tubes in flexible connectors shall be prevented from falling out of connector.
14.4.7.9.26 The bus post clamps shall be so dimensioned that clashing between the bus tube and
clamp does not occur during short circuit.
14.4.7.9.27 The bus post clamps shall be so dimensioned that it is not notably heated by
hysteresis and eddy current losses.
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14.4.8 GENERAL DESCRIPTION FOR TRIVECTO METER FOR TARIFF
(ENERGY/DEMAND) AND ENERGY AUDIT/LOAD SURVEY PURPOSE
1.0 SCOPE:
1.1 This specification provides for design, manufacture, testing, inspection, packing and dispatch,
to destination of TRIVECTO METER FOR TARIFF (ENERGY /DEMAND)AND ENERGY
AUDIT/LOAD SURVEYPURPOSE
2.0 PURPOSE OF PROVIDING METERS:
2.1 The scope of the present tender work includes supply at 66KV to Surat Electricity
Company through various 66 KV outgoing feeders from Dhanera Gas Based Power Station
switchyard. The meters are required to be very accurate, as slightest error will have the
implication of lacs of rupees to anyone of the contracting parties.
2.2 The meters shall be static type. The detailed description of meters to be procured is not
given herewith but shall be made available to the successful bidder who in turn will arrange
to procure these meters strictly as per the requirement of GEB.
3.0 GENERAL REQUIREMENT
3.1 The meters shall generally meet with the IS and IEC listed below:
IEC 687 (1992-06) - Static watt hour meters - Meteorological specifications for classes--
0.2S and 0.5S
IEC 14697(1999) AC static Transformer operated Watthour meter VAR hour meters,
Class 0.2S and 0.5S specification.
IEC 1036 - Static Energy Meters
IS 9000 - Environmental testing
IS 8161 (Draft) - Impulse wave testing
IS 13010 - AC Watt-hour meters Cl-0.5,1 &2
IS 12346 - specification for testing equipment for AC energy meters.
IS 8686 - w.r.t. High frequency disturbance testing
CBIP Report 88 (Revised May-1996 and amended in April-99 and Sept-99)
Specification for A.C. Static electrical energy meters.
PFC Spec. - For High precision 3 vector Energy Meter.
3.2 The meters shall have internal real time clock with a back up with a Lithium maintenance
free battery of minimum life of Ten (10) years. The quantities to be measured, monitored
and memorized shall be with polyphase supply (3 phase 4 wires). The measures will
include measurement of active and re-active power factor and other electrical quantities. In
addition to this, it will also indicate phase voltages, line currents, power factor, temperature,
cumulative imports and exports of active and re-active power.
88
3.3 The meters shall be with legible LED/LCD 6 digits automatic in cyclic order display. It
will also show the instantaneous and cumulative electrical quantities and have tampered
data identification system.
3.4 The meters shall be with the facility of maximum demand register, maximum demand reset,
energy audit/load survey capability, time of day tariff/demand, harmonic measurements,
data transfer and meter reading instrument.
3.5 The accuracies shall be as described in preceding para i.e. 0.5S Class accuracy of active
power and 0.5S class of accuracy static alternating current watt-hour meters for active
energy.
3.6 The meters shall be guaranteed for the performance in the climatic and system conditions
indicated in this tender. The GEB may guide or direct the contractor to purchase these
meters through a vender who has a proven ability in this field.
14.4.9 TECHNICAL SPECIFICATION FOR INSULATORS
1.0 SCOPE
1.1 This specification provides for design, manufacture, testing, inspection, packing and
despatch, to destination of Disc Insulators, specified herein for their satisfactory operation
in various transmission lines and substations of the State.
1.2 These Insulators are to be used as insulating part on single circuit and / or double circuit
220 / 132 / 66 KV transmission lines and / or sub-stations of the GEB.
2.0 STANDARDS
2.1 The Disc Insulators shall conform to the following Indian / International Standards, which
shall mean latest revisions, amendments / changes adopted and / or published as on the
date of opening of the Tender.
Sr.
No.
Indian
Standards
Title International Standards
1 IS : 731 1971 Specification For Porcelain Insulators.
2 IS : 2486
(Part III)
1974
Specification For Dimensions Of Pin Ball And
Socket.
3 IS : 2486
(Part-III)
1974
Specification For Security Clips IEC No. 372-I (1971)
4 Mechanical Performance Test IEC : 575
5 IS : 2629 Recommended practice for Hot dip galvanising
of Iron and Steel.
6 IS : 2633 Method of Testing uniformity of coating of zinc
coated articles.
7 IS : 4826 Galvanised coating quoting on round steel wire. ASTM A 472 729
BS : 443
89
8 IS : 6745 Methods of determination of weight of zinc
coating of zinc coated iron and steel articles.
BS : 443
2.2 However, in an event where the supplier offers Insulators conforming to standards
other than the above, then the salient points of comparison between the standards adopted
and the standards quoted herein shall be detailed in relevant schedule with an
authenticated English version of such standards referred to.
3.0 GENERAL TECHNICAL REQUIREMENT
3.1 The insulators shall be suitable for being installed directly in air supported on suspension
insulator hardware or anchored through tension insulator hardware at the power cross
arms of single circuit, double circuit or multi circuit transmission line towers.
3.2 The insulator shall therefore be suitable for satisfactory operation under the tropical
climatic conditions listed in the relevant clause. The applicable design particulars of the
insulator to be used on these lines is furnished in "System Particulars".
3.3 The design of the insulator discs shall be such that all the stresses due to expansion or
contraction in any part of the insulator under rapid temperature fluctuation, which may be
created due to variation in the loads or fault of any nature, while in service shall not lead to
any type of deterioration. Flat surface and corners shall not be allowed and shall be
completely rounded off.
3.4 The porcelain shall not engage directly with the hard metal and all metal in contact with the
cement shall be coated with the layer of chemically neutral and suitably yielding material or
paint which shall act as a cushion and lubricant for the slight relative expansion and
contraction of the parts.
3.5 The disc shall be cap and pin type with the ball and socket coupling. The caps and pins of
the disc insulators shall be heavily galvanised and mechanically strong. The pin balls shall
move freely in the cap sockets but shall be so designed that they do not get disengaged
while in service under various operating and atmospheric conditions.
3.6 The caps shall be made of heat treated malleable cast iron. These shall be free from cracks,
shrinks, air holes, burrs and rough edges, etc. The caps
shall be circular with the inner and outer surfaces concentric and of such design that they
will not yield or distort under stresses to the porcelain shells. The pins shall be of single
piece made of high tensile forged steel hardened and tempered and shall be free from laps,
folds, burrs, and rough edges. All bearing surfaces shall be smooth and uniform so as to
distribute the loading stresses evenly. The pins shall be of such a design that they will not
yield or distort under loaded condition. No joints in the pins shall be allowed, what so ever
the joint type may be. The zinc sleeve shall be made of zinc having minimum 99.95 %
purity.
90
3.7 Nominal dimensions of the pin, ball and socket interior shall be in accordance with the IS
indicated above. The mechanical strength rating of the pin ball shank shall not be less than
the electromechanical strength of the insulator discs as specified in this Specification.
3.8 The security clips for use with ball and socket coupling and split pins for use with cotter
belts shall be made of phosphor bronze or stainless steel. The security clips shall provide
positive locking of the coupling and shall be hump, back type of W shape for 90KN, and
R shape for 120KN and 160KN insulators in accordance with the relevant IS or IEC. The
logs of the security clips (split pins) shall be spread after installation to prevent withdrawal
from the socket. The locking devices should be resilient, corrosion resistant and of suitable
mechanical strength. There shall be no risk of the locking device being displaced
accidentally or being rotated when in position. Under no circumstances shall the locking
device allow separation of insulator units or fittings.
3.9 The finished porcelain shall be glazed to a chocolate brown colour. The glaze shall cover all
the exposed porcelain parts of the insulators and shall have a bright luster smooth surface
and shall have a good performance under extreme weather conditions of tropical climate
and heavily polluted atmosphere. The glaze shall not crack or get chipped due to ageing
effect under normal and abnormal service conditions or while handling during transit or
erection. The glaze shall have the same co-efficient of expansion as of porcelain body
through out the working range of the temperature.
3.10 An additional quantity of clips to the extent of 1.5 % shall be supplied with the insulators
free cost.
3.11 The design of the fittings and the insulators shall be such that there is no local corona
formation or discharges likely to cause the interference to either sound or vision
transmission.
3.12 The bidder shall be responsible for satisfying himself that all the insulators including
fittings in a string are suitable for the tower structures and conductors specified in this
specification.
3.12 The insulators shall be of standard design and made to gauge or a jig and the same shall be
interchangeable, in all respect with the similar items.
4.0 MATERIALS
4.1 The insulators shall be manufactured from good quality porcelain insulating material as per
approved design. The materials supplied shall be free from blow-holes, flaws, cracks, or
other defects and shall be smooth, close grained and of true forms and approved
dimensions. All machined surfaces shall be true, smooth, and well finished. The materials
used shall comply with all the relevant ISS, BSS, or other standards to be specified along
with the due justifications.
4.2 The porcelain shall be Ivory white, non-porous, of high dielectric, mechanical and thermal
strength. The materials shall be free from internal stresses, blisters, laminations, voids,
foreign matters / particles, imperfection of other defects which might in way render it
91
unsuitable as insulator shells. Porcelain shall be unaffected by climatic conditions, ozone,
acids, alkalies, zinc, dust etc.
4.2.1 The porcelain shells shall be made by wet process. They shall be clean, dense,
homogeneous, and shall be fired to a complete and uniform vitrification so that glaze is not
depended upon for insulation. The glaze shall be smooth, uniform and of Brown shade and
shall cover completely all exposed porcelain in parts of the insulator. The shells shall
posses the qualities best adopted to insulators for service at extra and ultra high voltages.
4.2.2 Metal fittings of drop forged steel or heat treated melliable cast iron for insulators are
required to have excellent mechanical properties such as strength, toughness, high corrosion
resistance, free from corona effects, etc.
4.2.3 Cement used in the construction of insulators, particularly for joining the metal parts with
the porcelain insulator, shall not cause fracture by expansion or loosening by contraction
and must have high compression and shearing strengths and be free from change in volume
due to ageing and temperature changes. The thickness of the cement shall be kept as less as
possible, however without affecting the strength of the joint, and proper care shall be taken
to correctly fix the individual parts. The cement shall not give rise to chemical reaction with
the metal fittings and/or thermal instability or chemical changes either in the porcelain
insulator or the metal parts themselves.
4.2.4 Galvanised steel parts shall be made from high quality steel produced by either acidic or
basic open hearth process, electric furnace process or basic oxygen process. All the
properties of the steel castings and hard drawn shall conform to the relevant standards.
4.2.5 The zinc used for galvanising shall be electrolytic high grade Zinc, Zn-98, not less than
98 percent purity. It shall conform to and satisfy all the requirements of relevant ISS,
BSS or other Standards to be specified with the due justification. Galvanising has to be
done hot dip galvanising process.
4.2.6 The bidder should specify the source of raw materials along with the proof of last purchases
made. The GEB may reject the tender of the Bidders whose raw material suppliers are
found to be supplying any poor quality or
non standard materials, to the GEB of this Specification or any other GEB.
5.0 FREEDOM FROM DEFECTS
5.1 The products shall be smooth and free from all imperfections such as spills, splits,
slag inclusion, die marks, scratches, fittings, blow-holes, projections, looseness,
overlapping of layers, chipping of porcelain layers, cracks, shrinks, sand, etc. and all
such other defects which may hamper the mechanical & electrical properties of the
insulator as also the installation of the same at the site etc. Special care should be taken to
keep away dirt, grit etc. during manufacturing.
6.0 SIZES
6.1 Nominal Size And Tolerances
92
The porcelain and galvanised steel parts for the complete insulator covered by this
standard shall have dimensions specified in this Specification and shall be within the
tolerances indicated therein. The dimensions of the steel galvanised parts shall be
measured over the zinc coating.
7.0 JOINTS IN INSULATOR & PARTS
7.1 Porcelain Parts
7.1.1 No joints shall be permitted in the porcelain parts in the insulators, in addition to those
made in the base materials before final production.
7.2 Galvanized Steel Parts
7.2.1 There shall be no joints in steel parts forming the fixing parts (core for mechanical
strength) of the insulator.
7.2.2 The steel used in the construction of galvanised steel insulator parts before and after putting
in position shall satisfy all the relevant requirements as per the standards indicated or any
other standards with due justification.
7.2.3 The zinc used for galvanising shall be electrolytic high grade Zinc. It shall conform to
and satisfy all the requirements of relevant standards indicated or any other standards with
due justification. Galvanising shall be done by hot dip galvanising process.
7.3 The insulators offered shall be suitable for employing Hot Line Maintenance Techniques
with the required speed, ease, and safety..
8.0 MARKING
8.1 Each insulators shall be legibly and indelibly mark with the trade mark of manufacturer, the
batch and year of manufacture, guaranteed Electrical & Mechanical strength and the
country of manufacture. Such marking on the porcelain shall be printed not embossed and
shall be applied before firing. The unit of E&M strength viz. Kg. should be given to
facilitate easy identification and to ensure correct use.
9.0 Type Tests
9.1. Type test certificate (nor older than 5 years on the due date of opening of tender) shall
include the following:
On Both Insulators
a) Visual Examination :
b) Varification Of Dimensions
c) Visible Discharge test
d) Impulse Withstand Test For Positive And Negative Wave
93
e) Impulse Flashover Test For Positive And Negative Wave
f) Dry And Wet Power Frequency Voltage Withstand test For One
Minute
g) Dry And Wet Power Frequency Flashover Test.
h) Temperature Cycle Test
On First Insulator
i) Mechanical Performance Test
j) Electro Mechanical Failing Load Test
k) Porosity Test
On Second Insulator
l) Puncture Test
m) Galvanising Test
9.2 All the above Electrical and Mechanical tests shall have to be carried out on minimum three
samples of each size and capacity of the insulators from the first lot offered at the third
party Government Approved testing laboratory as per clause no 12.9.1.
10.0 Acceptance Tests
a) Visual and dimensional check
b) Temperature Cycle Test
c) Mechanical Performance Test
Electro Mechanical Failing Load Test
d) Puncture Test
e) Porosity Test
g) Galvanising Test
11.0 Routine tests
a) Check that there are no cuts, fins etc. on the insulators.
b) Check that crates are as per specification.
c) Visual Examination
d) Mechanical Routine Tests
e) Electrical Routine Tests
f)All acceptance tests as mentioned in Clause 6.3 above shall be carried out on each
sample
SPECIFIC TECHNICAL REQUIREMENTS
94
2.0 SCOPE
2.1 This section covers the specific technical particulars requirements and desired deliveries
etc. suiting to which the insulators shall be offered. The insulators offered shall also
confirm to the General Technical requirements covered in this Specification.
SYSTEM PARTICULARS
A) Electrical System Data :
DETAILS OF CONDUCTORS
Sr.
No
Details Moose
400KV
Zebra
220KV
Panther
132KV
Dog
66KV
1 Number Of Strands
a) Aluminium
b) Steel
54
7
54
7
30
3
6
7
2 Wire Diameter mm
a) Aluminium
b) Steel
3.53
3.53
3.18
3.18
3
3
4.72
1.57
3 Approximate Weight
Kg / Km. 2004 1625 979 395
4 Overall Diameter mm 31.77 28.62 21 14.15
5 Ultimate Tensile Strength
- Kg 16500 13500 9200 3500
DETAILS OF INSULATORS
Sr.
No.
Details 160KN 120KN 90KN
1 Type Ball & Socket Ball & Socket Ball & Socket
2 Height mm 170 145 145
3 Diameter mm 305 280 or 305 255 or 280
4 Creepage mm
(Minimum)
a) Total
b) Protected
430
260
430
260
430
260
5 Ball Diameter mm 20 20 16
6 Colour Brown Brown Brown
7 Surface Glazed Glazed Glazed
95
8 Materials
a) Socket Cap
b) Ball Pin
c) Security Clip
d) Zinc Sleeve
e) Insulator
Malleable Cast Iron Hot Dip Galvanised
High Tensile Forged Steel (Hardened & Temp- ered)
Hot Dip Galvanised
Phospher Bronze Or Stainless Steel
99.95% Pure Zinc
Porcelain
9 Shape Of Security Clip R W
10 Dimensions Of Zinc Sleeve
mm
a) Thickness
b) Exposed Length from
Cement Surface
g) Minimum
h) Maximum
c) Total Length (Min.)
3
5
13
20
11 Minimum Failing Load
Kg. 16500 12500 9180
12 Minimum Electro
Mechanical Load Kg. 16500 12500 9180
13 Visible Discharge Test
Voltage KV (Min.)
9 9 9
14 Dry Impulse Flash Over
Voltage KV (Min. +ve
Peak Wave 1.2/50
Microsec.)
180 180 180
15 - DO But For ve Wave
195 195 195
16 Dry Impulse Withstand
Voltage KV (Min. +ve
Peak Wave 1.2/50
Microsec.)
180 180 180
17 - DO But For ve Wave
195 195 195
18 Power Frequency Flash
Over Voltage KV (RMS
Min.)
a) Dry
b) Wet
100
60
100
60
100
60
19 Power Frequency
Withstand Voltage KV
(RMS Min.)
c) Dry
d) Wet
85
55
85
55
85
50
20 Power Frequency Puncture
Voltage KV (RMS
Min.)
140 140 140
96
ILLUMINATION
1 LIGHTING SYSTEM
1.1 The scope of work comprises of design, engineering, testing, supply, installation,
testing and commissioning of various lighting fixtures complete with lamps,
supports and accessories, ceiling fans complete with regulators & accessories,
lighting panels, lighting poles complete with distribution boxes, galvanised rigid
steel conduits, lighting wires, G.I. Earthwire, receptacles, switchboards, switches,
junction boxes, pull out boxes complete with accessories, lighting transformer.
1.2 SYSTEM DESCRIPTION
A typical arrangement of lighting system is shown in enclosed sketch no. C-ENG-
GEN-LS .The lighting system shall comprise of the following:
1.2.1 AC Normal Lighting
AC lights will be connected to AC lighting panels. All the lights connected to the
AC lighting system in different areas will be connected to the main lighting
distribution boards to be supplied.
1.2.2 D.C. Emergency lighting
A few DC emergency lighting fixtures operated on the DC system will be provided
in the strategic locations including staircase, corridors, electrical rooms, Battery
charger room, LT switchgear room. in control room building, so that the operating
personnel can safely find their way even during emergency of a total AC failure.
These lights will be normally 'OFF' and will be switched 'ON' automatically when
under voltage occurs in the AC main lighting distribution board.
1.3 The lux levels to be maintained in the different areas shall be as per following:
Sr .No. Area Lux
i) Control Room 350
ii) PLCC Room 300
iii) M.C.C. Room 150
iv) DCDB Room 150
v) Cable Vault 150
vi) Pantry 150
vii) Battery Room 100
viii) Computer Room 300
ix) Entrance lobby 150
x) Corridor & landing 150
xi) Conference Room 300
xii) Shift Manager/Electrical Engineer 250
Staff room
97
xiii) Test Laboratory 300
xiv) DG Set Building 150
xv) Fire Fighting Pump House 150
xvi) Switchyard 50 lux on main Equipment
at first level (Equipment
connections level.)
20 lux on balance area of
switchyard.
xvii) Street/Road 20 lux
The lux levels indicated above are the minimum lux levels except for switchyard.
For switchyard the lux level indicated is average value. Further the minimum lux
level to average lux level ratio shuld not be less than 0.3 (ie Emin/Eav>0.3.)
For achieving the specified lux levels in the switchyard,the contractor can provide
luminaries of 1x400 W/1 x.250 W and 2x400/ 2x250 W flood light as per
requirement.
Bidder shall submit detailed calculation for reaching the above Lux levels.
Contractor shall conform the Lux levels at different locations by measurement.
In addition to the normal lighting provided in the switchyard area to maintain the
desired lux levels, few high beam fixtures on swivel support shall be provided in
strategic locations near equipments which shall be kept normally OFF and these
shall be switched ON in case of maintenance work. In F.F. pump house also
fixtures on swivel support mounted on wall shall be provided.
1.4 Battery operated portable fluorescent lamps assembly shall be provided as per
following:
Control room building - 4 Nos.
1.5 Ceiling fans (1400 mm sweep, AC 230 volts ) shall be provided the control room
building. Wall mounted fans shall be provided in the shift room / electrical engineer
room in control room building.
1.6 One no. of aluminium ladder of each size shall be supplied by the contractor for
maintenance purpose.
1.7 The following specific areas are included in the scope of lighting:
(i) 66kV switchyard Area.
(ii) Switchyard Control Room building.
(iii) DG set room
(iv) Fire fighting pump house
(v) Street lighitng (peripherial) inside switchyard fencing.
98
(vi) Any other area intimated to vendor during detail engineering.
1.8 The detailed drawings showing the lighting layout of these areas shall be prepared
by the Contractor and submitted for approval. The above layout drawings will
include disposition and location of lighting fixtures, receptacles, switchboards,
ceiling fan points, etc. The conduit layout for substation buildings, cable schedule
for substation yard etc. for wiring of these equipment shall also be prepared by the
Contractor.
1.9 Each cable and conduit run shall be tagged with number that appear in the cable and
conduit schedules. Cables and conduits shall be tagged at their entrance and/or exit
from any piece of equipment, junction or pull box, floor opening etc.
1.10 The tag shall be made up of aluminium with the number punched on it and securely
attached to the cable by not less than two turns of G.I. wire. Cable tags shall be
rectangular in shape for power cables and circular shape for control cables.
1.11 Location of cables laid directly under ground shall be indicated clearly by cable
marker made of galvanised iron plate embedded in concrete block.
1.12 The location of under ground cable joints if any, shall be clearly indicated with
cable marker with an additional inscription "cable joint".
1.13 The marker, which is a concrete block, shall project 150 mm above ground and shall
be spaced at an interval of 30 meters and at every change of direction. It shall also
be located on both sides of the road or drain crossing.
2. DESCRIPTION OF ITEMS
The Contractor shall supply and install the following equipment and accessories in
accordance with the specification.
2.1 Lighting Fixtures and Receptacles
Lighting Fixtures
---------------------------------------------------------------------------------------
Type Description
---------------------------------------------------------------------------------------
SC 150W SON-T Tubular Sodium
Vapour lamp in street lighting
luminare. A special optical
reflector clear acrylic cover, a
single piece die cast aluminium
housing made out of LM6 and
corrosion resistance proof.
Similar to Philips Cat No. SRP-
51 and Bajaj Cat No. BJMSC/
150 / Crompton Greaves.
99
Cat No. SSG 1515H .
SF2 400 /2x250W HP Sodium vapour
lamps in high Flood lighting
fixture suitable for outdoor
mounting with aluminium
enclosure : similar to Philips
Cat.No. SNT001/Bajaj Cat.
No. BJEF-22CA /Crompton
Greaves Cat No. FHD1224
MP 125 HP MV Lamp in weather
proof post top latern with case
aluminium canopy, mounting
piece, opal acrylic cover tropi-
cated gasket and all other
accessories for mounting on pole
top similar to philips Cat.No.
HRC-40/Bajaj / Crompton Greaves
Cat No. IPT 20BC
---------------------------------------------------------------------------------------
2.2 RECEPTACLES
RO 15A, 240V, Outdoor Receptacle
2 pole, 3- pin type
R1 5/15A, 240V, Indoor Receptacle
3-pin type.
RP 63A, 415V, Interlocked switch
socket, outdoor receptacle
---------------------------------------------------------------------------------------
2.3 SWITCH BOARDS
Decorative type switch-board
with adequate number of switches &
receptacle
---------------------------------------------------------------------------------------
2.4 JUNCTION BOXES with 5 Nos. of terminal blocks
---------------------------------------------------------------------------------------
2.5 LIGHTING POLES - (Type A1 poles &Type E1 poles)
100
---------------------------------------------------------------------------------------
2.6 CEILING FANS-1400 mm Sweep with Electronic regulator
---------------------------------------------------------------------------------------
2.7 MAINTENANCE EQUIPMENT
i) A type Aluminium ladder of 3 mtr vertical height.
ii) Cartwheel mounted aluminium ladder Vertical Height 7.5 Mtrs.
---------------------------------------------------------------------------------------
3. LIGHTING FIXTURES AND ACCESSORIES
3.1 General
All lighting fixtures and accessories shall be designed for continuous operation
under atmospheric conditions existing at site, without reduction in the life or
without any deterioration of materials, internal wiring.
3.2 Temperature Rise
All lighting fixtures and accessories shall be designed to have a low temperature rise
according to the relevant Indian Standards. The design ambient temperature shall be
taken as 50 deg.C.
3 .3 Supply Voltage
3.3.1 Lighting fixtures and accessories meant for 240V A.C. operation shall be suitable
for operation on 240V A.C. 50Hz, supply voltage variation of 10%, frequency
variation of 5% and combined voltage and frequency variation of 10%.
3.3.2 Lighting fixture and accessories meant for 220V DC operation shall be suitable for
operation on 220V DC with variation between 90 to 125 Volts.
3.4 Lighting Fixtures
The lighting fixtures shall be philips or Bajaj or Crompton Greaves make only. The
different types of lighting fixtures are as indicated elsewhere in this Section.
3.4.1 All fixtures shall be designed for minimum glare. The finish of the fixtures shall be
such that no bright spots are produced either by direct light source or by reflection.
3.4.2 All lighting fixtures shall be complete with fluorescent tubes/incandesent
lamps/mercury vapour/sodium vapour lamps as specified and shall be suitably wired
up.
3.4.3 All flourescent lamp fixture shall be complete with all accessories like ballasts,
power factor improvement capacitors, lamps, starters, holders etc.
101
3 4.4. High beam fixtures shall be suitable for pendant mounting and flood lights shall
have suitable base plate / frame for mounting on steel structural member. Hook
mounted high beam fixtures are not acceptable.
3.4.5 Each lighting fixture shall be provided with an earthing terminal suitable for
connection to 16 SWG GI earthing conductors.
3 .4 6. All light reflecting surfaces shall have optimum light reflecting co-efficient such as
to ensure the overall light output as specified by the manufacturer.
3.4.7 Height of fixtures should be such that it is easy to replace the lamps with normal
ladder/stool. In case the ceiling height is very high, the fixtures may be placed on
the walls for ground lighting.
3.5 ACCESSORIES
3.5.1 Reflectors
The reflectors shall be manufactured from sheet steel or aluminium as applicable of
not less than 22 SWG thickness. They shall be securely fixed to the captive type.
3.5.2 Lamp holders and Starter Holders
(a) Lamp holders/starter holders for fluorescent tubes shall be of the spring
loaded, low contact resistance, bi-pin rotor type, resistant to wear and
suitable for operation at the specified temperature, without deterioration in
insulation value, contact resistance or retention of the lamp/starter. They
shall hold the lamp/starter in position under normal condition of shock and
vibration.
(b) Lamp holders/starter for incandenscent lamps and HPMV/HPSV lamps shall
be of screwed type, manufactured in accordance with relevant standard and
designed to give long and satisfactory service.
3.5.3 Ballasts
a) The Ballasts shall be designed, manufactured and supplied in accordance
with relevant standard and function satisfactorily under site condition
specified. The ballasts shall be designed to have a long service life and low
power loss.
b) Ballasts shall be mounted using self locking anti-vibration fixing and shall
be easy to remove without dismantling the fixtures. They shall be totally
enclosed units.
c) The ballasts shall be of the inductive, heavy duty type, filled with
thermosetting insulating moisture repellent polyester compound filled under
pressure or vacuum. The ballast wiring shall be of copper wire. They shall
102
be free from hum. Ballasts which produce humming sound shall be replaced
free of cost by the Contractor. Ballasts for high pressure mercury
vapour/HPSV lamps shall be provided with suitable tappings to set the
voltage within the range specified. End connections and taps shall be
brought out in a suitable terminal block, rigidly fixed to the ballast
enclosure.
d) Separate ballast for each lamp shall be provided in case of multi-lamp
fixtures.
3.5.4 Starters
Starters shall have bimetal electrodes and high mechanical strength. Starters shall be
replaceable without disturbing the reflector or lamps and without the use of any tool.
Starters shall have brass contacts and radio interference suppressing capacitor.
3.5.5 Capacitors
a) The capacitors shall have a constant value of capacitance and shall be
connected across the supply of individual lamp circuits.
b) The capacitors shall be suitable for operation at supply voltage as specified
and shall have a value of capacitance so as to correct the power factors of its
corresponding lamp circuit to the extent of 0.98 lag.
c) The capacitors shall be hermetically sealed in a metal enclosure.
3.6 Lamps
3.6.1 General Lighting Services (GLS) lamps shall be provided with screwed caps and
shall be of 'clear' type unless otherwise specified.
3.6.2 The flourescent lamps shall be 'Day-light-colour' type unless otherwise specified
and shall also be provided with features to avoid blackening of lamps ends. The
Bidder should clearly state these features in the bid.
3.6.3 Mercury vapour lamps, sodium vapour lamps shall be colour corrected type, with
screwed caps.
3.7 The Bidder shall furnish typical wiring diagram for Fluorescent, HPMV & HPSV
fitting including all accessories. The diagram shall include technical details of
accessories i.e. starters, chokes, capacitors etc.
3.8 Flexible conduits if required, for any fixture shall be deemed to be included in
Contractors scope.
4. RECEPTACLES
103
a) All receptacles shall be of cast steel/aluminium, heavy duty type, suitable for
fixing on wall/column and complete with individual switch.
b) In general the receptacles to be installed are of the following types :
i) Type RO-15A, 240V, 2 pole, 3 pin type with third pin grounded,
metal clad with gasket having cable gland entry suitable for 2Cx6
sq.mm. PVC/aluminium armoured cable and a metallic cover tied to
it with a metallic chain and suitable for installation in moist location
and or outdoor. The switch shall be of rotary type. Receptacles shall
be housed in an enclosure made out of 2 mm thick Gl sheet with
hinged doors with padlocking arrangements. Door shall be lined
with good quality gasketing. This shall conform to IP-55.
ii) Type RI - Combination of 5A and 15A, 240V, 3 pin type with third
pin grounded, suitable for flush mounting. The switch shall be of
piano key type and shall be flush mounted.
iii) Type RP - 63A, 415V, 3 phase, 4 pin interlocked plug and switch
with earthing contacts. Other requirements shall be same as type
RO. The receptacle shall be suitable for 3.5C x 35/3.5Cx70 sq.mm.
aluminium conductor cable entry and shall also be suitable for loop-
in and loop out connection of cables of identical size. Receptacle
shall be suitable for outdoor application. Receptacles shall be housed
in a box made out of 2mm thick G.I. sheet, with hinged door with
padlocking arrangement. Door shall be lined with good quality gas-
keting. This shall conform to IP-55.
5. SWITCH AND SWITCHBOARD
(a) All switch boards/boxes shall be of bent steel construction, fabricated of 16
SWG sheet with 6 mm thick bakelite or 3 mm thick perspex sheet cover.
(b) Switch board/boxes located in office/building areas shall be flush mounted
type or brick wall with only the switch knob projecting outside.
(c) Switch boards/boxes shall have conduit knock outs on all the sides.
Adequate provision shall be made for ventilation of these boxes.
(d) Flush type receptacles provided shall be so located that only the plug project
outside.
(e) Switches shall be of piano key type having quick make and quick-break
mechanism complete with position indicator and shall conform to relevant
Indian Standard.
(f) All the components housed in the switchboard shall be wired to an outgoing
terminal block by 2.5 sq.mm. stranded copper wire The terminal block shall
be of adequately rated
104
(g) The exact number of switches including regulator for fans and layout of the
same in the switchboard shall be to suit the requirement during installation.
6. CONDUITS & CONDUIT ACCESSORIES
6.1 The conduits shall conform to IS:9537. All conduits shall be seemed by welding,
shall be of heavy gauge and shall be hot dip galvanised.
6.2 Flexible conduits wherever required shall be made with bright, cold rolled annealed
and electro-galvanised mild steel strips.
6.3 All conduits accessories shall conform to relevant IS and shall be hot dip
galvanised.
7. JUNCTION BOXES
7.1 The junction boxes shall be suitable for mounting on walls, columns, lighting poles,
structures etc..
7.2 Junction boxes shall be of square/rectangular type of 1.6 mm sheet steel with
minimum 6 mm thick pressure diecast aluminium material LM-6 and shall have
bolted cover with good quality gasket lining
7.3 The junction box and cover shall be hot dip galvanised.
7.4. The junction boxes shall be complete with conduit knockouts/threded nuts and
provided with terminal strips .The junction boxes shall be suitable for termination of
conduit/glands of dia 20 mm, 25 mm, 32 mm, 40 mm on all sides. The junction
boxes shall be provided with 4 way terminals suitable for two numbers 10 sq. mm.
wire & for street lighting/switchyard lighting suitable for 2 numbers 4C x 16 Sq.mm
Al. cable.
7.5 The junction boxes shall have the following indelible markings
(i) Circuit Nos. on the top.
(ii) Circuit Nos. with ferrules (inside) as per drawings.
(iii) DANGER sign in case of 415 volt junction box.
7.6 The junction boxes shall be weather proof type with gaskets conforming to IP-55 as
per IS:13947 (Part-I). The conduit connections shall also be properly sealed to
prevent entry of water.
8. TERMINAL BLOCKS
8.1 Each terminal shall be suitable for terminating upto 2 Nos. 10 sq.mm. stranded
Aluminium Conductors without any damage to the conducors or any looseness of
105
connections. Terminal strips provided in street - lighting poles shall be suitable for
terminating upto 2 nos. 4C x 16 sq. mm aluminium cables.
9. PULL OUT BOXES
9.1. The pull out boxes shall be suitable for mounting on walls, column, structures etc.
The supply of bolts, nuts and screws required for the erection shall be included in
the installation rates.
9.2 The pull out boxes shall be circular of cast iron or 16 SWG sheet steel and shall
have cover with good quality gasket lining.
9,3 The pull out boxes and cover shall be hot dip galvanised.
9.4 The pull out boxes shall be completed with conduit knock outs/threaded hubs and
provided at approximately 3 meters intervals in a conduit run.
9.5 The pull out boxes used outdoor shall be weather proof type with gaskets
conforming to IP-55 as per IS:13947 (Part-I).
10. LIGHTING PANELS (L.P.)
10.1 Each panel shall be provided with one incoming triple pole switch fuse unit with
neutral link and outgoing miniature circuit breakers as per clause 2.0. The panels
shall conform to IS-8623.
The Outdoor and Street Lighting panels shall be provided with a timer device
having twenty four hour hand set dial with a facility for setting ON & OFF times.
The main contacts shall be rated equal to the rating of main contacts in the incomer.
There will be a provision of selecting either the manual control or the automatic
control.
10.2 Constructional Features
10.2.1 Panels shall be sheet steel enclosed and shall be dust, weather and vermin proof.
Sheet steel used shall be of thickness not less than 2.00 mm (cold rolled) or 2.5 mm
(hot rolled) smoothly finished, levelled and free from flaws. Stiffners shall be
provided wherever necessary.
10.2.2 All outdoor panels and panels located in damp atmosphere shall have degree of
protection not less than IP-55 as per IS:13947 / (Part-I). All indoor panels shall
have degree of protection not less than IP-52 as per IS:13947 (Part-I).
10.2.3 The panels shall be of single front construction, front hinged and front connected,
suitable for either floor mounting on channels, sills or on walls/columns by suitable
M.S. brackets.
10.2.4 Panels shall have a dead front assembly provided with hinged door(s) with
padlocking arrangement with single key supplied in duplicate.
106
10.2.5 All doors, removable covers and plates shall be gasketed all around with neoprene
gaskets.
10.2 6 The panels shall be suitable for cable/conduit entry from the top and bottom.
Suitable removable cable gland-plate shall be provided on the top and bottom of
panels. Necessary number of double compression cable gland shall be supplied,
fitted on to this gland plate. The glands shall be screwed on top and made of tinned
brass.
10.2.7 The panels shall be so constructed as to permit free access to connection of
terminals and easy replacement of parts.
10.2.8 Each panel shall have a caution notice fixed on it.
10.2.9 Each panel shall be provided with a circuit directory plate (of anodised aluminium
with the inscriptions indelibly etched on the plate) which is fitted on the inside of
the door.
10.2.10 Each lighting panel shall be provided with one no. ON indicating lamp for each
phase alongwith fuses.
10.3 Main Bus Bars
10.3.1 Bus bars shall be of aluminium alloy conforming to IS:5082 and shall have adequate
cross-section to carry the rated continuous and withstand short circuit currents.
Maximum operating temperature of the bus bars shall not exceed 85 deg. C. The
bus bars shall be able to withstand a fault level of 9 kA for 1 sec. for AC panels and
4 KA for 1 sec. for DC panels.
10.4 Switch-Fuse Units
10.4.1 Switches shall be hand operated, air break, heavy duty, quick make, quick break
type conforming to IS:13947.
10.4.2 The rating of switch shall be so chosen as to get complete protection under all
normal/abnormal conditions such as full load, overload, short circuit etc.
10.4.3 All fuses shall be plug in HRC cartridge link type. The fuses shall be of Class 3
type (20 kA prospective breaking current) for AC circuits and class 1 (16 kA
prospective current) for DC circuit. Fuses shall be provided with visible operation
indicator to show that they have operated. All accessible live connections shall be
adequately shrouded, and it shall be possible to change fuses with the circuit alive,
without danger of contact with live metal.
107
10.5 Miniature Circuit Breaker (MCB)
a) The miniature circuit breakers shall be suitable for manual closing, opening,
automatic tripping under overload and short circuit. The MCBs shall also be
trip free.
b) Single pole as well as three pole versions shall be furnished as required in
the Schedule of Lighting Panels.
c) The MCBs and panel incomer fuse together shall be rated for full fault level.
In case the MCB rating is less than the specified fault level the bidder shall
co-ordinate these breaker characteristics with the back up fuse in incomer
switch fuse unit in such a way that if fault current is higher than breaker
rating, the fuse should blow earlier than the breaker. If the fault current is
less than MCB breaking capacity, MCB shall operate first and not the
incomer fuse.
d) The MCBs shall be suitable for housing in the lighting panels and shall be
suitable for connection with stranded copper wire connection at both the
incoming and outgoing side by copper lugs or for bus bar connection on the
incoming side.
e) The terminals of the MCBs and the open close and trip conditions shall
be clearly and indelibly marked.
f) The tenderer shall check and co-ordinate the ratings of MCBs with respect to
starting characteristics of discharge lamps. The vendor has to furnish
overload and short circuit curve of MCB as well as starting characteristics
curves of lamps for Employers approval.
g) The MCB shall generally conform to IS:8828.
h) MCBs shall be Moorarjee Dorman Smith or STANDARD make.
10.6 Contactors
Contactors shall be of the full voltage, direct-on line air break, single throw, electro-
magnetic type. They shall be provided with atleast 2-NC and 2NO auxiliary
contacts. Contactor shall be provided with the three element, positive acting,
ambient temperature compensated time lagged, hand reset type thermal overload
relay with adjustable settings to suit the rated current. Hand reset button shall be
flush with the front of the cabinet and suitable for resetting with starter compartment
door closed. The Contactor shall be suitable for switching on Tungsten filament
lamp also. The bidder shall check the adequacy of the Contactors rating wire with
respect to lighting load.
108
10.7 Push Buttons
All push buttons shall be of push to actuate type having 2 NO and 2 NC self
reset contacts. They shall be provided with integral escutcheon plates engraved
with their functions. Push buttons shall be of reputed make.
10.8 Labels
a) The lighting panels shall be provided on the front with panel designation
labels on a 3 mm thick plastic plate of approved type. The letter shall be
black engraved on white back ground.
b) All incoming and outgoing circuits shall be provided with labels. Labels
shall be made of non-rusting metal or 3 ply lamicold. Labels shall have
white letters on black or dark blue background.
10.9 Earthing Terminals
10.9.1 Panels shall be provided with two separate and distinct earthing terminals suitable to
receive the earthing conductors of size 50x6 G.S. Flat.
10.10 All lighting panels shall have to be tested for the following items and test
certificates shall be furnished for the same :
(i) Wiring continuity test
(ii) High voltage (2.5 KV for 1 minute) and insulation test
(iii) Operational test
(iv) Degree of protection
(v) Heat run test
10.11 Lighting Transformer -
Lighting transformer shall be located in MCC room, in seperate enclosure.
Enclosure shall have degree of protection not less than IP-42 as per ISO-13947
(Part-I).
11. Emergency Portable Lighting Fixtures
11.1 The portable fixtures shall have a built in battery rated for six hours, battery
chargers and solid state inverters. These shall be of approved make.
11.2 The portable fixtures shall be of a single unit, completely tropicalised and suitable
for prolonged use with no maintenance.
11.3 The portable fixtures shall be supplied and necessary supporting brackets of
galvanised steel suitable for wall/column mounting shall also be supplied.
109
11.4 The portable fixture shall come up automatically in the event of failure of normal
supply.
12. LIGHTING POLES
12.1 The Contractor shall supply, store and install the following types of steel tubular
lighting poles required for street lighting.
a) Type A1 Street Lighting Pole - for one fixture
b) Type E1 Post top lantern pole - for one fixture
12.2 Street/flood light poles shall conform to the enclosed drawings. The complete civil
works for erection of the lighting poles shall be included in the scope of work.
12.3 Lighting poles shall be complete with fixing brackets and junction boxes. Junction
boxes should be mounted one meter above ground level.
12.4 The lighting poles shall be coated with bituminous preservation paint on the inside
as well as on the embedded outside surface. Exposed outside surface shall be
coated with two coats of metal primer (comprising of red oxide and zinc chromate
in a synthetic medium).
12.5 The galvanized sheet steel junction box for the street lighting poles shall be
completely weather proof conforming to IP-55 and provided with a lockable door
and HRC fuse mounted on a fuse carrier and fuse base assembly. The fuses &
junction box shall be as specified in the specification. However, terminals shall be
stud type and suitable for 2 nos. 16 sq.mm. cable.
12.6 Wiring (by 2.5mm wire) from junction box at the bottom of the pole to the fixture at
the top of the pole shall be included in the price of the pole.
12.7 Distance of centre of pole from street edge should be approximately 1000 to 1200
mm.
12.8 Earthing of the poles should be connected to the switchyard main earth mat
wherever it is available and the same should be earthed through 3M long, 20 mm
dia, earth electrode.
15. PAINTING OF SHOP MADE ITEMS
15.1 All sheet steel work shall be phosphated in accordance with the following procedure
and in accordance with IS:6005 'Code of Practice for Phosphating Iron and Steel'.
15.2 Oil grease and dirt shall be thoroughly removed by emulsion cleaning.
15.3 Rust and scale shall be removed by pickling with dilute acid followed by washing
with running water, rinsing with slightly alkaline hot water and drying.
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15.4 After phosphating through rinsing shall be carried out with clean water, followed by
final rinsing with diluted dichromate solution and oven drying.
15.5 The phosphate coating shall be sealed by the application of two coats of ready
mixed stoving type metal primer (comprising of red oxide and Zinc chromate in a
synthetic medium). The first coat may be 'flash dried' while the second coat shall be
stoved.
15.6 After application of the primer, two coats of finishing synthetic enamel paint shall
be applied with each coat followed by stoving. The second finishing coat for the
external of panels shall be applied after completion of tests.
15.7 Both outside and inside of lighting panel, sheet metal fabricated junction boxes etc.
and outside of lighting fixtures shall be finished in light grey (IS-5 shade 631).
Inside of lighting fixtures shall be finished in white.
15.8 Each coat of primer and finishing paint shall be of slightly different shade so as to
enable inspection of the painting.
15.9 The final finished thickness of paint film on steel shall not be less than 100 microns
and shall not be more than 150 microns.
15.10 Finished painted appearance on equipment shall present on aesthetically pleasing
appearance, free from dents and uneven surfaces.
16. TESTS AND TEST REPORTS
16.1 All the items covered under this section should be type tested, design and
conforming to the relevant standard.
17.4 Lighting panels
17.4.1 The lighting panels shall be erected at the locations to be finalized during detailed
engineering.
17.4.2 Suitable foundations/supporting structures for all outdoor type lighting panels and
necessary supporting structures for indoor lighting panels shall be provided by the
Contractor.
17.5 Foundation & civil works
17.5.1 Foundation for street lighting poles and panel foundation and transformer
foundation shall be done by the Contractor. The rates for these civil works shall be
included in the erection rates of respective items.
17.5.2 All final adjustment of foundation levels, chipping and dressing of foundation
surfaces, setting and grouting of anchor bolts, sills, inserts and fastening devices
shall be carried out by the Contractor including minor modification of civil works as
may be required for erection.
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17.5.3 Any cutting of masonry/concrete work, which is necessary shall be done by the
Contractor at his own cost and shall be made good to match the original work.
2.1 LIGHTING PANELS
415 AC lighting panel with 415V, 63A, 3 phase 4 wire bus and one no. 63A, TP,
MCB with neutral unit as incomer and 20A, MCB as outgoing feeders, the details
are as follows. These panels are without lighting transformers.
---------------------------------------------------------------------------------------
Type Description Details of
outgoing
feeders)
---------------------------------------------------------------------------------------
ACP-I Indoor 8 nos.-20A single
pole MCB.
ACP-2 Outdoor 8 nos.-20A single
pole
MCB and
1 No. 20A Tripple
pole MCB with
Neutral and suitable
timer and con-
tactor for auto-
matic switching
ACP-3 Outdoor 3 nos.-20A Tripple
street pole MCB with
lighting Neutral with suitable
panel timer and contactor
for automatic switching
Note: The numbers of outgoing feeders indicated above are the minimum.
---------------------------------------------------------------------------------------
2.2 220V DC indoor type change over board and 220V DC 32A two wire bus and one
32A contactor backed up by 32A double pole MCB as incomer. The panel shall
have local push button controls. Following are the various types of panels required
with control timer.
---------------------------------------------------------------------------------------
Type Description Details of
outgoing
feeders)
---------------------------------------------------------------------------------------
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DCP Indoor 6 nos.-16A DP
MCB unit
---------------------------------------------------------------------------------------
2.3 Sub-Lighting Panels
---------------------------------------------------------------------------------------
Type Description
---------------------------------------------------------------------------------------
SLP 4 pole 32A Isolator suitable
for 415V, 50 cycles AC
supply, standard kopp make
Enclosure shall be suitable
for outdoor use with IP-55
degree of protection as per
IS:13947 (Part-1).
---------------------------------------------------------------------------------------
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SPECIFICATION
FOR
EQUIPMENTS INSTALLATION
15.0 INSTALLATION SPECIFICATION AND GUIDELINES:
15.1.1 Installation of equipments:
All the electrical installation shall conform to the Indian Electricity Act, Indian Electricity
Rules and regulations in force in the state by Electrical inspector. All the items required as
per electrical inspector shall be included in the scope of work. These shall be installed by
duly licensed and authorized person only.
The mechanical and other installation shall conform to the applicable Acts and Rules of
corresponding Inspector and other relevant authorities, if any.
All the works under this contract, including the installation of the equipment, shall be got
inspected and approved by the relevant authorities like Electrical Inspector etc.
15.1.2 Erection and Commissioning Tools and Tackles
The bidder shall provide all tools/tackles, jigs and fixtures, winches, alignment tools,
welding sets, testing kits, testing meters/instruments, breaker handling devices, all
consumable items and construction equipments as required to install all the equipment and
to complete the work in all respects, and shall necessarily include (but not be limited to)
bolts, nuts, rivets, welding rods, shims, wedges, packing sheets, packing compounds, oil,
flushings oil, protective greases and oils, all materials required for proper installation and
protection of individual equipment in storage and during erection, testing and
commissioning.
This shall also cover proper alignment, tag welding, tagging, laying, marking of, and
connection of cables, fabrication supply and installation of all support structures for
installation of various electrical equipments and cables.
Provision of cable glands, ferrules, cable lugs, tags, sealing kits (for HT Cables) shall be
arranged.
Supply and installation of first aid boxes, shock treatment charts, rubber mats, etc.
Erection, testing and commissioning of various equipments shall be done strictly as per
manufacturers instructions.
Successful bidder shall submit proposed test procedure to the Board for approval well in
advance and shall not commence testing until approval is conveyed.
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All plant equipments, painting of which has been damaged during transportation / erection
or by corrosion shall be given two coats of paint after removal of scales, rust oil, etc.
All iron frame work erected shall be provided with two coat of primer and two top coats of
finish paint light gray shed.
Cables shall be laid in GI, class A pipe of suitable diameter or a support girder/channel
up to 2 meters height above the floor in case of vertical run to avoid mechanical damage in
the switch yard.
Cables shall be laid in separate racks according to voltage levels. Sufficient Horizontal
clearance shall be provided.
Maximum cross section areas of cables passing through conduit shall not exceed 60 % of
cross section of conduit.
Approved type of danger boards, in Gujarati, describing ISOLATED DO NOT CLOSE,
MEN AT WORK shall be provided in sufficient numbers as per the instruction of E.I.C.
Special care shall be taken to make the enclosed equipment worming proofing
Cables supports shall be provided at every 1000 mm along horizontal run and perforated
trays shall be provided for control cables.
15.1.3 Stages of completion of works
The stages of completion of various works shall be as follows:
1. Completion of erection
Equipment shall be considered to have been completely erected when the following
activities have been completed.
Moving of all structure and equipments to the respective foundations.
Fixing of anchor bolts or tag welding as required.
Erection of all structure of equipments
Leveling and alignment of equipments.
Jumpering of equipment and bus.
Assembling of all accessories such as relays, CTs, PTs, meters, instruments etc. as
described in the job specification.
Drying of equipment as required and testing of oil for dielectric strength
Filtration and filling of oil as required
Cable laying, terminations with continuity check.
Applying of finishing coat of paint.
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Mounting of lighting fixtures and connections.
Testing of all system with operation of all protection system.
SOME SPECIFIC INSTRUCTION FOR INSTILATION.
15.2 11 KV VACUUM CIRCUIT BREAKER :
15.2.1 SCOPE :
The work covered under this scope includes installation, connection, testing and
commissioning of indoor VCB
15.2.2.1 INSPECTION :
(i) The VCBs shall be inspected on its arrival as per instruction manual of the supplier.
(ii) All mechanical fasteners shall be checked and tightened before installation.
(iii) The operating mechanism of circuit breaker should be checked for any damage.
(iv) All the internal wiring shall be checked upon installation of the panel.
15.2.2.2 INSTALLATION:
(i) The Indoor VCB unit shall be installed as per installation manual of supplier and
shall conform to relevant Indian Standards.
(ii) The Indoor VCB unit shall be installed in control room as per the suppliers drawing
and instructions.
(iii) Indoor VCB unit shall be earthed by using required size of Gl strip as per design and
earthing installation shall conform to latest Indian Standard IS : 3043-1987 and
detailed specification given under separate heading of EARTHING of this
specification.
15.2.2.3 TESTING AND COMMISSIONING:
Prior to commissioning of Indoor VCB unit, following tests shall be carried out:
(i) A mechanical endurance test shall be carried out by closing and opening of the
switchgear.
(ii) Insulation resistance test shall be carried out between phases and between phase to
earth.
(iii) Other tests, required for commissioning the outdoor switchgear unit shall be carried
out by the bidder without any extra cost as per instruction of engineer in charge.
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15.3 POWER TRANSFORMER:
15.3.1 INSPECTION:
(i) The transformer shall be inspected at site as per the inspection manual of the
transformer supplier.
(ii) The transformer shall be examined for any sign of damage and special attention
shall be given to following parts :
a. Oil tank and cooling tubes.
b. Oil indicating glass.
c. All mechanical connections and protruding fittings.
d. All insulator terminals and joints.
e. The silica gel colour shall be checked to identify absorption of moisture in
the winding.
15.3.2 INSTALLATION:
(i) The transformer shall be assembled and installed as per installation manual of the
transformer supplier and installation shall confirm to Indian Standard IS : 1896-
1967.
(ii) Necessary arrangement shall be made on channel/Rail for locking of transformer
wheels on the platform.
(iii) Oil supplied in separate drums, shall be filled in, up to correct level ensuring that no
air bubble remains inside the transformer.
(iv) Wiring for Buchholz Relay, O.T.I., W.T.I., CTs etc. mounted on the transformer
shall be carried out, Cables shall be bunched in neat manner and properly clamped.
(v) Other checks necessary in respect of transformer shall be carried out.
15.3.3 Testing and Commissioning:
(i) Prior to commissioning the transformer, following tests shall be performed.
(ii) The insulation resistance and PI value of HV and LV side shall be measured and
ambient temperature shall also be recorded
(iii) Electrical break down strength and water content PPM test of transformer oil shall
be checked in accordance with IS:335.
(iv) In case the values are below 50/60KV, the oil shall be filtered to achieve the
strength of the oil above 50/60KV as per the rated capacity of transformer.
(v) Operation of the Buchholz relay shall be done in conjunction with H.V. switch
Board to test Buchholz alarm trip and high temperature alarm.
(vi) Ten delta measurement for bushing and transformer winding
(vii) The transformer breather shall be cleaned and filled with oil and silica gel.
(viii) Voltage ratio test shall be carried out for every tap position.
(ix) Magnetic balance shall be checked and compared with laboratory test results for any
damage to core winding assembly during Transportation/erection etc.
(x) P.I. value of transformer should also be derived before commissioning.
(xi) DGA analysis of transformer oil.
(xii) Other test which may be necessary in respect of transformer shall also be carried
out, even if the same has been not stated above.
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15.4 OUTDOOR / SF6 GAS CIRCUIT BREAKER:
15.4.1 INSTALLATION:
a) Sulphur hexa-fluoride (SF6) gas circuit barker with its support structure shall be
installed on foundation. Prior to erection, proper leveling of the foundation shall be
checked. The equipment should be in plumb after erection.
b) All the components and sub-assemblies of the SF6 CB shall be assembled together
by the bidder. The pressure and dielectric strength shall be checked after
installation, if required. SF6 gas shall be filled up to the correct pressure as per
suppliers manual. Anti corrosive grease shall be applied at bimetallic connections.
c) Compressor and compressor panel shall be properly installed on the foundation with
leveling, if applicable.
d) All tubing work to be complete with proper connection between Air compressor to
receiver tank and Breaker (air and gas tubing.), wherever applicable.
e) All control cabling work to be done between control panel and Breaker.
15.4.2 TESTING AND COMMISSIONING:
15.4.2.1 Testing of Breaker shall be done as per requirement of applicable Standard and
Specification of GEB. After successful testing, commissioning will be done. All the
commissioning checks and testing shall be done as per the instruction manual or as
per the instruction of manufacturers representative present for commissioning.
15.5 220KV & 66KV ISOLATORS SWITCH:
15.5.1 INSTALLATION:
(a) Isolators along with supporting structure shall be installed on RCC foundation.
Adequate supports for the down rod shall be provided.
(b) All isolator insulators shall be installed in proper level.
(c) All contact alignment to be checked for proper contact pressure.
(d) Proper greasing to be done on movable contacts.
(e) Isolator and earthing switch interlocking to be properly checked.
(f) Complete assembly shall be checked for satisfactory 50 operations.
15.5.2 TESTING AND COMMISSIONING:
15.5.2.1 Testing of Isolator shall be done as per requirement of applicable Standard and
Specification of GEB. At least 50 nos. of open & close operations to be done after
complete installation of isolator. After successful testing, commissioning will be
done. The suppliers manual shall be referred to.
15.6 220KV & 66KV CT, PT AND PI:
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15.6.1 INSTALLATION:
(a) Outdoor CTs and PTs with supporting structures shall be installed on R.C.C.
foundations after checking the leveling of the foundation. The Polarity of primary
terminals shall be checked and verified as per instruction of Engineer in Charge.
(b) Accessories supplied loose shall be fitted on the equipments. Oil level shall be
checked and if required, oil shall be filled upto the correct level.
(c) Wiring of the CTs and PTs secondary box shall be checked and fuses provided shall
be checked for continuity.
15.6.2 TESTING AND COMMISSIONING:
15.6.2.1 Testing of 220kV & 66 KV CT, PT and PI shall be done as per requirement of
applicable Standard and Specification of GEB. After successful testing,
commissioning will be done.
15.7 SWITCH YARD STRUCTURE AND SWITCH YARD ANCILLARY
EQUIPMENT: (Structure to be supplied by Bidder)
15.7.1 GENERAL:
a. The scope of structural work includes design, engineering, fabrication, galvanizing,
supply and installation of all types of gantry column and gantry beam, supports, for
220kv & 66 KV switch yard as per design. This shall, also, include all types of
bolts, nuts, hangers, shackles, clamps, anti-climbing devices, bird plates, insert in
concrete and foundation bolts etc., as required to complete the job. Phase plate shall
be provided at each incoming gantry and bus bar gantry as per instruction of
Engineer In Charge.
b. The quoted price shall include cost of preparation of design, supply of all materials,
including taxes, duties, Octroi, labour, erection, plant and erection of equipments,
fixtures, fittings and all temporary and permanent respects. Unit prices per tones of
steel for the entire scope of work shall also be indicated. These prices would be used
for payment purpose in case the actual tonnage of steel used is less than minimum
guaranteed or if the tonnage of steel exceed due to change of scope of work.
c. Steel shall conform to IS : 226 / IS : 2062 where cut pieces out of plates are used by
butt welding to part of either flange plates or web plates of fabricated columns and
main frame beams. The length of such pieces shall not be less than three meters.
When cut pieces put of rolled sections are to be joined by butt welding splicing for
making beam members, truss members, rolled components of columns, the length of
such pieces shall not be less than three meters nor shall the total number of pieces in
any member exceed three meters.
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15.7.2 STANDARDS:
a. Standards: Any material, not specified herein and for which there is IS, shall
conform to the latest IS.
b. IS Specification: All work shall be done strictly as per the IS specifications and the
latest relevant IS standards and codes of practice, whether, mentioned in the
specification or otherwise. All materials shall be of best quality confirming to the
relevant IS standards.
15.7.3 DRAWINGS:
The fabrication drawings prepared by the bidder shall indicate the size and weight
of sections shown in the design drawings. All structure design shall be got approved
by Engineer-in-charge, consulting engineer and their weights with reference
identification (erection) marks shall be provided for purpose of dispatch and
erection etc. in form of Bills of materials including quantity and length of various
sizes of Bolt, Nuts, Anchor Bolts required to complete structure erection.
15.7.4 FABRICATION
a. The fabrication and erection of the works shall be carried out generally in
accordance with the IS - 800 as well as the stipulation contained in these
specifications.
b. All steel materials shall be straight and free from bend or twists. The edges of all
plates shall be perfectly straight and uniform through shearing, cropping and gas
cutting.
15.7.5 BOLTING:
Every bolt shall be provided with a steel washer under the nut so that no part of the
threaded portion is bolted together. All bolts and nuts shall be of steel with well
formed hexagonal heads unless specified or otherwise forged from the solid as they
are made. Flat washer shall be circular and of suitable thickness. Spring washers of
suitable size shall also be included for each Bolt confirming to relevant IS.
15.7.6 GALVANIZING:
a. All structural steel works shall be galvanized after fabrication. All burrs and
irregular edges will be ground smooth before galvanizing.
b. The galvanized surface shall consist of a continuous and uniform thick coating of
zinc, firmly adhering to the surface to steel. Members embedded in concrete shall be
galvanized from the top to a point at least 300 mm below the proposed elevation of
the concrete foundation. Before galvanizing, the steel section shall be thoroughly
cleaned. Picking shall be very carefully done and shall be proper.
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c. Galvanizing of each member shall be carried out in one complete immersion. When
the steel section is removed from galvanizing kettle, excess spelter shall be removed
by pumping process.
d. All members and accessories shall be treated with sodium dichromate or an
approved equivalent solution after galvanizing so as to prevent white storage stains.
15.7.7 SWITCHYARD ANCILLARY EQUIPMENTS (To be supplied by bidder)
a. Insulator hardware shall conform to the requirement, stipulated for clamps and
connectors. Insulator hardware assembly shall be designed for tensile load for 1000
Kg tensile load for each phase of switchyard with factor of safety two (2).
Hardware shall be subject to all routine tests in accordance to IS-731 and IS-2486
respectively and routine and acceptance test certificates shall be submitted.
b. Required A.C.S.R. Panther or any other Conductors as per the final lay out shall be
provided by the bidder.
Clamp & Connector :-
(i) For connecting ACSR: Aluminium casting
conductors confirming to designation
A-6 of IS ; 617.
(ii) For connecting : Bimetallic connectors
equipment terminals made from aluminium
made of copper to oil casting conforming to
ACSR conductor relevant standard with 4
Mm mm thick cast copper liner.
(iii) For connecting G.I : Malleable iron casting.
shield wire
(iv) Bolts nuts, plain : Galvanized High tensile
& spring steel washer etc.,
washer
All casting shall be free from blow holes, cracks and cavities. All sharp edges and corners
shall be blurred and rounded off. No part of a clamp or connector shall be less than 10 mm
thick. All ferrous parts shall be hot dip galvanized, confirming to IS : 2633.
For bimetallic clamps or connectors, copper alloy liner of minimum thickness 4 mm shall
be cast integral with aluminium alloy body.
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Flexible connectors shall be braided or laminated. Strip shall be made from tinned copper
sheets or aluminium laminated depending on the clamps. The terminal clamps for bus
supports shall be suitable for ACSR Panther conductor.
Size of the terminal/conductor for, which the clamp connector is suitable shall be embossed
/ punched on each components of the clamp / connector, except on the hardware. Clamps
shall be designed to carry the same current as the conductor & the temperature rise shall be
equal to / less than that of the conductor at the specified ambient temperature. All current
carrying parts shall be designed and manufactured to have minimum contact resistance.
Clamps and connectors shall be designed carona controlled.
15.7.8 BATTERY AND BATTERY CHARGER:
As specified in supply specification maintenance free batteries of lead acid type or
Ni Cad. type is required to be supplied, as such over and above the below
mentioned clauses the additional necessary provisions required for this type of
batteries are to be made.
(a) Each cell shall be inspected for breakage and condition of cover seals as soon as
received at site. Each cell shall be filled with electrolyte in accordance with
manufacturers instructions. All safety precautions shall be taken while handling
sulphuric acid.
Contact surface of the battery terminals and inter cell connector shall be cleaned,
coated with protective grease and assembled. Each connection shall be properly
tightened. Each cell be tested with hydrometer and thermometer.
(b) Bidder shall arrange for necessary charging and discharging equipments and carry out the
charging and discharging process as per manufacturers instruction. The readings during charge
and discharge test shall be recorded by bidder as per the manufacturers instruction and test result
shall -be submitted to site engineer-in-charge.
15.8 INSTALLATION SPECIFICATION OF LT PANEL :
15.8.1 INSPECTION:
(i) The switchboard shall be checked for any damage.
(ii) Meters, relays etc. shall be checked and fixed before installation.
(iii) All mechanical fasteners shall be checked and tightened before installation.
15.8.2 INSTALLATION:
(i) The distribution switchboard panel shall be assembled and aligned together and
installed on the M.S. frame properly.
(ii) The switchboard shall be erected and levelled on the foundation as per the suppliers
drawing.
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(iii) Busbar connections between the L.V. side of the transformer and incoming feeder
shall be checked after installation.
(iv) Busbar connections between the panels shall be checked and tightened as per the
suppliers drawings.
(v) Meters including two nos. of static energy meters and relays shall be fixed in
positions and connected as per the suppliers drawings.
(vi) All earthing connections of earthing system shall be visible for periodical checking.
(vii) The entire equipment earthing shall be done as per drawing and shall confirm to
Indian Standard IS : 3043-1987 and detailed specification given under separate
heading of EARTHING of these specifications.
15.8.3 TESTING AND COMMISSIONING:
Prior to commissioning the L.T. panel. Following tests shall be carried out by the
bidder.
(i) Insulation resistance test.
(ii) High voltage tests 2500 volts.
(iii) Tripping of breaker by applying secondary source and setting of relay and as per
instruction of engineer-in-charge.
(iv) Testing meters and calibration of all meters.
15.9 INSTALLATION SPECIFICATION FOR CABLING :
(a) GENERAL:
H.T./ L.T. cables shall be laid, tested and commissioned in accordance with
specification, relevant Indian Standard Specification and manufacturers
instructions.
15.9.1 LAYING OF CABLES:
Cables shall be laid by skilled and experienced workmen using adequate rollers to
minimize stretching of the cable. The cable drums shall be placed on joint before
unwinding the cable. Great care shall be exercised in laying cables to avoid forming
kinks. The drums shall be unrolled and cabling over wooden rollers in trenches at
intervals not exceeding 2 meters. Cables shall be laid at depth of 1000 mm below
ground level in the case of MV cables. A cushion of sand not less than 80 mm shall
be provided both above and below the cable, joint boxes and other accessories. HV
and MV. Cables shall not be laid in the same trench and / or along side of water
main. The cable shall be laid in excavated trench; 80 mm layer of sand shall be
spread over the cable. The cable then shall be lifted and placed over the sand. The
relative position of the cables laid in the same trench shall be preserved and the
cables shall not cross each other as far as possible. In case of changes in direction in
horizontal and vertical planes, the cable shall be bent smooth with a radius of bend
not less than 12 times the diameter of cable. Minimum 3 meter long loop shall be
provided at both sides of every straight joint and 5 meters at each end of the cable.
Distinguishing marks shall be made on the cable ends for identification. Insulation
tapes of appropriate voltage and in red, yellow and blue colours shall be wrapped
just below the sockets for phase identifications.
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15.9.2 CABLES TERMINATION:
Cable termination shall be done in terminal cable box using cable glands and the
cable ends sealed with seating compound. The cable end terminations of HT cables
shall strictly be done as per instructions of cable termination kit suppliers in
consultation with engineer-in-charge.
15.9.3 JOINTING OF CABLES:
15.9.3.1 GENERAL:
The bidder shall take care to see that all the cables are laid at various locations to
ensure no straight joints in the cable run. If the straight joint in cable is unavoidable
due to any specified reasons, prior permission shall be obtained from the engineer-
in-charge before the use of such straight joints in cable.
All end, straight and T-joints shall be of epoxy resin cast / heat shrinkable / cold
push on type with jointing kits of Raychem / M-Seal/
Denson makes or of approved equivalent make. All the jointing accessories used
shall be of approved jointing kit manufacturers only. All terminal ends of
conductors shall be heavily crimped to avoid unnecessary heating.
All same coloured cables shall be jointed and tested for insulation resistance and
continuity before jointing commences. The seals of cables mustnt be removed until
preparations for jointing are completed. Joints shall be finished on the same day as
commenced and sufficient protection from the weather shall be arranged. Joints
shall be made by means of suitable solder less crimping method for conductors, the
conductor being firmly bottled into the connections.
The conductors shall be efficiently insulated with high voltage insulating tape and
use of separators of approved size and pattern.
15.9.3.2 JOINTING BOX:
Cable jointing boxes shall be of appropriate size, suitable for cables of particular
voltage ratings and shall be manufactured by approved make.
15.9.3.3 CABLE TERMINATION:
Before making a cable end or straight joint, put the cables in proper position with
support below the cable. If required, cut the top insulation in proper manner after
measuring the length required for jointing. After insulation cutting, bind the cable
armoured with wire binder over the armour. Turn back the armoured wire over the
top insulation of the cable. Before turning of armoured wire, slip one hose clip over
the outer PVC insulation of cable. Apply three layers of PVC adhesive tape over the
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inner PVC sheath just above the armour. Remove the inner sheath up to the PVC
tape. Spread out the core. Apply three layers of PVC tape lightly over the copper
tape screen at the top end of the core to present loosening of the screen. Solder one
small earth braid to the copper tape screen of each core as per requirement. Connect
large earth braid to the armour. Insert the hose clip from on the earth braid and
tighten fully. Remove the copper tape screen as per requirement and clean the core
insulation with solution given in KIT by kit supplier. Insert the jointing sleeves on
the core insulation gradually and push it down. Start shrinking from down and
proceed upward for end termination. Crimp the lugs, file off burrs. Bidder has to
follow all instruction and spedal instruction given by cable end / straight joint kit
manufacturer.
The entire work of the cable jointing should be carried out through a skilled and
competent trained cable jointers.
15.9.4 BONDING OF CABLES:
Where a cable enters any piece of apparatus, it shall be connected to the casing by
means of an approved type of armoured clamp and gland. The clamps must grip the
armouring firmly to the gland or casing, so that in the event of ground movement,
no undue stress is passed on to the cable conductors.
15.9.5 PROTECTION OF CABLES:
The cable shall be protected by placing burnt bricks on two side and over the cables
on the top layer of sand for the full length of underground cable. Where more than
one cable is running in the same trench, the bricks shall cover all the cables and
shall project a minimum of 80 mm on either side of the cables.
Cables under road crossings and any surfaces subjected to heavy traffic shall be
protected by running them through Hume pipes of suitable size and proper grade.
15.9.6 CABLE INSIDE BUILDINGS:
Cables, inside buildings shall be laid either in masonry trenches or carried on cable
trays, racks or brackets. Where cables run in ducts inside the building, the cables
shall be adequately clamped to angle iron brackets / iron cable trays, secured to the
wall as directed and approved by the engineer-in-charge. Where cables are
suspended from ceilings they shall be carried over cable trays or racks as directed
and approved by the engineer-in-charge. The supports shall be placed not more than
600 mm apart. All cables passing through walls shall run through stoneware pipes or
Hume pipes of adequate diameter. Cables running along walls shall be supported
and clamped to saddles, or hanger, rigidly anchored at close intervals. Where called
for cable trenches they shall be filled with fine sand. The bidder shall ensure that
hangers, brackets and other supporting arrangements for cables are placed in proper
position at the time of building the walls, concrete may be carried out only with
prior permission of the consultants.
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15.9.7 EXCAVATION AND BACK FILLING:
Trenches shall be dug true to line and grades. Back fill for trenches shall be filled in
layers, not exceeding 250 mm. Each layer shall be properly rammed and
consolidated before laying the next layer. The bidder shall restore all surfaces,
roadways, side walks, curbs, walls or other works cut by excavation to their original
condition satisfactory to the engineer-in-charge.
15.9.8 MARKERS AND WARNING PLATES:
Approved CI cables markers shall be provided along the route of the cables at every
30 meter distance and at both ends of road crossing, indicating HV cables and MV
cables as applicable. Special CI marker shall be provided at all buried cable joints
indicating Electrical Cable Joints.
15.9.9 TESTING OF CABLE:
Prior to burying cable following tests shall be carried out:
Insulation test between phase to phase and phase to earth for each length of cable
before and after jointing, shall be carried out.
On completion of cable laying work and jointing, the following test shall be
conducted in the presence of the engineer-in-charge.
(a) Insulation resistance test.
(b) Continuity test.
(c) Earth test
(d) High voltage test.
All tests shall be carried out in accordance with relevant Indian Standard code of
practice and Indian Electricity Rules. The bidder shall provide necessary
instruments, equipment, engineers and labour for the above test and shall bear all
expenses in connection with such tests. All tests shall be carried out in the presence
of the engineer-in-charge.
15.10 INSTALLATION SPECIFICATION FOR EARTHING:
15.10.1 GENERAL:
All the non-current metal parts of electrical installation shall be earthed properly.
All metal conduits, trucking, cable sheaths, switchgear, distribution fuse boards,
lighting fittings & fixtures and all other parts made of metal shall be bonded
together and connected by means of specified earthing system. All earthing will be
conformed to Indian Standard Specifications IS : 3043 1987. The bidder shall
measure the resistivity of various places in the proposed sub stations and design
suitable earthing system and get it approved from G.E.B.
15.10.2 EARTHING CONDUCTORS:
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All earthing conductors shall be of high conductivity G.I./Aluminium/ copper and
shall be protected against mechanical injury or corrosion.
15.10.3 CONNECTION OF EARTHING CONDUCTORS:
(i) Main earthing conductors shall be taken from the earth connections at the main
switchboards to an earth electrode with which the connection is to be made. Sub-
main earthing conductors shall run from the main switchboard to the sub-
distribution boards. Final distribution boards earthing conductors shall run from
sub-distribution boards.
(ii) Circuit earthing conductor shall run from the exposed metal of equipment and shall
be connected to any point on the main earthing conductor or its distribution boards
or to an earth leakage circuit breaker. Metal conduits, cable sheathing and
armouring shall be earthed at the ends adjacent to switchboards at which they
originate or otherwise at the commencement of the run by an earthing conductor in
effective electrical contact with cable sheathing. Where equipment is connected by
flexible cord, all exposed metal parts of the equipment shall be earthed by means of
an earthing conductor enclosed with the current carrying conductors within the
flexible cord. Switches, accessories, lighting fitting etc. which are rigidly secured in
effective electrical contact with a run of metallic conduit shall not be considered as a
part of earthing conductor for earthing purposes, even though the run of metallic
conduit is earthed.
(iii) All metal clad switches and other equipment carrying single phase current, shall be
connected to earth by a single connection. All metal clad switches, carrying medium
voltages and high voltage shall be connected with earth by two separate and distinct
connections. The earthing conductors inside the building, wherever exposed, shall
be properly protected from mechanical injury by running the same in GI pipe of
adequate size.
(iv) Earthing conductors, outside the building, shall be laid 600 mm below the finished
ground level.
(v) In case of copper earthing strips, the cover lapping at joints (wherever required),
shall be of minimum 75 mm. Sweated lugs of adequate capacity and size shall be
used for ail termination of wires above 6 sq. mm size and bare copper wire above
2.5 mm dia. Lugs shall be bolted to the equipment body to be earthed after the metal
body is cleaned of paint and other oily substance and properly tinned.
(vi) Neutral conductor, sprinkler pipes or pipes conveying gas, water or flammable
liquid, structural steel work, metallic enclosures for cables and conductors, metallic
conduits and lightning protection stem conductors shall not be used as a means of
earthing an installation or even as a link in an earthing system. The electrical
resistance of metallic enclosures for cables and conductors measured between earth
connections at the main switchboard shall be low enough to permit the passage of
current necessary to operate fuse or circuit breakers and shall not exceed one ohm.
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15.10.5 PROTECTION FROM CORROSION:
Connections between copper and galvanized equipment shall be made on vertical
face and protected with paint and grease. Galvanized fixing clamps shall be used for
fixing earth conductors. When there is evidence that the soil is aggressive to copper,
buried earthing conductors shall be protected by suitable serving and sheathing.
15.10.6 EARTHING MASH:
Earthing Mash shall be installed as per the specification of Part II
15.10.7 PIPE ELECTRODE EARTHING:
The pipe electrode earthing is specified in Schedule B 1 , Item no. 14. The electrode
shall be in one piece and no joints shall be allowed in the electrode. Wherever
possible, earth electrodes shall be located close to water tap, water drain or a down
take pipe. Earth electrode shall not be located in proximity to a metal fence. It shall
be kept clear of the building foundations and in no case, it shall be nearer than 2
meters from the outer face of the wall.
15.10.8 EARTH RESISTANCE:
The earth resistivity result of the soil where the earthing stations are located shall be
submitted to the engineer-in-charge before the earthing work starts. If the earth
resistance is too high and multiple electrode earthing does not give adequate low
resistance to earth, the soil resistivity immediately surrounding the earth electrodes
shall be reduced by adding sodium chloride, calcium chloride, sodium carbonate,
copper sulphate, salt and soft coke or charcoal in suitable proportions as required.
15.10.9 RESISTANCE TO EARTH:
The resistance of each earth system shall not exceed 1 ohm in the case of M.V.
system and 0.5 ohm in the case of H.V. system.
15.11 INSTALLATION SPECIFICATION FOR LIGHT POINT WIRING:
15.11.1 SYSTEM OF WIRING:
The system of wiring shall consist of single core PVC insulated copper conductor
wires in PVC conduits All conduits shall be concealed unless other wise called for.
15.11.2 GENERAL:
Prior to the laying of conduits, the bidder shall submit the shop drawings for conduit
layout indicating the route of the conduit, number and size of conduits, location of
junction / inspection / pull boxes, size and location of the switch boxes, point outlet
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boxes and other details. These shop drawings shall be got approved by the Engineer-
in-charge before the laying of the conduits.
15.11.3 MATERIALS:
PVC conduits shall be used for concealed and exposed conduit work
(ii) PVC CONDUITS :
PVC Conduits shall be solid drawn of lap welded conduits. Stove enameled inside
and outside with minimum wall thickness of 1.5 mm for conduits upto 25 mm dia.
and 2.0 mm wall thickness for conduits above 25 mm dia. The conduits shall be
delivered at site of construction in original bundles of each length with the original
labels of the manufacturer. The number of insulated copper wires to be drawn into
the conduits of various sizes are given below & the fill shall not exceed 40 %.
15.11.4 MAXIMUM PERMISSIBLE NUMBER OF WIRES FOR CONDUITS:
(1100 Volts grade either single/Multi core PVC insulated wires that may be drawn
in rigid nonmetallic or metallic conduits)
Size of conduits (mm) Size of wire
(Nominal cross section area of conductor
sq. mm).
19 25 32
1.5 6 10 18
2.4 5 8 14
4.0 3 6 10
6.0 2 5 6
10 - 2 6
16 - - 3
25 - - 3
35 - - 2
15.11.5 PVC CONDUIT CONNECTION:
Conduit connections for PVC conduits shall be screwed metal to metal and be
painted with one coat of self etching zinc chromate primer and two coats of enamel
paint. The threads and sockets shall be free from burs, grease and oil. The
connections between screwed conduit and sheet metal boxes shall be by means of a
non metallic smooth bore bush, fixed inside the box checknuted inside and outside
box and
connected through a coupler to the conduit. The joints in conduits shall be free of
burrs to avoid damage to insulation of conductors while pulling them through the
conduits. Connections between PVC and MS conduits shall be through a junction
box. Direct connections between PVC and MS conduits are not allowed
15.1.6 BENDS IN CONDUIT:
Where necessary, bend or diversions may be achieved by means of bend or circular
inspection boxes with adequate and suitable inlet and outlet screwed joints. In case
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of recessed system, each junction box shall be provided with cover properly secured
and flush with the finished wall surface, so that the conductors inside the conduits
are easily accessible. No bends shall have radius less than 2.5 times the outside
diameter of the conduit.
15.11.7 FIXING OF CONDUITS:
Conduits and junction boxes shall be kept in position while the wall, slabs and
floors are under construction and proper holdfast shall be provided. Conduits shall
be so arranged as to facilitate easy drawing of wires through them. Adequate
junction boxes of approved shape and size shall be provided. Where conduits
crosses expansion joints in the building, adequate expansion fitting or other
approved devices shall be used to take care of any relative movement. All conduits
shall be installed such so as to avoid steam and hot water pipes. Conduits shall not
come in contact with any wooden members, unless otherwise stated. Conduits state
in floor / stabs shall be kept as short as possible above the finished floor level in
order to avoid any damage to them. After the conduits junction boxes, outlet boxes
and switch boxes are installed in position; their outlets shall be properly plugged or
covered so that water, mortar, insects or any other foreign matter does not enter into
the conduit system. Exposed conduit shall be fixed by means of space bar, saddles at
intervals not more than 1000 mm in normal run and 500 mm from both sides of
fitting or accessories. The saddles shall be of 3 mm x 19 mm galvanized mild steel
flat, properly treated with primer and painted and fixed to support by means of nuts
and bolts / raw / bolts and brass machined screws as required.
Conduits shall be laid in a neat and organized manner as directed and approved by
the Consultant. Conduit runs shall be planned such that it does not conflict with any
other service pipe lines / Ducts.
Where exposed conduits are suspended from the structure, they shall be clamped
firmly and rigidly to hangers of design to be approved by the Consultant. Where
hangers are to be anchored to reinforced concrete, appropriate inserts and necessary
devices for their fixing shall be left in position at the time of concreting. Making
holes or opening in the concrete will generally not be allowed. In case, it is
unavoidable prior permission of the Consultant shall be obtained.
15.11.8 PROTECTION
To minimize condensation or sweating inside the conduit pipes, all outlets of
conduit system shall be adequately ventilated as directed and approved by the
Consultant. All screwed and socketed connections shall be adequately made fully
water tight by the use of proper jointing materials.
15.11.9 SWITCH OUTLET BOXES AND JUNCTION BOXES:
All outlet boxes for switches, sockets and other receptacles shall be fabricated from
1.5 mm thick mild steel sheets, duly painted with rust proof paint as called for
finish. Junction boxes and outlet boxes in contact with earth or installed in areas
exposed, to the weather, shall be of 2 mm thick mild steel and hot dip galvanized
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after fabrication. Where called for outlet boxes for receiving switches, telephone
outlets power plugs etc. they shall be fabricated to the approved shape and size to
suit the cover plates of specified make for different utilities. The cover plates shall
be of best Perspex sheet cut to shape and size wherever regular piano switches used
and for brass toggle switches the cover plates of the switches shall be of 3 mm thick
powder coated aluminium sheet as approved by the Engineer-in-charge. Proper
supports shall be provided in the outlet boxes to fix the cover plates of switches as
required. Wherever the specified make of switch and its other connected utilities is
MK or equivalent make, the switch boxes shall be suited to receive MK or
equivalent make switches, plugs etc. only and the cover plate of the boxes housing
the switches shall be of MK or equivalent make suitable for receiving MK or
equivalent make logic modular kind of design of switches and its other utilities.
Separate screwed earth terminal shall be provided inside the box for earthing
purposes. All boxes shall have adequate number of knock out holes of required
diameter for conduit entry. Where called for outlet boxes for receiving switches and
fan regulators in one box, the boxes shall be fabricated to approved shape and size
so as to accommodate fan regulators switches. All junction boxes, pull boxes and
outlet boxes shall be provided with 3 mm thick Perspex sheet cover. The box cover
shall be secured to the box with adequate number of round head brass screws of
approved make. Outlets exposed to the weather shall be fully weather tight,
complete with rubber gasketed covers, glass where used shall be fully heat resistant
for its duty. The outlet boxes shall be painted with two coats of bitumastic paint
before they are fixed in position. Outlet boxes fixed in concrete shall be in position
and shall be of a minimum depth of 65 mm.
15.11.10 INSPECTION BOXES
Rust proof inspection boxes shall be of 1.5 mm thick mild steel sheet and of
required size, having smooth external and internal finish and shall be provided to
permit periodical inspection and to facilitate removal and replacement of wires,
when required. Inspection boxes shall be mounted flush with ceiling / walls finished
surface and shall be provided with screwed covers of 3 mm thick Perspex sheet
cover secured to the box with brass screws.
15.11.11 CONDUCTORS:
All PVC insulated conductor wires shall confirm, in all respects, of the relevant IS
codes & they shall bear an ISI mark.
15.11.12 BUNCHING OF WIRES:
Wires carrying current shall be so bunched in the conduit that the outgoing and
return wires are drawn into the same conduit. Wires originating from two different
phases shall not be run in the same conduit.
15.11.13 DRAWING OF CONDUCTORS:
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The drawing and jointing of insulated conductor wires shall be executed with due
regard and precautions. Care shall be taken so as to avoid scratches and kinks which
may cause damage to insulation and also breakage of conductors. There shall be no
sharp bend.
Insulation shall be shaved off for a length of 15 mm at the end of wire like
sharpening of a pencil and it shall not be removed by cutting it square or ringing.
PVC insulated copper conductor wire ends before connection, shall be properly
crimped by means of standard solder less crimping method. Strands of wires shall
not be cut for connecting to the terminals. All strands of wires shall be properly
crimped at the end before connection. The connecting brass screws shall have flat
ends. The pressure applied to tighten terminal screws shall be just adequate, neither
too much nor too less. At all bolted terminals, brass flats washer of large area and
approved steel spring washers shall be used. Brass nuts and bolts shall be used for
all connections.
Only certified wiremen and cable jointers shall be employed to do jointing work. All
wire shall bear the manufacturers fable and shall be brought to site in new and
original packages.
For all internal wiring PVC insulated wires of 660/1100 volts grade shall be used.
The sub-circuit wiring for points shall be carried out in looping system and no joint
shall be allowed in the length of conductors. No wire shall be drawn into any
conduit, until any work, that may cause injury to wire, is completed. Care shall be
taken in pulling the wires so that no damage occurs to the insulation of the wire.
Before the wires are drawn into the conduits the conduits shall be thoroughly
cleaned of moisture dust, and dirt or any other obstruction by forcing compressed air
through tide conduits. The minimum size of PVC insulated copper conductor wires
for all sub circuit wiring i.e., from switch boards to point outlet for lights, exhaust
fans and ceiling fan points shall be 1.5 sq. mm. In case of power circuit not more
than one.
20 / 1 5 amp power outlets shall be in one circuit, wiring for the power outlet shall
be carried out with 4 / 2.5 sq. mm PVC insulated copper wires. All 20 / 15 amp.
power outlet shall be connected with 2.5 /1.5 sq. mm copper wire to the earth
terminal of outlet. Separate circuit shall run with 4 sq. mm PVC insulated 7 / 0.029
copper conductor wires for each water heaters, Kitchen equipment, window air
conditioners and similar outlets.
The minimum size of copper conductor PVC insulated wire from final distribution
board to first tapping point in the circuit shall be 2.5 sq. mm Maximum lighting
points to be connected in a circuit shall be 10 (800 Watts maximum).
15.11.14 JOINTS:
All joints shall be made at main switches, distribution boards, socket outlets,
lighting outlets and switch boxes only. No joint shall be made inside conduits and
junction boxes. Conductors shall be continuous from outlet to outlet. Joints where
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unavoidable, due to any specified reasons, prior permission shall be obtained from
the Engineer-in-charge making such connections.
15.11.15 MAINS AND SUB-MAINS:
Mains and sub-mains wires, where called for, shall be of the rated capacity and
approved make. Every main and sub-main shall be drawn into an independent
adequate size conduit. Adequate size draw boxes shall be provided at convenient
locations to facilitate easy drawings of the mains and sub-mains. An independent
earth wire of proper rating shall be pro vided. Each phase shall be provided with
separate current transformer of accuracy Class I and suitable V.A. Burden for
operation of associated metering. Current transformers shall be in accordance with
IS: 2705-964.as amended up to date.
15.11.16 MINIATURE CIRCUIT BREAKER DISTRIBUTION BOARD:
The bidder has to use ready-made MCBDBs of approved make only. Fabricated
MCBDBs will not be permitted.
15.11.17 LABELS:
Engraved PVC lables shall be riveted / screwed on all incoming and outgoing feeder
switches. Circuit diagram, showing the arrangements of the circuit inside the
distribution board shall be pasted on inside of the panel door and covered with
transparent laminated plastic sheet.
15.11.18 EARTHING:
Copper / G.I. earthing strips of adequate size shall be connected to the MCBDBs at
minimum two earth terminals from the main earthing grid.
16.0 SITE TEST AND CHECKS:
16.1 General:
16.1.1 All the equipment shall be tested at site to know their condition and to prove
suitability for required performance. The list of tests / indicated to be conducted,
and all required equipment / instrument shall have to be arranged by the bidder. Any
other test which is considered necessary by the manufacturer of the equipment,
bidder or as mentioned in commissioning manual, shall have to be conducted at site.
In addition to the tests on individuals equipment, some tests / checks are to be
conducted / observed from overall system point of view to develop confidence for
charging of the system / equipment. Such checks are highlighted under
miscellaneous tests but these shall not be limited to as indicated, and shall be
finalized in consultation with Engineer-in-charge.
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All cheeks and tests shall be conducted in the presence of clients representative and
test results shall be submitted in three copies, to client and one copy to Electrical
Inspector. Test results shall be filled in proper Performa.
After clearance from Electrical inspector, system equipments shall be charged in
step by step method..
Based on the test results clear cut observation shall be indicated by testing engineer
with regard to suitability for charging of the equipment or reasons for not charging,
are to be brought out by the bidder.
16.2 HT SWITCHGEAR
1. IR test
2. HV one-minute test
3. Measurement of BDV of oil for Transformer, CT, PT etc.
4. Test to prove inter changeability of similar parts (including breaker module).
5. Testing of relays as per suppliers commissioning manual.
6. Testing and calibration of all meters.
7. Operation of all relays by secondary injection method.
8. Testing of CT polarities and CT ratio by primary injection test.
9. IR and voltage ratio test for PTs.
10. Functional test of all circuit components for each panel / feeder.
11. Test to prove closing / tripping operation at minimum and maximum specified
voltage in test and service position.
12. Check for draw out test and service position of breakers for all feeders.
13. Check for covering of all openings in the panel check for continuity and operation
of aux. contracts of breaker.
14. Check for pressure of SF6 gas and air (for SF6).
16.3 ISOLATOR:
1. IR test before and after HV test.
2. Operational test.
3. Checking of interlocking with earth switch.
4. Checking of operation of earth switch.
5. Checking for tightness of earth connections.
6. Check for continuity of aux. contacts.
16.4 HT CABLES
1. IR measurement before and after HT test.
2. HV test.
3. Checking tightness of bolts with torque wrench.
4. Checking for phase sequence marking.
5. Check for clearances between phase to phase and phase to earth.
6. Check for-minor damages of Insulation after laying.
7. Checking for inspection openings and accessibility for replacement of cables.
8. Check for tightness for earthing connection for armour.
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16.5 LT SWITCHGEAR
1. IR test.
2. HV test with 2.5 KV megger.
3. Functional test for all feeders.
4. Testing and calibration of all meters and relays.
5. Checking and calibration of overload relays.
6. Checking the local and remote operation of the contactors.
7. Checking of interlocking between incomers / and other feeders. Wherever required.
8. Test to prove interchangeability of similar parts.
9. Tests to prove correct operation of breakers at minimum and maximum specified
control voltages.
10. Checking of earthing connection for neutral-earth bus, cable armour, location
of EIF CT etc. as per the scheme.
16.6 TRANSFORMER :
1. IR test on each vending to ground, and between windings.
2. Turns ratio test on each tap.
3. Polarity and vector group test.
4. IR, wiring and operational tests on all control devices in control cabinet, oil level
indicator, winding and oil temp. indicators, etc.
5. Checking of earthing with respect to transformer tank (flexible from top cover to
tank) other parts, neutral and tank to electrodes etc.
6. Testing of buchholz relay for alarm and trip conditions.
7. For bushing CTs, tests applicable shall be as for current transformers.
8. Setting of oil / winding temperature indicators, level gauge and checking of alarm /
trip circuits.
9. Checking of OLTC operation.
10. Checking of insulators for cracks.
11. Checking for oil leakage and arresting of leakages (if there)
12. Checking of operation of all valves.
13. Checking for open position of all the valves (except drain and filter valves).
14. Filtration of oil by using line filter and heater set, If required.
15. BDV test on oil samples from top, bottom, and from OLTC tank.
16. Checking of oil for acidity, water content, tan delta etc. as per IS : 335-1983, If
required.
17. Measurement of magnetizing current and no load loss.
18. Checking of silica-gel breather.
19. Checking of other points given in the manufacturers commissioning manual.
20. Checking and calibration of remote vending / oil temp. indicators, tap position
indicators, annunciation system (where RTCC panel is there).
21. Checking of oil resistivity, surface tension and dissolved gas analysis. If required.
22. Stability test.
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16.7 BATTERY:
1. Checking for completion of civil / ventilation requirement of battery room.
2. Checking of adequacy of charger output / requirement with respect to current
required for battery charging as per the manual.
3. Checking for availability of safety devices, water and first aid box.
4. Checking the polarity of connections between battery and charger.
5. Visual inspection test for level and leakages.
6. Checking of layout as per approved drawing.
7. Checking of IR value from positive to earth and negative to earth.
8. Checking of voltage per cell and total voltage between positive negative and earth to
positive / negative.
9. Checking of tightness of connectors on each cell.
10. Checking of capacity test and hourly measurement of specific gravity and voltage
for each cell.
11. Charging discharging cycle as per standard practice and as per instruction of
Engineer-in-charge.
16.8 BATTERY CHARGER
1. IR test.
2. Checking the voltage ratio of boost and float mode transformers
3. Checking for charging mode of batteries, constant current and constant voltage
mode.
4. Load test on charges by running of DC drives (if there and by liquid resistance
system.
5. Checking of tightness of earthing connections.
6. Check for all alarm conditions.
7. Checking and calibration of alt indicating meters.
8. Cheek for functional operation of charger, auto manual change over from float to
boost to float etc.
9. Checking and setting of all relays.
10. Cheek for AC ripple in boost and float mode after charging.
11. Check for polarity of cables connected to battery.
16.9 ACDB / DCDB :
1. IR test before and after HV test.
2. HV test by HV megger (2.5 KV).
3. Checking for functions of components for each module.
4. Checking for interchangeability of similar components.
5. Checking of tightness of earth connections.
6. Testing and calibration of all indicating meters.
7. Cheek for output of each feeder after energisation.
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16.10 CABLES AND CABLE SUPPORTING STRUCTURES:
1. Checking of continuity and IR values for all the cables before and after HV test.
2. HV test and measurement of leakage current after termination of cable kits (for HT
cables.).
3. Checking of earth continuity for armour and fourth core (If applicable).
4. Check for mechanical protection of cables.
5. Check for identification (tag number system) placement of cable marker, cable joint
etc. as per the cable layout drawing.
6. Check for earthing of cable structures.
7. Check for proper fixing of cable structures.
8. Check for proper drainage and removal of water (if any).
16.11 EARTHING:
1. Check for tightness of all earth connections.
2. Check for earthing of all metallic equipments, cable trays, busbar supporting
structures, yard fencing steel structures of yard, rails, gates, building columns (if
steel) all elect. Equipments, gas / oil / water pipe lines etc. as per the drawing /
specification.
3. Measurement of earth resistance for each electrode.
4. Measurement of total earth resistance.
5. Measurement of earth loop resistance for E/F path of biggest LT drive.
16.12 MISCELLANEOUS:
1. Checking of continuity of the system.
2. Checking of phase sequence from overhead line to sub-station.
3. Checking for safe accessibility of all operating points.
4. Cheek for availability of emergency lighting.
5. Check for availability of control / aux. supply.
6. Ensure availability of first aid box, fire fighting equipments, earth discharge roads,
rubber mats, rubber glove.
7. Check for oil drainage system for transformer oil in each transformer.
8. Check for filling of gravels in yard and in transformer pits.
9. Cheek the working of ventilation system for battery room-switchgear room etc.
10. Check for safe movement of operators from yard to control room switchgear etc.
with respect to proper illumination, escape light, uncovered openings, provision of
hand railings in stairs etc.
11. Check for proper covering of cable channels.
12. Placement of shock treatment chart, danger, boards, provision of boards indicating
Man on Work, Do not switch ON, Do not switch OFF, EARTHED etc.
13. Check for proper dressing of cables, mechanical protection of cables, placement of
cable markers.
14. Check for sealing of all cable openings including conduit opening with fire
resistance material.
15. Checked for sealing of all openings at bottom of elect., panels.
17.1 COMPLETION OF ERECTION WORK (GENERAL)
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Equipment shall be considered to have been completely erected when following
activities have been completed:
N Moving of all equipments with respective foundations.
N Fixing of anchor bolts or tech welding as required.
N Leveling and alignment of equipments.
N Assembling all accessories such as relays, CTs and PTs, meters, instruments etc.
N Drawing of equipments as required and testing of oil for dielectric strength.
N Filtration and filling of oil as required.
N Cable laying, termination with continuity checks.
N Applying of finishing coat of paint wherever required.
N Mounting of lighting fixtures and connections.
N Pasting of all system with operation of all protection system.
17.2 ERECTION OF SWITCHYARD STRUCTURES
17.2.1 The erection of switchyard structures shall mean erection of gantry, column,
beams, equipment support structure and lighting masts, VHF masts (if any) etc.
strictly as per the approved set of structural drawings of GEB. The foundation
work of switchyard structures is in the scope of bidder and hence foundation
with concreted anchor bolts shall be made available before start of erection of
structures.
17.2.2 The erected column shall be truly vertical well aligned and no pre-stress shall be
applied to the erected column for bringing the structure in alignment/plumb.
The erection of beams shall be done in phased manner on already erected
columns. The elevation faces of the beams should be first fastened to the
column one by one and thereafter plan bracings should be provided one by one
to complete the beam geometry. The cross-connected beams should be perfectly
at right angle and matching with respective phases of the column. There should
not be any missing member on column or beam. After erection of columns and
beams, the bolts and nuts should be properly tightened and punched. The thread
of the protruding bolt should be dented in the contact surface of nut at 3 point
120 degrees apart to eliminate loosening of bolt due to vibration.
17.2.3 The equipment support structures should also be erected as above. They should
well be in plumb with all members fitted as per approved drawings and bolt nuts
are properly tightened.
17.3 STRINGING OF BUS BAR AND JUMPERING
17.3.1 After completion of erection of gantry structures and equipments support
structures; the bidder shall take up the work of stringing bus bar and Jumpering
of various feeders and transformers bays. It should be ensured by the bidder that
bus bar stringing is completed at a stretch and jumpering shall be carried out
after erection of all equipments in switchyard. No joint or use of repair sleeve
will be permitted in the bus bar and jumpering.
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17.3.2 All the insulator strings to be used on the structure shall be properly cleaned
with cloth. Compression dead end joints of the conductor shall be made after
proper marking without any difference in the position amongst three phases.
17.3.3 After completion of the bus bar stringing work, the bidder shall undertake erection
of all the switchyard equipments. Thereafter the bidder shall provide
jumpers/droppers for the equipment connections to the bus bar or line
conductors by using prescribed clamps and connectors. For bus bar connection
only bolt less clamps shall be used.
17.4 ERECTION OF SECONDARY EQUIPMENTS
N The secondary equipments like CT, PT, LA, PI and all other equipments like
circuit breaker, isolators, battery set and battery charger, 220kV & 66kV
C&R panels, 11kV VCBs, LT panel etc. shall be received by the bidder
directly from the the manufacturer since the supply of all equipments and
materials is in scope of the contractor. The bidder is required to keep the
same in his custody at his site store center. and shall transport the same to
the erection site at the cost of bidder. The loading and unloading of these
equipments shall be done by the bidder at his cost as indicated in general
conditions volumes.
N After transporting the equipments at site, packing shall be gently removed
without causing any damage to the equipment. The equipment shall be
checked for its correctness of dimension, make etc. as per the approved
drawing and shall be cleaned by cloth to make it ready for erection.
N The equipment shall be mounted on structures and to be checked for its
vertical alignment (in plumb).
N All the clamp connectors and fitting shall be provided as per the approved
drawing. The junction box of the equipment shall be opened, cleaned and all
the connections should be checked for CTs and PTs. Fuse, links provided in
the secondary box of CT/PT shall be checked for their position and
continuity and any lacuna observed shall be set right. The arcing horns or
corona control rings and all other fittings shall be provided as per the
approved drawing for LA.
N The electrical connection of the equipments through jumpers shall be carried
out, along with the cable connection of respective equipment to the
marshaling kiosk or to the control relay panel. Bus bar connections shall be
made with bolt less clamps.
N All equipments mounted on structures shall be earthed by 50x6 mm size
mild steel galvanized earthing stripes, running from top to bottom of the
structure and to the earthing pit or earth grid.
N Polarity of the equipment to be connected on HV side should be checked
prior to erection. The oil level (if any) of the equipment should be checked
for its totality. If the level is inadequate, toping of oil should be carried out
by availing oil from GEB free of cost.
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17.5 ERECTION OF CIRCUIT BREAKER
N 220kV & 66kV SF6 circuit breaker to be supplied by the bidder shall be
received by the bidder him self and arrange to keep in safe custody at site
store. From site store bidder shall transport to the erection site at bidders
cost. The crates containing the insulators, parts and accessories shall be
opened carefully. Insulator parts and other accessories shall be thoroughly
cleaned with cloth.
N The breaker shall be erected on its structures in up right position without any
inclination. Main parts of the breaker shall be assembled as per drawing.
The services of the commissioning engineer of breaker manufacturer shall be
arranged by GEB, if required. However the bidder will not remain
contended with the instructions and guidelines given by the manufacturer's
engineer and shall also use his own judgment.
N After erection of breaker on structure, it should be thoroughly inspected in
MK box and any lacuna shall be reported to GEB.
N The operating mechanism in the breaker MK box, as well as the contacts and
power supply circuits shall be properly checked for its operation. All piping
for gas/air shall be fixed as per approved drawing. The air receiver or
compressor shall also be positioned as per relevant drawing. In case of
breaker with spring charging mechanism, the trials of the mechanism should
be done by actuating to ensure its proper functioning.
N The earthing points of the breaker and MK box shall be connected to earth
grid.
17.6 ERECTION OF POWER TRANSFORMER
N The power transformer of 220/66KV 100MVA ,66/11 10 MVA and other
transformer (as the case may be) to be supplied by the bidder shall be
unloaded on the rails of the RCC plinth at the sub-station site. All the
accessories/spares and transformer oil shall be transported by bidder at this
location and unload at site of erection at his own cost.. Contactor shall
ensure that the transformer plinth with rail is made ready well in time to
receive the transformer at site.
N The bidder shall carefully open the casings/covers etc. and erect and
commission the transfermer as per standards.
N After the completion of erection of above-mentioned accessories, filling of
oil under vacuum should be started. Random sampling and testing of oil
should be carried out before filling. The oil level in the conservator tank,
condenser bushing should be checked for its desired mark. After completion
of oil filling work, final filtration of oil should be done to obtain PPM and
BDV values as per the requirement of IS. The filter machine of sufficient
capacity and reputed make approved by Engineer-in-charge shall be
arranged by the bidder at his cost.
N The final testing and commissioning of the transformer should be done as
per the instruction of GEB Engineer.
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17.7 ERECTION OF ISOLATORS
N 220kV & 66kV isolators with structures to be supplied by the bidder
including transportation the sub-station site by bidder at his own cost. All
the spare parts shall be properly unpacked and cleaned.
N 220kV & 66kV isolator with EB shall be erected on the gantry structure and
isolator without EB shall be erected on isolator structure already erected as
per the final lay out.
N The bidder shall check the erected support structure for their alignment
vertically with tightness of nut bolts, before mounting the isolators. The
mounting arrangement for the operating mechanism shall be verified for the
structures provided. Any modification of the structures or isolator
mechanism shall be carried out free of cost by the bidder.
N The parts of the isolator like insulators, fixed and moving contacts, earthing
rod, operating rod shall be handled carefully to avoid breakage or distortion
during the erection. The inter locking between operating rod and earthing
rod of isolator with EB should be checked.
N During the erection of isolator it should be ensured for proper alignment
with respect to bus conductor or line conductors. The erected isolator shall
be in plumb and its operating mechanism rod, isolator blade and rotating
insulators shall be checked for their proper function. It should be ensured
that movement of fixed and moving contacts and their reach is within
permissible limit.
N 50 close-open operations in presence of GEB representative should be
carried out after erection.
17.8 ERECTION OF C&R PANELS, LT PANEL AND BATTERY CHARGER,
IN THE CONTROL ROOM
N The bidder shall transport all above equipments to site store. They shall be
unpacked carefully in up side position and cleaned. After visual inspection,
the panel door shall be opened and checked up for circuit connection,
terminal connector, power connection etc.
N The front side of the panel shall be verified for meter, relay, semaphore
indicator, hooter etc. for their position, rating and dimension by comparing
them with the approved drawing. Any short coming in the panel shall be
informed to Engineer-in-charge.
N The panels shall be shifted in the control room and shall be erected/grouted
in the space provided on the floor of the control room as per the instruction
of Engineer-in-charge and approved drawing of control room.
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17.9 CABLING WORK
N The bidder shall first prepare cable schedule after studying the various
control, metering and protection schemes as per the approved drawing for
laying control cables. Similarly the cable schedule shall be prepared for
laying LT cables from station transformer to LT panel and further to
switchyard, colony, pump room, battery room, panels etc. All the schedules
shall be got approved from Engineer-in-charge.
N The size and number of cores of cables shall be brought from the outdoor
equipment like breaker, CT/PT to the control and relay panel as per
predetermined study through cable trench and shall be laid very gently on
the cable racks provided in the cable trench. Utmost care shall be taken to
prevent damage to outer insulation and the armours of the cables. No mid
joint shall be permitted to the cable.
N The required size of XLPE power cable shall be laid from power transformer
to 11 KV transformer panel through cable trench and from 11 KV feeder
panels to the double pole structures and station transformer.
N The ends of the control cables shall be terminated using correct size of lug
and ferrules giving the identification number of various cores of the cables.
The proper tools shall be used for termination to have a rigid connection of
the control terminals. The LT cable shall be terminated with lug of proper
size. The XLPE power cable shall be terminated with the special type of
joints like heat shrinkable of any standard acceptable make or push on type.
In no case compound type joint for power cable should be used.
17.10 ERECTION OF BATTERY AND BATTERY CHARGER
N The battery charger and the battery set with acid solution shall be transported
by the bidder at his own cost at sub-station site. The battery set with all
accessories and acid solution shall be shifted to battery room after painting
the later with anti acid paint on walls and washing the floor and platform.
N The battery cells and other accessories shall be unpacked carefully to
prevent any damage and then shall be cleaned to remove any
dust/deposition. The battery rack shall be placed in such a fashion that rows
of battery cell can be easily connected to each other.
N As per the drawing, the battery cells shall be provided on the rack with
insulator support below it. The battery cells shall be connected in series by
inter cell connectors and inter row connectors and shall be terminated to LT
panel and charger. The battery cell shall be filled with requisite quantity of
electrolyte and with proper specific gravity, upto the mark of maximum level
indicated on the cell. The individual cell shall be checked for their voltage
across the terminal and polarity before series connection and for total
voltage of 220/110 Volt DC after completion of inter connections of cells.
The racks and battery cells shall be cleaned for any deposition of electrolyte
and other particles. The entire battery room shall be completely cleaned.
N The charge discharge cycle shall be given to the battery set as per the
instruction manual or as per the general practice for initial charging of the
battery. After completion of this load test, the voltage and its specific
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gravity of each cell and total voltage shall be measured to achieve correct
required values. The test load then shall be removed and battery shall be
ultimately connected to LT panel and charger for its commercial use.
N The battery charger shall be grouted on the specified place on the floor,
cleaned with air blower by opening the door / shutter on back side and all the
cable connections to be made with LT panel, battery set and 220KV,66 KV
and 11 KV panels etc. The working of all the meters, switches, relays on the
front of the charger shall be checked along with fuses and links and
transformer connections inside the charger. The functional operation of the
charger for auto and manual mode from floor to boost and vice a versa shall
be checked.
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Earthing Design for 220KV Dhanera S/S.
1. General
2.
1. 1 Earthing Mesh for 220KV switch yard and 66 KV switch yard may be laid at a depth of 0.6
mtr below the normal earth surface. as per figure 1.1 and 1.2 .Along the periphery of the
mesh ,at all the junction points of parallel conductors,20 mm dia steel vertical rods should
be driven 3.0 Meters. into the soil below the mesh
1. 2 Each and every structure, bodies of all the equipments, steel rods of the foundations should
be connected to the mesh with a 50x6 GI strip welded and bolted with 12x25 mm double
nut bolts.
1. 3 All the neutrals of transformers, LA s, CVTs, Panels should be provided with pipe type
earthing as per design given hereunder.
1. 4 Power transformer neutrals should be earthed through 40x6 copper strips.
The complete design is based on the following data for the sub-station i.e.220KV Dhanera S/S.
a. Fault level of 220KV bus -------3815.3 MVA i.e. 10 KA
b. Fault level of 66 KV bus -------988 MVA i.e. 8.64KA
c. Average resistivity of 220KV switchyard ------26 ohm-mtr.
d. Average resistivity of 66 KV switchyard -------35 ohm-mtr.
2 Specific Design of Earthing mesh and pipe type earthing.
2. 1 Mesh for 220KV Switch yard.
2. 1.1 Size of mesh = 192 x 120 Mtr.
2. 1.2 Spacing between conductors =12.0 mtr
2. 1.3 Size of conductor = 50x6 mm GI strip
2. 1.4 No. of conductors in X direction = 17
2. 1.5 No. of conductors in Y direction = 11
2. 1.6 Total no. of conductors = 28
2. 1.7 Total length of the conductors used = (192x11) + (120x7) = 4870 mtr.
2. 1.8 No. of junction points of conductors = 54
2. 1.9 No. of vertical ground rods = 54
2. 1.10 Size of ground rods = 20 mm dia steel rods each of 3.0 mtr length.
2. 1.11 Total length of ground rods 54x3 =162 mtr.
2. 1.12 Depth of mesh = 0.6 mtr below the normal surface of soil.
2. 1.13 Depth of ground rods = 3.0 mtr below the mesh.
2. 1.14 Vertical ground rods should be driven into the soil below the mesh at each junction
points and on top side each would be joined together with welding and 12x25 mm
double bolt nuts.
2. 2 Mesh for 66KV Switch yard.
2.2 .1 Size of mesh = 160x 64 Mtr.
2.2 .2 Spacing between conductors =8.0 mtr
2.2 .3 Size of conductor = 50x6 mm GI strip
2.2 .4 No. of conductors in X direction = 21
2.2 .5 No. of conductors in Y direction = 9
2.2 .6 Total no. of conductors = 30
2.2 .7 Total length of the conductors used = (160x9) + (64x21) = 2784 mtr.
2.2 .8 No. of junction points of conductors = 58
2.2 .9 No. of vertical ground rods = 58
2.2 .10 Size of ground rods = 20 mm dia steel rods each of 3.0 mtr length.
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2.2 .11 Total length of ground rods 58x3= 174 mtr.
2.2 .12 Depth of mesh = 0.6 mtr below the normal surface of soil.
2.2 .13 Depth of ground rods = 3.0 mtr below the mesh.
2.2 .14 Vertical ground rods should be driven into the soil below the mesh at each junction
points and on top side each would be joined together with welding and 12x25 mm double
bolt nuts.
2.3. Pipe type earthings. By drilling a bore (hole) of 100 mm or so up to the depth as specified
50 mm dia GI pipe of 13 mm thickness should be inserted inside .This pipe should have
holes two nos.alternate along the periphery of pipe of 12 mm dia at an interval of 1.0 mtr.
Each pipe should be connected to respective earth points of equipments through 50x6 GI
strips.
2.3.1 Power transformer neutrals 2x4 = 8 Nos. with 50mm dia 15.0 mtr pipe.
2.3.2 Power transformer body 1x2 = 2 Nos. with 50 mm dia 15.0 mtr pipe.
2.3.3 Power Trans 66/11 KV neutrals 2x2 =4 Nos.with 50mm dia 15.0 mtr pipe.
2.3.4 ------------do------------but body 1x2= 2 Nos.with 50 mm dia 15.0 mtr pipe.
2.3.5 Dist. transformer neutrals 1x3 = 3 Nos.with 50 mm dia 15.0 mtr pipe.
2.3.6 220KV LAs 4x3 =12 Nos. with 50mm dia 9.0 mtr pipe
2.3.7 220KV CVTs 2x2= 4Nos. with 50 mm dia 9.0 mtr pipe.
2.3.8 66 KV LA s 6x3 =18 Nos. with 50mm dia 9.0 mtr pipe.
2.3.9 C/R panels (220KV 1No. +66 KV 1No. +11KV & charger etc. 1Nos. + 1No.for
computer & lighting etc. = total 3) 3Nos. with 50 mm dia 30mtr pipe.
3 Bill of Materials for the complete earthing scheme.
3..1Total length of 50x6 mm GI strip (mesh1&2+ connections) =13700 mtr.
3..2 Total length of 20 mm dia steel rods (mesh 1&2) = 336 mtr.
3..3 Total length of 40x6 copper strip for power tr. = 300 mtr.
3..4 Total length of 50 mm dia 13mm thick GI pipe = 651 mtr.
3..5 12x25 mm GI / SS bolt nuts = 1000 nos approx.
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Fig. 1 Detailed drawing of Mesh (ABCD) for 220KV switch yard.
LEGEND
____ = Horizontal Conductor for the mat 50x6 mm size GI/MS strip each separated by D = 12 mtr.
Total cond. 192x11+120x17= 4870 Mtr.
. = Vertical ground rod 20 nn dia steel rod with 3.0 mtr length (total qty = 64 Nos)
Size of the mesh ---------- Rectangular shapes 192x120 mtr.
Depth of the mesh -------------------- 0.6 mtr
Execution details:
1 Each parallel conductor should be connected solidly at their junction by welding and bolt nuts
(12x25 mm)
2 E ach conductors shoul d be covered with bentonite clay (at least 0.01 mtr layers) /not needed.
3 Each ground rod should be driven into soil in 50 mm bore at 3.0 mtr depth and side and space
be filled up with bentonite slurry.
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Fig. 2 Detailed drawing of Mesh (ABCD) for 66 KV switch yard.
LEGEND
____ = Horizontal Conductor for the mat 50x6 mm size GI/MS strip each separated by D = 8.0 mtr.
Total cond. 160x9+64x21= 2784 Mtr.
. = Vertical ground rod 20 nn dia steel rod with 3.0 mtr length (total qty = 58 Nos)
Size of the mesh ---------- Rectangular shapes 160x64 mtr.
Depth of the mesh -------------------- 0.6 mtr
Execution details:
1 Each parallel conductor should be connected solidly at their junction by welding and bolt nuts
(12x25 mm)
2 E ach conductors should be covered with bentonite clay (at least 0.01 mtr layers) /not needed.
3 Each ground rod should be driven into soil in 50 mm bore at 3.0 mtr depth a nd side and space
be filled up with bentonite slurry.