SECTION - 5 Technical Specification

SECTION 5 TECHNICAL SPECIFICATIONS TECHNICAL SPECIFICATIONS FOR ERECTION OF 33/11KV SUB-STATIONS WITH CONNECTED 33KV & 11KV LINES
Section-5 : Technical Specification
TECHNICAL SPECIFICATION FOR 5 MVA POWER TRANSFORMERS FOR 33/11KV SUBSTATIONS: 1.0 Scope: This specification covers the design manufacture, testing, supply, delivery at site according to the following specifications of the following transformer. 3Ph, 33/11KV, 5000KVA/8000KVA Power Transformer with on load tap changer (OLTC) The material should be guaranteed for Five (5) years from the date of commissioning of Power Transformer. It is not the intent to specify completely herein all the details of the design and construction of equipment. However the equipment shall conform in all respects to high standards of engineering, design and workmanship and shall be capable of performing in continuous commercial operation up to the Bidder's guarantee, in a manner acceptable to APEPDCL, who will interpret the meanings of drawings and specification and shall have the power to reject any work or material which, in his judgment is not in accordance there with. The offered equipment shall be complete with all components necessary for their effective and trouble free operation. Such, components shall be deemed to be within the scope of Bidder's supply irrespective of whether those are specifically brought out in this specification and/or the commercial order or not. Standards: The transformers shall conform in all respects to IS-2026/1977 (with latest Amendments) / IEC 600 76 1993 (with latest Amendments if any). Except where specified otherwise. Equipment meeting any other authoritative standard, which ensures an equal or better quality than the standards mentioned above will also, is acceptable. In such a case, a copy of standard (English version) followed should be enclosed with the tender. The finished Power Transformer, oil, bushings, tap changer etc., that are used in manufacturing of transformer shall conform in all respects to the relevant Indian Standard Specifications / IEC Standards, with latest amendments as indicated below. Indian Standard Title IS-2026/1977 IS : 335/1993 IS-3347 and IS 2099/1986 IS 8468-1977 2.1 International & Internationally recognized standard Power IEC 600 76 1993 Power Transformers Part 1 to 5. Electrical IEC 60 071
Specification for transformers Part I to IV New insulating oils Clearances Bushings for alternating voltages above 1000V. Specification for Tap changer
CONFLICT OF STANDARDS: Equipment conforming to other internationally accepted standards, which ensure equal or higher quality than the standards mentioned above would also be acceptable. In case the Bidders who wish to offer material conforming to the other standards, salient points
of difference between the standards adopted and the specific standards shall be clearly brought out in relevant schedule. Four copies of such standards with authentic English Translations shall be furnished along with the offer. In case of conflict the order of precedence shall be (i) IS (ii) IEC (iii) Other standards. In case of any difference between provisions of these standards and provisions of this specification, the provisions contained in this specification shall prevail. CLIMATIC CONDITIONS : As noted in clause No.23 service conditions of GCC, the Power Transformer to be supplied against this Specification shall be suitable for satisfactory continuous operation under the following climatic conditions. i) ii) iii) iv) v) vi) vii) viii) ix) x) Location Max. ambient air temperature (deg.C) Min. ambient air temperature (deg.C) Average daily ambient air temperature (deg.C) Max. Relative Humidity (%) Max. altitude above mean sea level (Meters) Average Annual rainfall (mm). Max. wind pressure(kg/sq.m.) Isoceraunic level (days per year) Seismic level (Horizontal accn.) At various locations in the state of Andhra Pradesh 50 7.5 35 100 1000 925 200 50 0.3 g.
The equipment shall be for use in moderately hot and humid tropical climate, conducive to rust and fungus growth. 4.0 4.1.1 PRINCIPAL PARAMETERS : Design and Standardisation: The transformer and accessories shall be designed to facilitate operation, inspection, maintenance and repairs. All apparatus shall also be designed to ensure satisfactory operation under such sudden variations of the load and voltage as may be met with under working conditions on the system, including those due to short circuit. The design shall incorporate every reasonable precaution and provision for the safety of all those concerned in the operation and maintenance of the equipment keeping in view the requirements of Indian Electricity Rules. All materials used shall be of the best quality and of the class most suitable for working under the conditions specified and shall withstand the variations of temperature, and atmospheric conditions arising under working conditions without undue distortion or deterioration or the setting up of undue stresses in any part, and also without affecting the strength and suitability of various parts for the work for which they have to perform. Corresponding parts liable for replacement shall be interchangeable. Cast iron shall not be used for chambers of oil filled apparatus or for any part of the equipment, which is in tension or subject to impact stresses. This clause is not intended
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4.1.2
4.1.3
4.1.4 4.1.5
to prohibit the use of suitable grades of cast iron for parts where service experience has shown it to be satisfactory e.g. Large valve bodies, unless otherwise specified. 4.1.6 4.1.7 4.1.8 4.1.9 All out-door apparatus, including bushing insulators with their mountings, shall be designed so as to avoid pockets in which water can collect. Means shall be provided for easy lubrication of all bearings and where necessary of any mechanism or moving parts that are not oil immersed. All mechanism where necessary shall be constructed of stainless steel, brass or gun metal to prevent sticking due to rust or corrosion. All taper pins used in any mechanism shall be of the split type complying with IS No. 2393 (latest version) for these items.
4.1.10 All connections and contacts shall be of sample section and surface for carrying continuously the specified currents without undue heating and fixed connections shall be secured with bolts or set screws of ample size, adequately locked. Lock nuts shall be used on stud connections carrying current. 4.1.11 All apparatus shall be designed to minimize the risk or accidental short circuit caused by animals, birds or vermin. 4.2 4.2.1 GALVANISING: Galvanizing shall be applied by hot-dip process or by electro galvanizing process for all parts other than steel wires and shall consist of a thick ness of zinc coating equivalent to not less than 610 gm zinc per square meter of surface. The zinc coating shall be smooth clean and of uniform thickness and free from defects. The preparation for galvanizing and the galvanizing itself shall not adversely affect the mechanical properties of the coated material. The quality will be established by tests as per IS:2630 (latest version). (Alternatively to galvanizing Aluminizing may also be considered). All drilling, punching, cutting, bending and welding of parts shall be completed and all burrs shall be removed before the galvanizing process is applied. Galvanizing of wires shall be applied by the hot-dip process and shall meet the requirements of the relevant IS. The zinc coating shall be smooth, clean and uniform thickness and free from defects. The preparation for galvanizing and the galvanizing itself shall not adversely affect the mechanical properties of wire. Surfaces, which are in contact with oil, shall not be galvanized. LABLES: Lables shall be provided for all apparatus such as relays, switches, fuses contained in any cubicle or marshaling kiosk. Descriptive lables for mounting indoors or inside cubicles and kiosks shall be of material that will ensure permanence of lettering. A matt or satin finish shall be provided to avoid dazzle from reflected light. Lables mounted on dark surface shall
4.2.2 4.2.3
4.2.4 4.3 4.3.1 4.3.2
have white lettering on a black background. Danger notices shall have red lettering on a white back ground. 4.3.3 4.3.4 4.4 4.4.1 4.4.2 All plates shall be of incorrosible material. Lables shall be attached to panels with brass screws or with stool screws, which have received rust preventive treatment, or those can be stuck with araldite also. BOLTS & NUTS: Steel bolts and nuts exposed to atmosphere with suitable finishes like cadmium plated or zinc All nuts and pins shall be locked in position with the exception of those external to the transformer. Bolts and nuts external to the transformers shall be provided with double flat washer and one spring washer. On out-door equipment, all bolts, nuts and washers in contact with non-ferrous parts which carry current shall be of phosphor bronze where the transfer of current is through the bolt. If bolts and nuts are placed so that they are in accessible by means of ordinary spanners, suitable special spanners shall be provided by the supplier. CLEANING AND PAINTING: Before painting or filling with oil in case of Transformer, all un-galvanized parts shall be completely clean and free from rust, scale and grease and all external rough surface cavities on castings shall be filled by metal deposition. The interior of all transformer tanks and other oil filled chambers and internal structural steel work shall be cleaned of all scale and rust by shot-blasting or other approved method. These surfaces shall be painted with hot oil resisting epoxy paint. Minimum paint thickness shall be 40 microns. Except for nuts, bolts and washers, which may have to be removed for maintenance purposes, all external surfaces shall receive a minimum of three coats of paint. The primary coat shall be applied immediately after cleaning. The second coat shall be of an oil and weather resisting nature and preferably of a shade or colour easily distinguishable from the primary and final coats shall be applied after the second coat has been touched up where necessary. The final coat shall be of a glassy, oil and weather resisting non-fading paint of shade No. 631 of IS.5. Primer paint shall be readymade zinc chromate as per IS-104 intermediate and final coats of paint shall be as per IS-2932. Nuts, bolts and washers, which may have to be removed for maintenance purposes shall receive a minimum of one coat of paint after erection. All interior surfaces of mechanism chambers and kiosks except those which have received anti-corrosion treatment shall receive three coats of paint applied to the
4.4.3
4.4.4 4.5 4.5.1
4.5.2
4.5.3 4.5.4
4.5.5 4.5.6
thoroughly cleaned metal surface. The final coat shall be of a light coloured anticondensation mixture. 4.5.7 Any damage to paint work incurred during transport and erection shall be made good by the supplier by thoroughly cleaning the damaged portion and applying the full number of coats of paint that had been applied before the damage was occurred. The paint work shall be guaranteed for a minimum period of 5 years from the date of receipt of the equipment. One coat of additional paint shall be given at site by the supplier. Supplier shall supply the requisite quantity of paint. TECHNICAL REQUIREMENTS: OIL: The transformers and all associated equipment shall normally be supplied along with the fresh filled oil. The oil shall conform as per IS : 335/1993 with latest amendment and it shall be free from moisture and have uniform quality throughout. Oil filled in transformers. The important characteristic of the transformer oil after it is filled in the transformer (within 3 months of filling) shall be as follows: Sl.No 1. 2. 3. 4. 5. 6. 7. 5.1.3 Characteristics Electric strength (BDV) (2.5mm gap) Dielectric dissipation factor (Tan delta) at 90o C Specific resistance (resistivity) at 27oC (Ohm-cm) Flash point ponsky Marton Inter facial tension at 27 Deg C Neutralisation value (total acidity) (maximum) Water content PPM Specification 30 KV (minimum) 0.02 (max) 1500x1012 (min) 140 Deg. C (min) 0.04 N/M (min) 0.03 mg KOH/gm 50 (max)
4.5.8 4.5.9 5.0 5.1 5.1.1
5.1.2
Prevention of Acidity: The design and all materials and process used in the construction of the transformers shall be such as to reduce to a minimum the risk of the development of acidity in the oil. Special measures, such as nitrogen sealing or the use of inhibited oil, shall not be resorted to.
5.1.4
Electrical Characteristics and Performance: Type of transformers and operating conditions, transformers shall be oil immersed and naturally cooled, core type and shall be suitable for out-door installation, and shall be provided with conservator vessels. The type of cooling shall be as stated in the relevant specifications.
5.1.5
CONTINUOUS MAXIMUM RATING AND OVERLOADS:
Transformers shall comply as regards to rating temperature rise and overload with the appropriate requirements of IS 2026 when operating with ONAN cooling. Transformers shall be capable of operation continuously in accordance with IS loading guide at their C.M.R and at any ratio irrespective of the direction of flow of power and with voltage of the untapped winding maintained at the voltage stated in the ordering schedule. Transformers having tapping ranges extending not more than 5 percent below the nominal voltage shall operate on the principal / tapping without exceeding the limits laid down in IS-2026 for oil temperature rise and winding temperature rise as measured by resistance. On the other tappings, they shall operate continuously without injurious heating. 5..1.7 Transformers except where stated below with tapping ranges extending more than 5 percent below the nominal voltage, shall meet the temperature rise limits specified in IS 2026 on all tappings on which the rated current is not more than 95 percent of the maximum rated current on the lowest voltage tapping. On other tappings, they shall operate continuously without injurious heating. The loading of the transformers, is to be in accordance with IS 6600. Guide for loading of oil immersed transformers. 5.1.8 The transformers may be operated without danger on any particular tapping at the rated KVA provided that the voltage does not vary by more than + or 10% of the voltage corresponding to the tapping. Note: Operation of a transformer at rated KVA at reduced voltage may give rise to excessive losses and temperature rise. 5.2 VOLTAGE RATIO : The voltage between phases on the higher and lower voltage winding of each transformer measured at no load and corresponding to the normal ratio of transformation shall be those stated in the ordering schedule. Means shall be provided for varying the normal ratio of transformation in accordance with the clause 5.35 voltage control on load type. 5.3 ELECTRICAL CONNECTIONS: Transformers shall be connected in accordance with the IS group symbol Dy 11. 5.4 FREQUENCY: The transformers shall be suitable for continuous operation with frequency variation of + or 3% from normal 50 C/S without exceeding specified temperature rise. 5.5 5.5.1 DUTY UNDER FAULT CONDITIONS: Except where modified below, it is to be assumed that the amount of generating plant simultaneously connected is such that normal voltage will be maintained on one side of any transformer when there is a short circuit between phases or phase to earth on the other side. Any transformer may be directly connected to an underground cable or over
head transmission line and switched into and out of service together with its associated transmission line. 5.5.2 5.6 5.6.1 All Transformers shall be capable of withstanding without any damage to external short circuit between phases and phase to ground according to IS: 2026 or its latest version. LOSSES: The maximum loss of each transformer shall be as indicated below: The tolerance on the losses of each transformer shall be in accordance with IS:2026. The fixed losses should be as low as is consistent with normal design, reliability and economical use of material. The offers for transformers with higher losses will be rejected. Losses 5 MVA 8 MVA No load losses 6500 W 8500 W Load losses 34000 W 50000 W Note: The tenderer shall furnish the calculation for the losses quoted by them with core loss curves. 5.6.2 Penalty for excessive losses: During testing if it is found that actual measured losses are more than the values quoted by the bidder penalty shall be recovered from the Bidder at double the loss rate as specified below. For Fraction of a KW evaluation will be on prorata basis. No load losses Load losses 5.6.3 : Rs. 2,17,515 per KW : Rs. 28,772 per KW Tolerance 10% of total losses +15% of each component losses. The lower of the following 0.5% of the declared ratio A percentage of the declared ratio equal to 1/10th of the actual % impedance voltage at rated current. +10% of the declared impedance voltage for that tapping. +3% of the declared no load current.
Tolerance: Sl.No Item Total losses Component losses provided that the 1 tolerance for total losses of 10% is not exceeded II. Voltage ratio at principal tapping Impedance voltage at rated current (Principal tapping) No load current
III. IV. 5.7
REGULATION AND IMPEDANCE: The impedance voltage at normal ratio of transformation and normal rating shall be 7.15% for 5.0 MVA transformers and 8.35% for 8.0MVA Power Transformers.
5.8
TEMPERATURE:
The Power Transformers shall be suitable for installation at location where ambient temperature is as indicated below and temperature rise final not to exceed the limit prescribed below: 1. 2. 3. 5.9 5.9.1 Maximum Ambient Temperature 50 Deg C Maximum oil temperature rise by thermometer 40 Deg C Maximum winding temperature rise by winding resistance 50 Deg C measurement
FLUX DENSITY: The maximum flux density in any part of the core and yoke, at normal ratio and at normal voltage and frequency, of each transformer shall be stated. The normal flux density for cold rolled grain oriented steel laminations shall not exceed 1.6tesla, at normal tap position. Over fluxing should be limited to 12.5%. However, incase of transformers with variable flux the voltage variation which would affect flux density at every tap shall be kept in view while designing transformers.
5.9.2
5.10 VIBRATION AND NOISE: 5.10.1 Every care shall be taken to ensure that the design and manufacture of all transformers and auxiliary plant shall be such as to reduce noise and vibration to the level of that obtained in good modern practice. The maximum noise level should be below 45db. 5.10.2 The manufacturer will ensure that the noise level shall not be more than 5 decibels above he NEMA standard publication TR-1. 5.11 SUPRESSION OF HARMONICS: 5.11.1 The transformers shall be designed with particular attention to the suppression of harmonic voltages, especially the third and fifth, so as to eliminate wave form distortion and from any possibility of high frequency disturbances, inductive effect loop circulating currents between the neutral points at different transforming stations reaching such a magnitude as to cause interference with communication circuits. For achieving this suppression of harmonics delta connected stabilizing winding should be avoided. 5.12 CORE: The core shall be constructed from high grade cold rolled non-ageing grain oriented silicon steel laminations, M4 or Superior Grade. Only prime quality CRGO sheets should be used in the transformers and no Second/Defective/Scrap CRGO finds way into transformers. Therefore regarding quality control following documents are to be furnished before giving the inspection offer. Invoices of supplier Mills test certificate Packing list. Bill of landing Bill of entry certificate by custom Description of material, electrical analysis, Physical inspection, certificate for surface defects, thickness and width of the material.
Subjecting to at least 10% of the transformers to routine tests and no load and load loss measurement. It is to note that, using seconds/defective CRGO sheets or load losses found to be more than stipulated limit, heavy penalty will be imposed or the suppliers will be black listed. 5.13 MAGNETIC CIRCUIT :
5.13.1 The design of the magnetic circuit shall be such as to avoid static discharges, development of short circuit paths within itself of to the earthed clamping structure and the production of flux components at right angles to the planes of the laminations which may cause local heating. 5.13.2 Every care shall be exercised in the selection, treatment and handling of core steel to ensure that as practicable the laminations are flat and the finally assembled core is free from distortion. 5.13.3 Each lamination shall be insulated with a material that will not deteriorate due to pressure and the action of hot oil. 5.13.4 Oil ducts shall be provided where necessary to ensure adequate cooling. The winding structure and major insulation shall not obstruct the free flow of oil through such ducts, where the magnetic circuit is divided into pockets by cooling ducts parallel to the plane of the laminations or by insulation material above 0.25mm thick tinned copper strip brazing pieces shall be inserted to maintain electrical continuity between pockets. 5.13.5 The frame work and clamping arrangements shall be earthed. 5.13.6 The class and type of insulation used on the core bolts and under the nuts and side plates shall be stated in the guaranteed technical particulars. Adequate core clamping arrangements shall be made to prevent distortion or wavy form of laminations and withstand short circuit forces. Core clamping bolts shall be effectively insulated with craft paper and fibre glass tubes. 5.14 MECHANICAL CONSTRUCTION OF CORE 5.14.1 All parts of the cores shall be of robust design capable of withstanding any shocks to which they may be subjected during lifting, transport, installation and service. 5.14.2 All structural members of the assembled cores shall be of steel. All castings shall be fitted and structural steel adequately cleaned and painted before being built into the structure. Any non-magnetic or high resistance alloy used shall be of established quality. 5.14.3 Adequate filaments shall be provided to enable the core and windings to be lifted. 5.14.4 Suitable provision shall be made for the storage of any removable portions of the lifting tackle on the transformer tank. 5.14.5 Adequate provision shall be made to prevent movement of the core and winding relative to the tank during transport and installation or while in service.
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5.14.6 The supporting frame work of the cores shall be so designed as to avoid the presence of pockets which would prevent complete emptying of the tank through the drain valve or cause trapping or air during filling. 5.15 WINDINGS:
5.15.1 All windings shall be made of electrolytic high conductivity copper, shall be fully insulated as defined in IS:2026. All neutral points shall be insulated for the voltage specified in IS 2026. The windings shall be so designed that all coil assemblies of identical voltage, rating shall be inter changeable. The maximum allowable current density is 2.5 sq. mm 5.15.2 Power Transformer shall be designed to withstand the impulse test voltage as per IS 2026. 5.15.3 The transformer shall withstand the power frequency voltage test as per IS:2026. 5.15.4 The windings shall be designed to reduce to a minimum the out-of-balance forces in the transformer at all voltage ratios. 5.15.5 The insulation of transformer windings and connection shall be free from insulating composition liable to soften, ooze out, shrink or collapse during service. 5.15.6 The stacks of windings shall receive adequate shrinkage treatment before final assembly. 5.15.7 The coil clamping arrangement and the finished dimensions of any oil duct shall be such as will not impede the free circulation of oil through the ducts. 5.15.8 No strip conductor wound on edge shall have a width exceeding six times its thickness. 5.15.9 The conductors shall be transposed at sufficient intervals in order to minimise eddy currents and equalize the distribution of currents and temperature along the windings. 5.15.10The HV winding shall be arranged so as able to be removed without hindrance to and causing any damage to the LV winding. 5.16 BRACING OF WINDING :
5.16.1 The windings and connections of all transformers shall be braced to withstand shocks which may occur during transport or due to switching and other transport condition during service. 5.16.2 Coil clamping rings, if provided shall be of steel. 5.16.3 Any metal pieces in contact with laminated rings shall be so designed and secured that they do not weaken the electrical or the mechanical properties of the rings. 5.16.4 If the transformer winding is built up of section of disc coils, separated by spacers, the clamping arrangements shall be such that equal pressure are applied to all columns of spacers.
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5.16.5 All such spacers shall be securely located, shall be of suitable material and shall receive adequate shrinkage treatment before assembly. 5.17 INTERNAL EARTHING ARRANGEMENTS
5.17.1 INTERNAL EARTHING GENERAL: All metal parts of the transformer with the exception of the individual core laminations, core bolts, and associated individual clamping plates shall be maintained at some fixed potential. 5.17.2 EARTHING OF CORE CLAMPING STRUCTURE: The top main core clamping structure shall be connected to the tank body by a copper strip. One or more of the following methods shall earth the bottom clamping structure. By connection through vertical tie-rods to the top structure By direct metal-to-metal contact with the tank base, maintained by the weight of the core windings. By a connection to the top structure on the same side of core as the main earth connection to the tank. 5.18 EARTHING OF MAGNETIC CIRCUIT:
5.18.1 The magnetic circuit shall be earthed to the clamping structure at one point only through a link placed in an accessible position beneath an inspection opening in the tank cover. The connection to the link shall be on the same side of the core as the main earth connection. 5.18.2 Magnetic circuits having an insulated sectional construction shall be provided with a separate link for each individual section where oil ducts or insulating barriers parallel to the plane of the laminations divide the magnetic circuit into two or more electrically separate parts the ducts or barriers shall be bridged in accordance with Clause 5.13.4 and the magnetic circuit shall not be regarded as being of sectional construction. 5.19 EARTHING OF COIL CLAMPING RINGS: Where coil-clamping rings are of metal at earth potential, each ring shall be connected to the adjacent core clamping structure on the same side of transformer as the main earth connections. 5.20 SIZE OF EARTHING CONNECTIONS:
All earthing connections with exception of those from the individual coil clamping rings shall have cross sectional areas of not less than 0.8 Sq cms. Connections inserted between laminations may have the cross sectional area reduced to 0.2 Sq cm. 5.21 TANK : 5.21.1 Tank Construction: The tanks of all transformers shall be complete with all accessories and shall be designed so as to allow the complete transformer in the tank and filled with oil to be lifted by crane or jacks, transported by road, rail or water without over straining any joint and without causing subsequent leakage of oil.
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5.21.2 The main tank body excluding tap changing compartments, shall be capable of withstanding a full vacuum of 760 mm of mercury, when empty of oil. 5.21.3 The base of each tank shall be so designed that it shall be possible to move the complete transformer unit by skidding in any direction without injury when using rollers, plates or rails. 5.21.4 Normally a detachable under base will be used, but in case transport facilities permit, a fixed under base can be used. 5.21.5 Where the base is of a channel with iron construction, it shall be designed to prevent retention of water. 5.21.6 The base channels for the transformers covered by this specification shall be 200x75/76 mm Transformers. 5.21.7 Tank stiffeners shall be continuously welded to the tank and designed to prevent retention. 5.21.8 Wherever possible the transformer tank and its accessories shall be designed without pockets wherein gas may collect. Where pockets cannot be avoided pipes shall be provided to vent the gas into the main expansion pipe. The vent pipes shall have minimum inside diameter of 15mm except for short branch pipes which may be 6mm minimum inside diameter. 5.21.9 All joints other than these which may have to be broken shall be welded. 5.21 LIFTING AND HAULAGE FACILITIES: Each tank shall be provided with: Lifting lugs suitable for lifting the transformer complete with oil. A minimum of four jacking lugs, in accessible positions to enable the transformers complete with oil to be raised or lowered using hydraulic or screw jacks. The maximum height of the lugs above the base shall be: Transformers upto and including 10 tonnes weight, 800 mm excluding the under base dimensions. Transformers above 10 tonnes weight, 500 mm excluding the under base dimensions. Suitable haulage holes shall be provided. 5.23 TANK COVER :
5.23.1 Each tank cover shall be of adequate strength, and shall not distort when lifted. Inspection openings shall be provided as necessary to give easy access to bushings, for
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changing ratio or winding connections, or testing the earth connections at the link board. Each inspection opening shall be of suitable size for the purpose for which it is provided and atleast two openings one at each end of the tank shall be provided. 5.23.2 The tank cover and inspection covers shall be provided with suitable lifting arrangements. Unless otherwise approved inspection covers shall not weigh more than 25 kg each. 5.23.3 The tank cover shall be fitted with pockets for a thermometer and for the bulbs of the oil winding temperature indicators, protection shall be provided wherever necessary for each capillary tube. 5.23.4 The thermometer pocket shall be fitted with a captive screwed cap to prevent the ingress of water. 5.23.5 The pockets shall be located in the position of maximum oil temperature at CMR and it be possible to remove the instrument bulbs without lowering the oil in the tank (C.M.R Continuous Maximum Rating) 5.24 CONSERVATOR VESSELS, OIL GAUGES AND BREATHERS:
5.24.1 A conservator complete with sump and drain valve shall be provided in such a position as not to obstruct the electrical connections to the transformer having the capacity between highest and lowest visible levels to meet the requirement of expansion of the total cold oil volume in the transformer and the cooling equipment from the minimum ambient temperature to 90 Deg C the minimum indicated oil level shall be with the lead pipe from the main tank covered with not less than 15mm depth of oil and the indicated range of oil levels shall be from minimum to maximum. 5.24.2 If the sump is formed by extending the foot pipe inside the conservator vessel, this extension shall be for atleast 25mm. The conservator shall be designed so that it can be completely drained by means of the drain valve provided, when mounted as in service. 5.24.3 One end of the conservator shall be bolted into position so that it can be removed for cleaning purpose. -Normally one oil gauge magnetic / prismatic / plain type shall be provided. -The oil level is 10 Deg, 30 Deg and 98 Deg (Max.) shall be marked on the gauge. -Taps or Valves shall not be fitted to oil gauge. -The oil connection from the transformer tank to the conservator vessel shall be arranged at a rising angle of 3 to 9 Degrees to the horizontal upto the Buchholtz relay and shall consists of -For transformers from 1600 to 8000kVA50mm inside dia. pipes as per IS: 3639. -A valve shall be provided at the conservator to cut off oil supply to the transformer after providing a straight run of pipe for atleast a length of five times the internal diameter of the pipe on the tank side of the gas and oil actuated relay and atleast three times the internal diameter of the pipe on the conservator side of the gas and oil actuated relay. 5.24.4 Each conservator vessel shall be fitted with a breather in which a silica gel is the dehydrating agent and designed so that: -The passage of air is through the silica gel. -The external atmosphere is not continually in contact with the silicagel through provision of an oil seal.
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-The moisture absorption indicated by a change in colour of the tinted crystals can be easily observed from distance. -All breathers shall be mounted at approximately 1400 mm above ground level. -The breather shall be poly breather with see-through container for silicagel and with metallic frames with suitable threading to fix the breather to the pipe of the transformer. Plastic frames are not acceptable. The samples of Breather are to be got approved by the AP EPDCL before supply. 5.25
FILTER DRAIN VALVES, SAMPLING DEVICES AND AIR RELEASE PLUG:
-Each transformer shall be fitted with the following: -One drain valve of minimum 50mm shall be provided -One 50 mm valve at the top and one 50 mm valve at the bottom of the tank mounted diagonally opposite to each other for filtration purpose. -A drain valve as specified below shall be fitted to each conservator. -For diameter up to 650 mm, size of the valve 15mm, for diameter above 650mm size of valve 25mm. -A robust oil-sampling device shall be provided at the top and bottom of the main tank. The sampling device shall not be fitted on the filter valve. -One 15 mm air release plug. -All other valves opening to atmosphere shall be fitted with blank flanges. 5.26 5.27 COOLER AND RADIATOR CONNECTIONS: Valves and valve mountings shall be provided as specified under cooling plant section 40. VALVES:
5.27.1 All valves shall be of gun metal or cast steel or may have cast iron bodies with gun metal fittings. They shall be of way type with internal screw and shall be opened by turning counter clock wise when facing the hand-wheel. The valves shall be of robust construction and it should be possible to operate the valves without application of much force. 5.27.2 Means shall be provided for pad locking the bottom valves in the open and close positions. This is required for the valves where opening device like hand-wheel, keys etc are the integral part. 5.27.3 Every valve shall be provided with an indicator to show clearly the position of the valves. All valves shall be provided with flanges having machined faces. The drilling of valve flanges shall comply with the requirements of IS: 3639. 5.28 PRESSURE RELIEF DEVICE:
5.28.1 The pressure relief device shall be provided of sufficient size for rapid release of pressure that may be generated within the tank, and which might result in damage to the equipment. The device shall operate at static pressure of less than the hydraulic test pressure for transformers tanks. Means shall be provided to prevent the ingress of rain. 5.28.2 Unless otherwise approved the relief device shall be mounted on the main tank, if on the cover, shall be fitted with skirt projecting 25mm inside the tank and of such a design to prevent gas accumulation. 5.28.3 Two diaphrams of suitable design and material shall be used one at the base and the other at the mouth of the vent pipe.
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5.28.4 An oil gauge is required on the stand pipe for indicating fracture of diaphragm. 5.28.5 One of the following methods shall be used for relieving or equalizing the pressures in the pressure relief devices. 5.28.6 An equalizer pipe connecting the pressure relief device to the conservator. 5.28.7 The fitting of silica gel breather to the pressure relief device breather being mounted in a suitable position for access at ground level. 5.29 EARTHING TERMINAL: Two earthing terminals capable of carrying for a second, full lower voltage short circuit current of the transformer shall be provided. Provisions shall be made at positions close to each of the bottom two corners of the tank for bolting the earthing terminals to the tank structure to suit local conditions. RATING AND DIAGRAM AND PROPERTY PLATES: The following plates shall be fixed to the transformer tank at an average height of about 1750 mm above ground level. A rating plate bearing the data specified in the appropriate clauses of IS : 2026. A diagram plate showing the internal connections and also the voltage vector relationship of the several windings in accordance with IS : 2026 and in addition a plain view of the transformer giving the correct physical relationship of the terminals. When links are provided in accordance with clause 5.2 (voltage ratio) for changing the transformer ratio, than approved means shall be provided for clearly indicating ratio for which the transformer is connected, no load voltage shall be indicated for each tap. A plate showing the location and function of all valves and air release corks or plugs. This plate shall also warn operators to refer to the maintenance instructions before applying the vacuum treatment for drying. The above plates shall be of material capable of withstanding continuous outdoor service. 5.31 JOINTS AND GASKETS:
5.30
All gaskets used for making oil tight joints shall be of proven material such as granulated cork bonded with neoprene rubber unless otherwise specified, and samples shall be got approved by the Engineer. 5.32 COOLING PLANT: General: 5.32.1 Radiators and Coolers shall be so designed as to avoid pockets in which moisture may collect and shall withstand the pressure tests. 5.32.2 Unless the pipe work is shielded by adequate earth metal the clearance between all pipe work and live parts shall be more than the clearance for live parts to earth.
16
5.33
RADIATORS MOUNTED DIRECTLY TO THE TANK/BANKED :
5.33.1 Radiators connected directly to the tank shall be detachable and shall be provided with machined or ground flanged inlet and outlet branches. 19mm drain plug shall be provided at the bottom and 19mm air release plug shall be provided at the top of each radiator for draining and filling. These two plugs shall have neoprene rubber gaskets only. 5.33.2 The radiator fins shall be manufactured from a steel sheet with a thickness of not less than 1.25 mm. 5.33.3 Valves shall be provided on the tank at each point of connection to the tank. These valves shall have neoprene rubber gaskets 6mm thick on either side. The oil circuits of oil coolers shall be provided with the following: A valve at each point of connection to the transformers tank. Removable blanking plates to permit the blanking off the main oil connection of each cooler. A drain valve of 25mm at the lowest point of each bank of cooler. Air release plug 15 mm All radiator groups shall be provided with belting /by 50x50x6mm MS angle. 5.34 5.35 OIL PIPING AND FLANGES: Drain valves / plugs shall be provided in order that each section of pipe work can be drained independently. VOLTAGE CONTROL (On load type): The OLTC shall confirm to IS: 8468 1977. 5MVA/8MVA transformers voltage control equipment shall be of on load changing type on the HV side for HV variation of +5% to 15% in the equal steps of 1.25% for 5MVA/8MVA PTR, varying its effective transformation ratio while the transformers are on-load and without producing phase displacement. It shall not be possible to operate the electric work drive when the manual operating gear is in use. 5.36 VOLTAGE CONTROL OFF LOAD:
5.36.1 The equipment for local electrical and local manual operation shall be provided and shall comply with the following conditions. a) b) It shall not be possible for any two electric controls to be in operation at the same time. Operation from local/ remote control switch shall cause one tap movement only.
17
c) d) e)
All electrical control switches and the local operating gear shall be clearly labeled in a suitable manner to indicate the direction of the tap changing. The local control switches shall be mounted in the marshalling box or driving gear housing. The equipment shall be so arranged as to ensure that when a tap change has been commenced it shall be completed independently of the operation of the control relays or switches. If a failure of the auxiliary supply during tap changing or any other contingency would result in that movement not being completed adequate means shall be provided to safeguard the transformer and its auxiliary equipment.
5.36.2 Suitable apparatus shall be provided for each transformer to give indications as follows: A mechanical indication of the number of tapping position shall be provided to the OLTC gear of the transformer. 5.36.3 All relays and operated devices shall operate correctly at a voltage between the limits specified in the relevant Indian standards. 5.36.4 The tap changing switches and mechanism shall be mounted in oil tanks or compartments mounted at an accessible position on the transformer tank. 5.36.5 Any enclosed compartment not oil filled shall be adequately ventilated. Metal clad heaters shall be provided in the driving mechanism chamber and in the marshalling box, all contractor relay coils or other parts shall be suitably protected against corrosion or deterioration due to condensation, fungi etc. 5.36.6 The location of OLTC tank as viewed from the 33 KV side shall be on left side of the transformer. 5.36.7 The oil in those compartments of the main tap changing apparatus which do not contain contacts used for making or breaking current shall be maintained under conservator head by means of pipe connection from the highest point of the chamber to the conservator. This connection shall be controlled by suitable valve and shall be arranged so that any gas leaving the chamber will pass into the gas and oil actuated relay. A separate Bucholtz relay / oil surge relay shall be provided for the on load tap changer chamber. 5.36.8 It shall not be possible for the oil in those compartments of the tap change equipment which contain contacts used for making or breaking current to mix with the oil in the compartments containing contracts not used for making or breaking current. 5.36.9 Any DROP DOWN tanks with tap changing apparatus shall be fitted with guide rods to control the movement during lifting or lowering operations. The guide rods shall be so designed as to take support of the associated tank when in the fully lowered position. Lifting gear fitted to DROP DOWN tanks shall include suitable device to prevent run away during lifting and lowering operations. 5.36.10Each compartment in which the oil is not maintained under conservator head shall be provided with a suitable direct reading oil guage. 5.36.11The alternating supply for electrical operation of the control and indicating gear shall
18
be standard 415 volts, three phase, 4 wire, 50 Hz. 5.36.12Limit switches shall be provided to prevent over running of the mechanism and except where modified in clause shall be directly connected in the circuit of the operating motor. In addition a mechanical stop or other approved device shall be provided to prevent over running of the mechanism under any conditions. Limit switches may be connected in the control circuit of the operating motor provided that a mechanical declutching mechanism is incorporated. 5.36.13Thermal devices or other means shall be provided to protect the motor and control circuits. All relays, switches, fuses etc., shall be mounted in the marshalling box or driving gear housing and shall be clearly marked for purposes of identification. 5.36.14The control circuits shall operate at 110 V single phase to be supplied from a transformer having a ratio of 240/55-0-55V with the centre point earthed through a removable link mounted in the marshalling box or tap changer drive. 5.36.15The whole of the apparatus shall be of robust design and capable of giving satisfactory service without undue maintenance under the conditions to be met in service, including frequent operation. 5.36.16 A five digit counter shall be fitted to the tap changing mechanism to indicate the number of operations completed by the equipment. 5.36.17 A permanently legible lubrication chart shall be fitted within the driving mechanism chamber. 5.37 ON LOAD TAP CHANGER
5.37.1 The following type and routine tests shall be carried out on on-load tap changer and motor drive mechanism in accordance with IS 8468-1977 or its latest version. Type Test:a) b) c) d) e) f) g) h) Type tests shall be performed on the samples of the relevant tap changers or components after their final development. The following shall constitute the type tests. Mechanical test Auxiliary circuits insulation tests Test for temperature rise of contracts Switching tests Short circuit current tests Transition impedance tests Mechanical life test Dielectric test
Routine Tests:- The following shall constitute the routine tests a) Mechanical test b) Auxiliary circuits insulation tests c) Dielectric tests. 5.37.2 MOTOR DRIVE MECHANISM Type Tests: The following shall constitute the type tests: Mechanical Tests Auxiliary circuits insulation test
19
Mechanical load test Over run test Protection of motor drive cubicles. Routine Tests: The following shall constitute the routine tests. Mechanical test Auxiliary circuit insulation test 5.37.3 TRANSFORMERS WITH REMOTE ON LOAD TAP CHANGER PROVISION: In the wiring diagram of local control switch provision shall be made for connecting a remote control panel suitable for remote operation, if necessary in future for OLTC operation. 5.38 BUSHINGS, INSULATORS AND TERMINALS:
5.38.1 Transformers shall be fitted with bushing insulators. 5.38.2 The electrical characteristics of bushings and bushing rods shall be in accordance with IS 3347 and IS 2099. 5.38.3 Bushing insulators for 33 KV shall be provided with arcing horns except for neutral bushings. 5.38.4 Clamps with double nuts and spring washers shall be provided for the Bushing Rods. 5.38.5 The rod gap shall be adjustable type to enable a coordination of insulation level with surge diverters. 5.38.6 Any stress shield shall be considered as integral part of the bushing assembly. 5.38.7 Special precautions shall be taken to exclude moisture from paper insulation during manufacture, assembly, transport and erection. The surface of all paper insulations shall be finished with non-hydro scopic varnish which cannot be damaged easily. 5.38.8 Each porcelain bushing or insulator, and paper bushing shall have marked upon it the manufactures identification mark, and such other mark as may be required to assist in the representative allocation of batches for the purposes of the samples tests. 5.38.9 Clamps and fittings made of steel or malleable iron shall be galvanised. All bolts threads shall be greased before erection. 5.38.10The bushing flanges shall not be of re-entrant shape which may trap air. 5.38.11The bushing turrets shall be provided with vent pipes which shall be connected to route any gas collection through the Bucholtz relay. 5.38.12The clearances in air between live conductive parts and live conductive part to earthed structures shall be as follows: Nominal system voltage KV rms. 11 kV 33 kV Test Voltage impulse KV P 75 kV P 170 kV P Clearances Phase to phase Phase to earth mm mm 280 mm 205 mm 350 mm 320 mm
20
5.38.13Necessary features on transformer tank for mounting LAS on both HV and LV sides shall be provided. They should be detachable type and not to be welded. A suitable earth strip shall also be provided for each LA and it should be brought out separately to the ground insulation from the tank. 5.39 TEMPERATURE INDICATING DEVICES AND ALARM:
5.39.1 Transformer shall be provided with Temperature indications for measuring Transformer oil temperature and Transformer winding temperature. These samples of temperature indicator shall be got approved before supply. 5.39.2 Except where outdoor types of indicators are supplied, the temperature indicators shall be housed in the marshalling box. Winding temperature indicators are to be provided for 3.15 MVA and above transformers. 5.39.3 The tripping contacts of winding temperature indicators shall be adjustable to close between 60 Deg. C and 120 Deg. C and alarm contacts to close between 50 Deg. C and 100 Deg. C and both shall reopen when the temperature has fallen by about 10 Deg. C. 5.39.4 All contacts shall be adjustable on a scale and shall be accessible on removal of the cover. 5.39.5 The temperature indicators shall be so designed that it shall be possible to check the operation of the contacts and associated equipment. 5.39.6 Connections shall be brought from the device to terminals placed inside the marshalling box. 5.40 GAS AND OIL ACTUATED RELAYS:
5.40.1 Each transformer shall be fitted with gas and oil actuated relay [Buchholtz Relay] equipment having contacts which close following oil surge or low oil level conditions. 5.40.2 Each gas and oil actuated relay shall be provided with a test cock and a flexible pipe connection for checking the operation of the relay. 5.40.3 Where specified to allow gas to be collected at ground level a pipe approximately 5mm inside diameter shall be connected to the gas release cock of the gas and oil actuated relay and brought down to a point approximately 1.25mts above ground level, where it shall be terminated by a cock. 5.40.4 A machined surface shall be provided on the top of each relay to facilitate the setting of the relays and to check the mounting angle in the pipe and the cross level of the relay. 5.40.5 The design of the relay mounting arrangements, the associated pipe work and the cooling plant shall be such that mal operation of the relays shall not take place under normal service conditions. 5.40.6 The pipe work shall be so arranged that oil and gas arising from the transformer shall pass into oil actuated relays. The oil circuit through the relay shall not form delivery path in parallel with any circulation oil pipe, nor shall it be tied into or connected through a pressure relief vent, sharp bends in the pipe work shall be avoided. 5.40.7 When a transformer is provided with two conservators the gas and oil actuated relays shall be arranged as follows.
21
5.40.8 If the two conservators are connected to the transformer by common oil pipe one relay shall be installed in the common pipe. 5.40.8 If the two conservators are piped separately to the transformer two relays shall be installed, one in each pipe connection. 5.40.10Adequate clearances between all pipe work and live metal shall be provided. 5.41 MARSHALLING BOX:
5.41.1 The sheet steel vermin proof, with ventilated and weather proof marshaling box (as per IP55) of a suitable construction shall be provided for the transformer ancillary apparatus. The box shall have sloping roof and the interior and exterior painting shall be in accordance with relevant clause of cleaning and painting. 5.41.2 The marshalling box, wherever provided, shall accommodate the following equipments. Alternative weather proof instruments can be mounted out door. Temperature indicators Control and protection equipment for the local electrical control of tap changer, if the same cannot be accommodated in the motor driving gear housing and Terminal board and gland plates for incoming and out going cables. 5.41.3 All the above equipments except (c) shall be mounted on panels and back of panel wiring shall be used for inter connection. 5.41.4 The temperature indicators shall be so mounted that the dials are not more than 1600 mm ground level and the door(s) to adequate size. 5.41.5 To prevent internal condensation an approved type of metal clad heater shall be provided controlled by suitable switch. Ventilation levels shall be provided. 5.41.6 All incoming cables shall enter the kiosk form the bottom and gland plate shall be not less than 450mm from the base of box. The gland plate and associated compartment shall be sealed in suitable manner to prevent the ingress of moisture form the cable trench. 5.41.7 Undrilled gland plate shall be provided for accommodating glands for incoming and outgoing cables. 5.42
CONTROL CONNECTIONS AND INSTRUMENT WIRING, TERMINAL BOARDS & FUSES
5.42.1 All wiring connections, terminal boards, fuses and links shall be suitable for tropical atmosphere. Any wiring liable to be in contact with oil shall have oil resisting insulation and the bared ends of stranded wire shall be sweated together to prevent creepage of oil along the wire. 5.42.2 There shall be no possibility of oil entering, connection boxes used for cables or wiring.
Section-5 : Technical Specification 22
5.42.3 Panel connections shall be neatly and squarely fixed to the panel. All instruments and panel wiring shall be run in PVC or non rusting metal cleats of the limits compression type. All wiring to a panel shall be taken from suitable terminal boards. 5.42.4 Where conduits are used, the runs shall be laid with suitable falls, and lowest parts of the run shall be external to the boxes. All conduits runs shall be adequately drained and ventilated. Conduits shall not be run at or below ground level. 5.42.5 When 415 volts connections are taken through junction boxes or marshalling boxes they shall be adequately screened and 415 VOLTS DANGER notices must be affixed to the outside of the junction boxes or marshaling boxes. 5.42.6 All box wiring shall be in accordance with relevant IS. All wiring shall be of a stranded copper of 660 V grade and size not less than 4.00 sq mm for CT leads and not less than 2.5 sq mm for other connections. 5.42.7 All wires of panels and all multi core cables shall have ferrules, which bear the same number at both ends. 5.42.8 At these ends of inter connection between the wiring carried out by separate contractors; where a change of number cannot be avoided double ferrules shall be provided on each wire. The change of numbering shall be shown on the appropriate diagram of the equipment. 5.42.9 The same ferrule number shall not be used on wires in different circuits on the same panels. 5.42.10Ferrules shall be of white insulating material shall be provided with glassy finish to prevent the addition of dirt. They shall be clearly and durably marked in block and shall not be affected by damp or oil. 5.42.11Stranded wires shall be terminated with crimped tubular lugs. Separate washers shall be used for each wire. The size of the washers shall be suited to the size of the wire terminated. Wiring shall in general be accommodated in the sides of the box and the wires for each circuit shall be separately grouped. Back of the panel wiring shall be arranged so that access to the connecting stems of relays and other apparatus is not impeded. 5.42.12Wires shall not be jointed or tied between terminal points 5.42.13Wherever practicable circuits in which the voltage exceeds 125 volts, shall be kept physically separated from the remaining wiring. The function of each circuit shall be marked on the associated terminal boards. 5.42.14Where apparatus is mounted on panels all metal cases shall be separately earthed by means of copper wire or strip having a cross section of not less than 2 sq. mm. Where strip is used, the joints shall be sweated.
23
5.42.15All wiring diagram for control and relay panel shall preferably be drawn as viewed from the back and shall show the terminals boards arranged as in service. All diagrams shall show which view is employed. 5.42.16Multi core cable tails shall be so bound that each wire may be traced without difficulty to its cables. 5.42.17The screens of screen pairs of multi core cables shall be earthed at one end of the cable only. The position of earthing connections shall be shown clearly on the diagrams. 5.42.18All terminal boards shall be mounted towards the rear doors to give easy access to obliquely and to enable ferrule numbers to be read without difficulty. 5.42.19Terminal boards rows should be spaced adequately not less than 100 mm apart to permit convenient access to wires and terminations. 5.42.20Terminal boards shall be so placed with respect to the cable gland (at the minimum distance of 200 mm) as to permit satisfactory arrangements of multi core cable tails. 5.42.21Terminal board shall have pairs of terminals for incoming and outgoing wires. Insulating barriers shall be provided between adjacent connections, the height of the barriers and the spacing between terminals such as to give adequate protection, while allowing easy access to terminals. The terminals shall be adequately protected with insulating dust proof covers. 5.42.22 No live metal shall be exposed at the back of the terminal boards. 5.42.23 All fuses shall be of the cartridge type and shall conform to relevant IS 5.42.24 Fuses and links shall be labeled. 6.0 6.1 6.1.1 6.1.2 TESTS: TYPE TESTS: The type, acceptance and routine tests and tests during manufacture, shall be carried out on the transformer as per the provisions of IS 2026. For all type and acceptance tests, the acceptance values shall be the values guaranteed by the supplier in the proforma for Guaranteed Technical Particulars furnished in this specification or acceptance value specified in this specification, whichever is more stringent for that particular test. Test certificate of not more than three years old, from a recognized national laboratory with NABL accreditation shall be furnished. The bidder shall furnish two sets of type test reports as per relevant standards along with the bid.
BIDS WITHOUT THE FOLLOWING TYPE TEST REPORTS WILL BE TREATED AS NON-RESPONSIVE.
6.1.3
Note: 6.1.4
Type test as listed below shall be performed on the transformer as specified in IS:2026. a) Impulse voltage withstand test.
24
b) c) d) 6.1.5
Dielectric type tests. Temperature rise test. Short circuit.
For any change in the design/type already tested and design/type offered against this specification, the AP EPDCL reserves the right to demand repetition of the tests without any extra cost. The type test reports including short circuit withstand test report and impulse test report must accompany the offer. The short circuit withstand test report must accompany the active part, general arrangement drawings, duly inspected and certified by testing agency. The expenses to be incurred towards the tests shall be to their account. The S.C. tested unit will not be accepted for supply to the AP EPDCL. ACCEPTANCE AND ROUTINE TESTS : a) Measurement of winding resistance b) Measurement of ratio, polarity and phase relationship c) Measurement of impedance voltage d) Measurement of load loss. e) Measurement of no load and no load current. f) Measurement of insulation resistance. The insulation resistance of each winding in turn to all the other windings, core, frame and tank connected together and to earth shall be measured by standard megger and the values shall not be less than the values indicated below. Resistances 33 kV to earth 11 kV to earth g) h) At 30oC 500 M.Ohms 400 M Ohms At 40 Deg C 250 M.Ohms 200 M Ohms At 50 Deg C 125 M.Ohms 100 M Ohms At 60 Deg C 65 M.Ohms 50 M Ohms
6.1.6
6.2
Induced over voltage withstand test. The separate source voltage withstand test.
6.2.1
All acceptance and routine tests stipulated in the relevant standards shall be carried out by the supplier in presence of purchasers representative. The purchaser reserves the right to insist for witnessing the acceptance/routine testing of the bought out items to pass tests. Tests during manufacture: The Bidder shall furnish details of tests carried out during the process of manufacture and end inspection by the bidder to ensure the desired quality of the equipment to be supplied. ADDITIONAL TESTS: SPECIAL TEST: Special tests as specified in IEC 60 076 1993 in clause 10.1.3 shall also be undertaken with an agreement between the manufacturer and the purchaser. The purchaser reserves the right of having at his own expenses any other tests(s) of reasonable nature carried out at Bidders premises, at site, or in any other place in addition to the aforesaid type, acceptance and routine tests, to satisfy himself that the material comply with the specifications.
6.2.2
6.3 6.3.1 6.3.2
25
6.3.3
In case of failure in any type test, the supplier is required to modify the design of the material and the material shall be type tested again for the modified design, without any extra cost to the purchaser. No delivery extension shall be given for this additional testing. The entire cost of testing for the acceptance and routine tests and tests during manufacture shall be treated as included in the quoted unit price. TEST REPORTS / TEST CERTIFICATES: Record of routine test reports shall be maintained by the Bidder at his works for periodic inspection by the purchasers representative. Test certificates of tests conducted during manufacture shall be maintained by the Bidder. These shall be produced for verification as and when desired by the purchaser.
6.3.4 6.4
6.5 6.5.1
TEST FACILITIES: The tests shall be carried out as per relevant Standards and test certificates shall be furnished for approval. The Bidder shall indicate the details of the equipment available with him for carrying out the various tests as per relevant Standards. The bidder shall indicate the sources of all materials. He shall indicate the name of the supplier and make of meters, relays, conductor, insulating oil, electrical steel laminations constructional steel etc. NOTE : The Meters used for conducting tests shall be calibrated periodically at reputed Government Accredited Test Laboratories and test certificates shall be available at works for verification by purchasers representative. Tests as per applicable standards should be carried out in respect of porcelain bushings, galvanization, relays and meters. Manufacture shall submit the calculations to confirm the thermal ability as per clause No. 9.1 of IS-2026 part I of 1977. TESTS REPORTS ON THE ANALYSIS OF RAW MATERIALS : The tender shall indicate the source of raw material and enclose test certificates and report on the analysis of electrolytic copper used for the winding and the steel used for the core, insulation materials as also bought out items from sub-suppliers. TANKS Routine tests: Oil leakage test : All tanks and oil filled compartments shall be tested for oil tightness by being completely filled with air/oil of a viscosity not greater than that of insulating oil as per IS. 335 at an ambient temperature and subjected to a pressure equal to the normal pressure plus 35 KN/m2(5lb/sq.in) measured at the base of the tank. This pressure shall be maintained for a period of not less than 12 hours for oil and 1 hour for air, during which time no leakage shall occur. Type Tests:
6.5.2
6.5.3 6.5.4 6.6
6.7 a)
b)
26
i)
Vacuum Test: One transformer tank of each size shall be subjected to the specified vacuum shall be tested at an internal pressure of 3.33 KN/m2 ( 25 mm of Hg) for one hour. The permanent deflection of flat plates after the vacuum has been released shall not exceed the value specified below without affecting the performance of the transformer. Horizontal length of flat plate (in mm) Permanent deflection (in mm) Upto and including 750 5 751 to 1250 6.5 1251 to 1750 8 1751 to 2000 9.5 2001 to 2250 11 1151 to 2500 12.5 2501 to 3000 16 Above 3000 19 Pressure Test: One transformer tank of each size together with its radiators, conservator vessel and other fitting shall be subjected to a pressure corresponding to twice the normal head of oil or to the normal pressure plus 35 KN/m2 (5 lb/sq.in) whichever is lower measured at the base of the tank and will be maintained for one hour. The permanent deflection of flat plates after the excess pressure has been released shall not exceed the figure specified above. Training of DISCOM PERSONNEL: AP EPDCL reserves the right to depute AP EPDCLs personnel for training at your works relating to design, manufacture, assembly, testing and operation & maintenance in batches. You shall provide necessary facilities during training period specified by AP EPDCL Manufacturer authorized representative shall be present at the time of commissioning of Power Transformer. INSPECTION: The purchasers representative shall, at all times, be entitled to have access to the works and at all places of manufacture where equipment offered shall be manufactured and the representative shall have full facilities for unrestricted inspection of the bidders works, raw materials and process of manufacture and conducting necessary tests as detailed herein. The Bidder shall keep the purchaser informed in advance of the time of starting and of the progress of manufacture of the offered equipment in its various stages so that arrangements can be made for inspection. The supplier shall give 15days advance intimation to enable the employer to depute his representative for witnessing acceptance and routine tests. No material shall be dispatched from its point of manufacture before it has been satisfactorily inspected and tested, unless the inspection is waived off, by the employer in writing.
ii)
6.8
6.9 7.0 7.1
7.2
7.3 7.4
27
7.5
The acceptance of any quantity of material shall in no way relieve the Bidder of any of his responsibilities for meeting all requirements of the specification, and shall not prevent subsequent rejection if such material is later found to be defective. APEPDCL may its option get the materials inspected stage wise by the 3rd party on each unit/units offered for inspection along with a APEPDCLs representative, if it feels necessary. If a 2nd time inspection becomes necessary the inspection charges shall be borne by you. The bidder shall indicate the name(s) of reputed inspection agencies and the inspection charges clearly for each lot. The inspection charges will be borne by the purchaser. However the employer reserves the right to appoint at its cost any inspection agency to carry out the inspection. The APEPDCL reserves the right to insist for witnessing the acceptance routine testing of the bought out items. ANNEXURE I GUARANTEED TECHNICAL PARTICULARS FOR OILS
7.6
7.7
7.8
Sl. No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
Characteristics Appearance Density at 29.5 deg. C (Max.) Kinematics viscosity at 27 deg. C (Max.) Interfacial tension at 27 deg. C (Max.) Flash point. Pensky-Marten (Closed) (Min.) Pour Point (Max.) Neutralization value : Total acidity (Max.) Inorganic acidity / alkalinity Corrosive sulphur Electric strength (break down voltage) (Min.) New un-filtered oil After filtration Dielectric dissipation factor (Tan Delta at 90 deg. C) (max.) Specific resistance (Resistivity) At 90 deg. C (Min.) At 27 deg. C (Min.) Oxidation stability Neutralisation value after oxidation (Max.) Total sludge, after oxidation (Max.) Agening characteristics after accelerating ageing (Open Breaker Method with copper catalyst) for 96 Hrs. as per ASTM D-1934-1978 Specific resistance(Resistivity)
Particulars as per ISS:335/93 The oil shall be clear & transparent & free from suspended matter or sediments. 0.89 g/cm3 27 CST 0.04 N/m 140 deg. C -6 deg. C 0.03 NIL Non corrosive 30 kV (rms) 60 kV (rms) 0.002 35 x 1012 ohms cm 1500 x 1012ohms cm 0.40 mg KOH/g 0.10% by Wt.
28
Sl. No.
Characteristics i)At 27 deg. C (Min.) ii)At 90 deg. C (Min.) Dielectric dissipation factor Tan Delta at 90 deg. C (Max.) Total acidity (Max.) Total sludge value (Max.) Presence of oxidation inhibitor Water content (Max.) ANNEXURE I-A
Particulars as per ISS:335/93 2.5 x 1012 ohms cm 0.20 x 1012 0hms cm 0.20 0.05 0.05 NIL 50 ppm
14. 15.
SCHEDULE OF DETAILED PRICES OF TOOLS AND SPARE PARTS FOR 33/11KV 5MVA/8MVA DELTA/STAR POWER TRANSFORMERS Sl No. Description AS per section IV Schedule of Materials Item I Item - II Qty Nos. FADS Price Rs. Gross Weight Kgs. Delivery to destination Stores in weeks Remarks
ANNEXURE I-B GUARANTEED TECHNICAL PARTICULARS TO BE FURNISHED BY THE MANUFACTURER I. STANDARD FORM OF TECHNICAL PARTICULARS: 1. Name of the Manufacturer 2. Service 3. Ratings : - Rated KVA Rated Voltage of HV/LV KV Temperature rise in oil deg. C Temperature rise by resistance/ winding of deg. C Rated frequency : c/s 4. Number of Phases 5. Connections- High Voltage
29
6. 7. 8. 9. 10. 11.
12. 13. 14.
15. 16. 17. 18. 19.
- Low Voltage - Vector group of reference Tappings- High Voltage % Low Voltage % No load loss at rated voltage kW Load loss at rated current at 75 deg.C(kW) %Impedance at rated current and freq. At 75 deg.C Reactance at rated current and frequency % Efficiencies at 75 deg.C at unity power Factor At full load % At full load % At full load % Regulation at full load at 75 deg.C At unity power factor % At 0.8 Power factor lagging % No load current at rated voltage and frequency Approximate weights : KG Core KG Windings KG Core with frame KG Tank and fittings KG Oil(Excluding OLTCG Oil) KG Total weight KG Approximate quantity of oil Ltrs. (including OLTC OIL) Approximate overall dimensions- Length mm Breadth mm Height mm Terminal arrangements - High Voltage Low Voltage Reference standard Remarks
II ADDITIONAL TECHNICAL PARTICULARS: 1. Approximate Max. flux density at rated Vol. & Frequency CGS Lines/cm2 2. Efficiencies at 75 deg.C at 0.8 Power Factor lagging At full load % At full load % At full load % 3. Load at which maximum efficiency occur (full load) % 4. Maximum efficiency 5. Impulse levels with 1/50 ms wave High voltage kV Low voltage kV
30
6. 7. 8. 9.
10. a) b)
No load loss at 110% rated voltage and rated frequency kW No load current at 110% rated voltage and rated frequency A Type of windings High voltage Low voltage Insulation materials Turn insulation high voltage Turn insulation low voltage Insulation core to low voltage Insulation high voltage to low voltage Clearances Minimum clearance between phases In oil mm Out of oil mm Minimum clearance high voltage to(mm) Earth in oil Minimum clearance high voltage to tank(mm) in oil Details of tank: Length x Breadth x Height mm Approximate thickness of sides mm Approximate thickness of top mm Approximate thickness of bottom mm Approximate thickness of tube mm Radiators Minimum clearance height for lifting core and windings from tank (mm) Shipping details - Parts detached for transport Approximate weight of heaviest package (Kg) Approximate dimensions of largest package Length (mm) Breadth (mm) Height (mm) DETAILS OF AUXILIARY WINDINGS: Rating Rated KVA Rated voltage kV Connections Tappings Impedance at 75 deg/C/rated current at With respect to high voltage % With respect to low voltage %
III 1 2 3 4 5 6 7
IV 1. 2. 3. 4.
DETAILS OF BUSHINGS: 1. Type 2. Momentary Power Freq. dry withstand voltage kV 3. Visible power freq. Discharge voltage kV
31
4. 5. 6. 7. 8. 9. 10. VI
One minute dry withstand power freq. voltage kV One minute wet withstand power freq. voltage kV Full wave withstand impulse voltage kV Under oil flashover or puncture withstand voltage kV Creepage distance in air (mm) Recommended gap setting (mm) Weight of assembled bushing (Kg)
DETAILS OF ON LOAD TAP CHANGING GEAR: 1. Make 2. Type 3. Rating MVA Rated voltage kV Rated current A Step voltage V No. steps 4. Control 5. Auxiliary supply details 6. Voltage control 7. Line drop compensation 8. Parallel operation 9. Protective devices 10. Approx. overall weight Kg 11. Approx. overall dimensions (mm) 12. Approx. overall quantity of oil (Ltrs) DOCUMENTATION : All drawings shall conform to International Standards Organisation (ISO) À series of drawings sheet/India Standards Specifications IS:656. All drawings shall be in ink and suitable for micro filming. All dimensions and data shall be in S.I.Units.
10.0
10.2
LIST OF DRAWINGS AND DOCUMENTS: Four sets of complete dimensioned drawings showing the general arrangements, fitting details clearance, winding details shall be furnished along with the tender as under. Outline dimensional drawings of transformer and accessories including LA mounting arrangement the tank with necessary clearances between the tank and HV/LV side LAs as per IS 2026. -Assembly drawings and weights of main component parts -Tap changing and rare plate diagrams. -Schematic control and wiring diagram for all auxiliary equipment. -Schematic diagram showing the flow of oil in the cooling system as well as each limb and winding, longitudinal and cross sectional views showing the duct sizes, cooling pipe etc. for transformer/ heat exchanger drawn to scale shall be furnished.
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-Large scale drawing of high and low tension winding of the transformer showing the nature and arrangement of insulation and terminal connections. -Six copies of instruction books erection manual and operation and maintenance manuals and spare part bulletins for each consignee. 10.2.2 Descriptive literature and data on transformer construction, winding bushing, heat exchanger, tap changing gear etc., The successful Bidder shall, within 2 weeks of placement of order, submit three sets of final versions of all the above said drawings for purchasers approval. The purchaser shall communicate his comments/approval on the drawings to the supplier within four weeks. The supplier shall, if necessary, modify the drawings and resubmit three copies of the modified drawings for their approval. The supplier shall within two weeks, submit 23 prints and two good quality report copies of the approved drawings for purchasers use. 10.2.3 Six sets of the type test reports, duly approved by the purchaser, shall be submitted by the supplier for distribution before commencement of supply. Adequate copies of acceptance and routine test certificates, duly approved by the purchaser, shall accompany the dispatch consignment. 10.2.4 The manufacturing of the equipment shall be strictly in accordance with the approved drawings and no deviation shall be permitted without the written approval of the purchaser. All manufacturing and fabrication work in connection with the equipment prior to the approval of the drawing shall be at the suppliers risk. 10.2.5 Two set of nicely printed bound volumes of operation, maintenance and erection manuals and approved drawings in English language shall be supplied along with each circuit breaker, in addition to the five sets to be sent directly to the purchaser. 10.2.6 Approval of drawings/work by purchaser shall not relieve the supplier of his responsibility and liability for ensuring correctness and correct interpretation of the drawings for meeting the requirements of the latest revision of application standards, rules and codes of practices. The equipment shall conform in all respects to high standards of engineering, design, workmanship and latest revisions of relevant standards at the time of ordering and purchaser shall have to power to reject any work or materials which, in his judgment is not in full accordance therewith. 11.0 PACKING & FORWARDING: The equipment shall be packed in crates suitable for vertical/horizontal transport as the case may be, and suitable to withstand handling during transport and outdoor storage during transit. The supplier shall be responsible for any damage to the equipment during transit, due to improper and inadequate packing. The easily damageable material shall be carefully packed and marked with the appropriate caution symbol. Wherever necessary, proper arrangement for lifting, such as lifting hooks etc., shall be provided. Supplier without any extra cost shall supply any material found short inside the packing cases immediately. 11.2 Each consignment shall be accompanied with a detailed packing list containing the following information. a) b) Name of the consignee. Details of consignment.
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c) d) e) f) 11.3
Destination. Total weight of consignment Handling and packing instructions. Bill of Material indicating contents of each package.
The supplier shall ensure that the purchaser before dispatch approves the packing list and bill of material. The packing shall be done as per the manufacturers standard practice. However, he should ensure the packing is such that, Rail/Road should not damage the material during transit. The marking on each package shall be as per the relevant standards and shall also contain APEPDCL JBIC-II.
11.4
CENTRE OF GRAVITY: The centre of gravity of the assembled transformers shall be low and as near to the vertical central line as possible. The transformer shall be stable with or without oil. If the centre of gravity is eccentric relating to the track either with or without oil, its location shall be shown on the outline drawing.
12.0
QUANTITY AND DELIVERY REQUIREMENTS: The quantity and delivery requirement are indicated in Section -IV
13.0
SUPERVISION SERVICES: The bidder will arrange for unloading of the consignments.
14.0 14.1
MANDATORY SPARES & TOOLS: NECESSORY ACCESSORIES AND FITTINGS: Oil conservator with filling hole and gap and drain in cock. Oil level guage with 10 C, 30 C, 60 C and 90 C marking. . Silica gel breather. Air release plug Two numbers of earthing terminals with lugs On load tap changing gear with Buchholtz relay / oil surge relay. Drain valve, filter valve Buchholtz relay (double float) Radiators with valves (size LxBxH) Qty (Nos.) Lifting lugs with fastening holes Four Nos. Jacking pads Inspection covers (2 Nos.) Thermometer pockets (2 Nos.) Winding temperature indicator with two contacts) Pressure relief device. Rating and diagram plate and flow chart Oil temperature indicator (dial type with one contact for alarm) Marshaling box
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HT & LT bushings. These bushings shall be provided with bimetallic clamps suitable for panther ACSR Conductor. The bushing rods for all capacities should be of dia. for HV and 1 dia. for LV or M20 copper size for all capacities Necessary oil for first filling. Bottom mounting channel (min. size of channel shall be 200x75/76mm for 5.0 MVA Necessary features on transformer tank for mounting LAs on both HV & LV shall be provided and they shall be detachable type and not to be welded. Explosion vent with diaphragm Valve in equalising pipe Pulling eyes 8 Nos. Sampling devices (bottom and top) Note: Any other fittings that are necessary for the satisfactory operation of the transformers shall be provided without any extra cost. 14.2 OPTIONAL SPARES:- The tender shall quote separately for the following spares. i) Set of coils for one limb of the winding. ii) HT bushing. iii) LT bushing. iv) Neutral bushing. v) One set of gaskets vi) One set of thermometers vii) One oil gauge. The tender shall also quote for any item of spares recommended for 5 years normal operation. The employer will decide on the actual spares to be ordered on the basis of the list and item prices of spares. Detailed prices of tools and spare parts shall be indicated as per Annexure I-A
14.3
15.0 WARRANTY: 15.1 The general terms and conditions the warranty clause applicable to Power Transformers of this specification is as follows. The period of warranty will be 5 years (five years) from the date of commissioning of PTR. EPDCL reserves the right to claim the financial loss incurred / suffered due to the failure of Power Transformers during the guarantee period. For Power Transformers: If the PTR failed within the guarantee period, the bidder shall arrange for rectification/replacement within 60days from the date of intimation of the defects, starting from transporting the PTR from the Site, rectification and re-commissioning at site, free of cost at the ultimate destination. The contractor shall take over the replaced parts/materials/ equipment at the time of their replacement. No claim whatsoever shall lie on APEPDCL for the replaced parts/materials/ equipment thereafter. In the event of any correction of defects or replacement of defective material during the warranty period, the warranty for the corrected/ replaced material will be extended to a further period of 12 months. For equipments other than Power Transformers: If the bidder shall arrange for rectification/ replacement within 30 days from the date of intimation of the defects, free of cost at the ultimate destination. The contractor shall take over the replaced parts/materials/ equipment at the time of their replacement. No claim whatsoever shall lie on APEPDCL for the replaced parts/materials/ equipment thereafter. In the event of
15.2
15.3
35
any correction of defects or replacement of defective material during the warranty period, the warranty for the corrected/ replaced material will be extended to a further period of 12 months. 15.4 If the bidder, having been notified, fails to remedy the defects(s) within the above period, EPDCL may proceed to take such remedial action as may be necessary, at the contractors risk and expense duly deducting the expenditure from the subsequent bills/bank guarantee and without prejudice to any other rights which EPDCL may have against the bidder under the contract. TECHNICAL DEVIATIONS: Any deviation in Technical Specification as indicated in Section-V shall be specifically and clearly indicated in the enclosed schedule of deviation format as per Annexure II. GUARANTEED TECHNICAL PARTICULARS: The Bidder shall furnish the guaranteed Technical Particulars as per Annexure I-B enclosed and submit the same with the Tender. Schedule of detailed prices of tools and spare parts shall be indicated as per section-V. Annexure I-A. The schedule of quantity and prices shall be indicated as per Price Schedule. The prices of 5MVA/8MVA Power Transformers with OLTC are FIRM.
16.0
17.0
SCHEDULE OF REQUIREMENTS
Sl. No. Description of material 3-phase, 33/11 kV, 5000KVA/8000KVA, Delta/Star, Dyn11, 50 cycles, oil immersed, naturally self cooled, core type, outdoor power transformer (double wound with insulated copper wire conductor) conforming to latest IS-2026/77 (WITH AMENDMENTS IF ANY) with ON LOAD TAP CHANGING GEAR on HV side for HV variation of +5% to 15% in 16 equal steps of 1.25% with accessories and with required oil conforming to ISS 335/83 with latest amendment effective from 1st July 1987. Metal oxide lighting arresters (Dis-connector type).
TECHNICAL SPECIFICATION FOR 11KV & 33KV VCBS WITH CTS & CR PANEL
1.
1.0
SCOPE: This specification covers the manufacture, assembly, stage testing, inspection and testing before supply and delivery at site of the 11KV, 3Pole, 50Hz Vacuum Circuit Breakers with Current Transformers and Control & Relay Panel and 33kV, 3 Pole, 50 Hz Vacuum Circuit Breakers with Current Transformers and Control & Relay Panel. It is not the intent to specify completely herein all the details of the design and construction of equipment. However the equipment shall conform in all respects to high standards of engineering, design and workmanship and shall be capable of performing in continuous commercial operation up to the Bidder's guarantee, in a manner acceptable to the purchaser, who will interpret the meanings of drawings and specification and shall have the power to reject any work or material which, in his judgment is not in accordance there with. The offered equipment shall be complete
1.1
36
with all components necessary for their effective and trouble free operation. Such, components shall be deemed to be within the scope of Bidder's supply irrespective of whether those are specifically brought out in this specification and/or the commercial order or not. 2.0 2.1 STANDARDS: The materials shall conform in all respects to the relevant Indian Standard Specifications/ IEC Standards, with latest amendments indicated below. Indian Standard ISS-13118/1991 ISS-2705/1992 ISS-2099/1986 ISS-2633/1964 ISS-3231/1986 ISS-1248/1983 ISS-335/1983 ISS-2147/1962 2.2 International & Internationally recognized standard General requirements for Circuit breakers for IEC voltage above 1000V. 62271-100-1/2001 Current Transformers Bushings for alternating voltages above 1000V. Methods of testing uniformity of coating of zinc coated articles. Electrical relays for power system protection Specification for Ammeters & Voltmeters IEC 71 New insulating oils Electrical Clearances (For oils in CTs) Degree of protection provided by enclosures for low voltage switchgear & control gear Title
CONFLICT OF STANDARDS: Equipment conforming to other internationally accepted standards, which ensure equal or higher quality than the standards mentioned above would also be acceptable. In case the Bidders who wish to offer material conforming to the other standards, salient points of difference between the standards adopted and the specific standards shall be clearly brought out in relevant schedule. Four copies of such standards with authentic English Translations, shall be furnished along with the offer. In case of conflict the order of precedence shall be (i) IS (ii) IEC (iii) Other standards. In case of any difference between provisions of these standards and provisions of this specification, the provisions contained in this specification shall prevail.
3.0
CLIMATIC CONDITIONS: The Vacuum Circuit Breakers to be supplied against this Specification shall be suitable for satisfactory continuous operation under the following climatic conditions. Sl. No. i) ii) iii) iv) v) vi) Location Max. ambient air temperature (deg.C) Min. ambient air temperature (deg.C) Average daily ambient air temperature (deg.C) Max. Relative Humidity (%) Max. altitude above mean sea level (Meters) Average Annual rainfall (mm). At various locations in the state of Andhra Pradesh 50 7.5 35 100 1000 925
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vii) viii) ix)
Max. wind pressure(kg/sq.m.) Isoceraunic level (days per year) Seismic level (Horizontal accn.)
200 50 0.3 g.
The equipment shall be for use in moderately hot and humid tropical climate, conducive to rust and fungus growth. 4.0 PRINCIPAL PARAMETERS: 11KV Out door Vacuum Porcelain clad (Outdoor) Three 11/12kV 50 Hz Neutral solidly grounded 75 KVp 28 kV(rms) 2 kV(rms) 630 A 20 kA 20 kA 2.55 times Rated breaking Current 5 Cycles(max) Not less than 300mm Steel Structure O-0.3sec.-CO-3min.-CO. Motor operated/Manual spring charged. The standard DC voltage for the operating devices shall be 24V DC. Operation Voltage for motor spring charging mechanism shall be 240 V AC single phase. Normally the breaker shall be operated by power and there shall be provision for manual operation. Provision shall be made for slow closing of VCB without spring charging. Aluminium suitable for PANTHER conductor The limits of temperature rise shall be in accordance with relevant standard (IEC 62271) The maximum difference between instants of contact touching during closing and the maximum difference between the instant of contacts separation during opening between 3 poles shall not exceed one half cycle of the rated frequency. The breaker shall open and close
4.1 A. CIRCUIT BERAKERS : Service Type No. of Poles/Phases Rated Voltage (Nominal/Max.) Rated frequency System of earthing Impulse withstand Voltage
Power frequency withstand voltage for 1min Power frequency withstand voltage on Auxiliary circuit: Rated Current Rated breaking Capacity Symmetrical Rated short time withstand current for 3 sec Rating making capacity Total break time Bushing Insulator creepage distance Mounting Operating duty for gang operation. Operating Mechanism
Terminal connector Material (for outdoor) Limits of temperature rise Requirement of simultaneity of poles
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Protection
simultaneously on all the three phases for fault on any phase and or on all the phases i) The Breakers shall be provided with 3 Over current (3O/L) and one Earth fault (1 E/L) IDMT relay with min. setting 5% having CTs of ratio 400-200-100 / 1-1A. ii) The Breakers shall be provided with 3 Over current (3O/L) and one Earth fault (1 E/L) IDMT relays. 2 Nos. 24V DC auxiliary relays are to be provided for power transformer protection with 2NO + 2NC contacts & Hand reset type.
iii) Three phase high speed harmonic restraint biased (percentage) differential relay for differential protection of Power Transformers (8MVA and above) for LV control VCBs having CTs of ratio 600-300/1-1-0.5775A Pad locking for both mechanism box, control panel should be provided All angles 65 mm X 65 mm X 6 mm minimum size for breaker structure should be provided Bell is operated 24 V DC 4.1 B. CIRCUIT BERAKERS: 33 KV Service Type No. of Poles/Phases Rated Voltage (Nominal/Max.) Rated frequency System of earthing Impulse withstand Voltage Power frequency withstand voltage for 1min Power frequency withstand voltage on Auxiliary circuit: Rated Current Rated breaking Capacity Symmetrical Rated short time withstand current for 3 sec Rating making capacity Total break time Bushing Insulator creepage distance Mounting Operating duty for gang operation. Operating Mechanism Out door Vacuum Porcelain clad (Outdoor) Three 33/36Kv 50 Hz Neutral solidly grounded 170 KVp 75kV(rms) 2 kV(rms) 1250 A 25 kA 25 kA 2.55 times Rated breaking Current 5 Cycles(max) Not less than 900mm Steel Structure O-0.3 sec.-CO-3 min.-CO. Motor operated/Manual spring charged. The standard DC voltage for the operating devices shall be 24V DC. Operation Voltage for motor spring charging mechanism shall be 240 V AC single phase. Normally the breaker shall be operated by power and there shall be provision for manual operation. Provision shall be made for slow closing of VCB without spring charging.
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Terminal connector Material (for outdoor) Limits of temperature rise Requirement of simultaneity of poles
Aluminium suitable for 420 Sqmm conductor The limits of temperature rise shall be in accordance with relevant standard (IEC 62271) The maximum difference between instants of contact touching during closing and the maximum difference between the instant of contacts separation during opening between 3 poles shall not exceed one half cycle of the rated frequency. The breaker shall open and close simultaneously on all the three phases for fault on any phase and or on all the phases The Breakers shall be provided with 3 Over current (3O/L) and one Earth fault (1 E/L) IDMT relay with min. 5% setting with high set Instantaneous elements. 2Nos. 24V DC auxiliary relays are to be provided for power transformer protection with 2NO+2 NC contacts & Hand reset type for LV control VCBs having CTs of ratio 200-100/1-1-1A. Pad locking for both mechanism box, control panel should be provided All angles 65 mm X 65 mm X 6 mm minimum size for breaker structure should be provided Bell is operated 24 V DC
Protection
Pad locking for both mechanism box, control panel should be provided All angles 65 mm X 65 mm X 6 mm minimum size for breaker structure should be provided Bell is operated 24 V DC
Note: The relays shall be numerical relays of Alstrom / ABB / ER / L&T makes with IDMT (Inverse Definite Minimum Time) characteristics and also with high set instantaneous elements for high fault currents and shall comply with relevant standard. The accuracy class of relays shall be clearly specified as per IS. 4.2 Auxiliary Electrical equipment shall be suitable for operation on the following supply system. 240V single phase-4 wire 50c/s. and Power devices (drive motors) and lighting lighting neutral grounded AC supply. DC supply 24VDC ungrounded 2wire The above supply voltage may vary as indicated below and all devices shall be suitable for continuous operation over the entire range of voltages. AC Supply DC Supply 4.3 Voltage +10% to -15% : Frequency +/-5% +10% to -20%.
SUPPLY POINT: Auxiliary power supplies listed above will be made available to each circuit breaker as given below. AC Supply Single feeder DC Supply Single feeder MCB ( Miniature Circuit Breaker) Shall be provided at the circuit breaker for each incoming AC supply. For DC supply double pole MCB shall be provided.(with different colours for easy identification).
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4.4
A. CURRENT TRANSFORMERS FOR 11KV BREAKERS Rated Voltage 11kV Type Single Phase outdoor oil cooled vacuum impregnated CTs for out door VCBs. Earthing Solidly earthed Insulation level Nominal System Voltage 11kV Maximum System Voltage 12kV Impulse withstand voltage 75kVp One minute power frequency withstand 28kV voltage Frequency 50 Hz +/- 5% Transformation Ratio 400-200-100/1-1A Transformation Ratio for 11 KV LV VCBs 600-300/1-1-0.5775A with differential protection Rated Secondary Current Amps 1A Core-I (Protection) 1A Core-II (Metering) Core-III (Class PS; protection for LV 0.5775 breakers) Rated Output (VA) Protection 15 Metering 5 Differential protection ---Class of Accuracy Protection (Core-I) 10P Metering (Core-II) 0.5 Differential protection (core-III) PS Short time Thermal current The short time thermal current should suit the breaker rupturing capacity and duration to suit the maximum tripping time. Accuracy limit factor 10 for protective core ISF < 5 for metering core Current transformers stand cross bracing should be provided B. CURRENT TRANSFORMER FOR 33KV BREAKERS Rated Voltage Type Earthing Insulation level Nominal System Voltage Maximum System Voltage Impulse withstand voltage One minute power frequency withstand voltage Frequency Transformation Ratio 33KV Single Phase outdoor oil cooled vacuum impregnated CTs for out door VCBs Solidly earthed 33Kv 36Kv 170kVp 75Kv 50 Hz +/- 5% i) 200-100 / 1-1-1A
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Rated Secondary Current Amps Core-I (Protection) Core-II (Metering) Core-III (Class PS; protection for LV breakers) Rated Output (VA) Protection Metering Differential protection Class of Accuracy Protection (Core-I) Metering (Core-II) Differential protection (core-III) Max. knee point voltage requirement Short time Thermal current
1A 1A 1A 15 5 ----
5P 0.2 PS 40 I (Rct+10); I = Rated Current of CT The short time thermal current should suit the breaker rupturing capacity and duration to suit the maximum tripping time. Accuracy limit factor 10 for protective core ISF <5 for metering core Current transformers stand cross bracing should be provided STANDARDS: The equipment shall conform in all respects to the latest version of Relevant IS indicated below as applicable. 1. Current Transformers : IS 2705 (Part I to IV) 2. HV Porcelain Bushings : IS 2099 3. Oil : IS 335 4. Galvanization : IS 2633 5. Primary Terminals : IS 10601 6. Insulation coordination : IS 2165 7. Dimensions of porcelain Bushings : IS 3347 8. Method of high voltage rating : IS 2071 The tendered shall go through the above IS thoroughly before making his offer. Note: The Current Transformer shall be offered with first filling of oil conforming to relevant standards. 5.0 TECHNICAL REQUIREMENTS: The following technical particulars are common for outdoor/Indoor VCBs except where specifically mentioned. CIRCUIT BREAKERS: -The equipment will be installed out door in hot, humid and tropical atmosphere -The maximum temperature in any part of the equipment at specified rating shall not exceed the permissible limits as stipulated in the relevant standards. -The equipment shall be capable of withstanding the dynamic and thermal stresses of listed short circuit current without any damage or deterioration. -The safety clearances of all live parts of the equipment shall be as per relevant standards. -All equipment, accessories and wiring shall have tropical protection, involving special treatment of metal and insulation against fungus, insects and corrosion
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5.1
TYPE AND DUTY: The 11KV circuit breakers shall be outdoor, 3-pole, vacuum type having internal isolation without any sequential interlock. The duty of the circuit breaker shall involve satisfactory interruption of short circuit currents as listed in principal parameters. The breaker shall be capable of interruption of reactive current (lagging/leading) without under /over voltage
5.2 CONSTRUCTIONAL FEATURES: 5.2.1 GENERAL ARRANGEMENTS: The circuit breaker shall have fixed type construction consisting three single identical poles, complete with a gang operated sealed porcelain housing conforming to IP-65 protection conforming to relevant standards. All three poles of circuit breaker shall be linked together electrically/mechanically to ensure simultaneous closing of all poles. The trip free operating mechanism, 3 phases inter connection links shall be completely accommodated in the base. There shall be sufficient clearance between live parts of the circuit breakers and the ground. The circuit breaker shall be completed with operating mechanism, other accessories/materials to ensure complete assembly and proper functioning. The current transformers shall be externally mounted on the supporting structure integrated with circuit Breaker structure. Terminal connectors suitable for Panther conductor should be supplied for Circuit Breakers and Current Transformers. The circuit breaker shall be provided with proper standard earthing and with terminal earth bar for earthing connection. Suitable inter - connection between Circuit Breaker terminals and Current Transformer Terminals are to be provided. Note : Neither the circuit breaker nor any part of the switchgear or its supporting structures shall be permanently strained due to vibration etc., when making or breaking the rated short circuit currents. The details of any device incorporated in the circuit breakers to limit or control the rate of restriking voltage across the circuit breaking contacts shall be stated. The vacuum interrupter assembly used in the circuit breakers shall be interchangeable with indigenously available vacuum interrupters (make and type shall be mentioned). 5.2.2 MAIN CONTACTS AND ARC QUENCHING CHAMBER: The main contacts shall have adequate area and contact pressure for carrying rated continuous and short time currents without excessive heating liable to cause pitting and welding. The tips of the arcing & main contacts shall be heavily silver plated. The contacts that are adjustable to allow for wear, shall be easily replaceable and shall have minimum moveable part and adjustments. The arc-quenching device shall be of robust construction and shall not require any critical adjustments. The devices shall be easily accessible and removable for access to the breaker contacts.
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5.2.3
INTERLOCK: All electrical and mechanical interlocks, which are necessary for safe and satisfactory operation of the circuit breaker, shall be furnished. It is intended that before lockout occurs the breaker shall be in trip position.
5.2.4 AUXILIARY CONTACTS: Each breaker shall be provided with Four (4) normally open and Four (4) normally closed electrically separate spare Auxiliary contacts in addition to those required for its own operation and indication exclusively for purchasers use. The auxiliary contacts shall be convertible type so that normally open contacts can be converted into normally close contact and vice verse at site. The auxiliary contacts shall be rated for 10A for AC and 5A for DC 5.2.5 INSULATORS: Bushing insulator for circuit Breakers shall comply wherever possible with relevant standard for High voltage porcelain bushings. Insulators shall be wet process porcelain, brown glazed and free from all blemishes. Ferrous metal parts and hardware shall be hot-dip galvanised. Insulator shall have adequate mechanical strength and rigidity to withstand the duty involved. When operated at maximum system voltage there shall be no electrical discharge. Shielding rings, if necessary, shall be provided. Insulation shall be coordinated with basic impulse level of the system. The creepage distance shall correspond to heavily polluted atmosphere. 5.3 OPERATING MECHANISM: The operating mechanism shall be motor operated/ manual operated spring closing with trip free features complete with shunt trip coils. All three poles of the breaker shall operate simultaneously, It shall operate in such a way that the closing springs after each closing operation are automatically charged by the motor and locked in the charged position by a latch. Means shall be provided to charge the springs manually also. Provision shall be made for slow closing of VCB without spring charging. The springs shall get changed within appropriate time to facilitate auto-reclosing operations. The mechanism to be operated for the reclosing operations should the circuit breaker trip. The contact loading spring shall be designed in such a way that the contact bounce is eliminated and it shall be ensured and the opening stroke is commenced only from fully closed position. All the breakers shall be suitable for manual operation as well as slow closing without spring charging. Anti pumping device shall be incorporated.
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Operation counter and mechanically operated indicator to show whether the circuit breaker is open or closed shall be provided on the circuit breaker operating mechanism. All manually operating gear shall be so designed that the circuit breaker can be operated by one movement. The mechanism shall be such that the tripping spring can be charged while the circuit breaker is closed and the closing mechanism when charged shall not be operated by vibration caused by the circuit breaker opening under fault conditions. The spring shall be suitable for 4 short reclosing operations. The mechanism shall be designed for electrical control from remote. Local manual close/trip (lever/button) shall be provided in the mechanism box. 5.4 CONTROL CUBICLE (MECHANISM BOX) FOR OUTDOOR VCBS: A common control cubicle shall be furnished to house electrical controls, monitoring devices and all other accessories except those, which must be located on individual poles. The cubicle shall have IP-55 of gasketed whether proof construction, fabricated from sheet steel minimum 2.5 mm thick. The cubicle shall have front access door with lock and keys, and removable gland plate at the bottom for cable entry. 5.5 5.5.1 WIRING & TERMINAL BLOCKS: WIRING: Wiring shall be complete in all respects to ensure proper functioning of the control, protection, monitoring and interlocking schemes. Wiring shall be done with flexible 1100 V grade, PVC insulated, switchboard wires with 2.5 sq.mm stranded copper conductor, and Wiring between individual poles and control cubicle shall be routed through G.I Conduits. Each wire shall be identified at both ends with permanent markers bearing wire numbers as per wiring diagram. The wiring schematic may conform to relevant standards. Wire termination shall be done with crimping type connectors with insulating sleeves. Wires shall be spliced between terminals. All spare contacts of relays, push buttons auxiliary switches etc. shall be wired upto terminal blocks in the control cubicle. 5.5.2 TERMINAL BLOCKS: Terminal blocks shall be 1100 V grade, box clamp type (Stud type). Not more than two wires shall be connected to any terminal Spare terminals equal in number to 20% active terminal shall be furnished.
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Terminal blocks shall be located to allow easy access. Wiring shall be so arranged that individual wires of an external cable can be connected to constructive terminals. 5.6 NAME /RATING PLATE: CIRCUIT BREAKERS : Each circuit-breaker shall be provided with a name plate or plates legibly and indelibly marked with atleast the following information : a) b) c) d) e) f) g) h) Name of manufacturer Type designation and serial number Rated voltage and current. Rated frequency Rated symmetrical breaking capacity Rated making capacity and Rated short-time current and its duration (which shall be either one or three seconds) P.O No. & Date and year of supply
Note: The word Rated need not appear on the nameplate recognized abbreviations may be used to express the above quantities. When the circuit breaker is fitted with closing and/or tripping devices necessitating an auxiliary supply the nature of the auxiliary supply shall be stated either on the circuit breaker nameplate or in any other acceptable position. The words APEPDCL-JBIC-II must be etched on the nameplate. 5.7 5.7.1 CONTROL & RELAY PANELS: CONSTRUCTION: The Control Panels to house meters, relays and other items as specified in Cl. 5.8.3. shall be weather proof and vermin proof and of rust-free pressed steel cubicle type with hinged door and locking device. Ventilation louvers shall be provided with GI mesh. The frame shall be made of angle iron or structural steel of sufficient weight and strength to ensure permanent rigidity and alignment. The control panel shall be provided with inter connections, small wiring leads, terminal bolts, fuses, earth bar, multi core cable glands, earth connections etc. The panel should be provided with locking handle with built-in-door lock and the lock shall be provided with duplicate keys. The outdoor panels shall be preferably of the following dimensions: Height 1750 mm, from plinth level to live part. Width 500mm Depth to be adjusted to accommodate relays & relays instruments but not less than 500mm. The exterior of the panels shall be epoxy painted with dark admiral Grey colour and interior should be painted with half white colour. The panel shall be provided with MCBs for AC circuit fuse units for potential Circuit (potential coil connections to static trivector meters etc.) and DC control circuit, Indication circuit etc. The internal wiring
46
of the panels shall be with 2.5 Sq.mm 1100V grade standard copper PVC insulated wiring of reputed make. The thickness of the sheet steel for the front of the panels (where the meters etc. are fixed) and supporting members of the panels shall be of 3mm and for the other members of the panel sheet steel thickness shall be 2mm. Wherever control panels are fixed to the breaker structure necessary clearance from the ground to read the meters and to operate the switches shall be maintained. The cables from circuit breakers and current transformers to control panels shall be provided. 5.7.2 PAINTING: Before painting all ungalvansied parts shall be completely cleaned and made free of rust, scale and grease and all external rough surface cavities on casting shall be filled by metal deposition. The interior parts and internal structural steel work shall be cleaned of all scale and rust by sand blasting and given a primary coat and two coats of oil and weather resisting epoxy paint. All external surfaces shall receive a minimum of 3 coats of paint. The paint shall be guaranteed for 5 years from the date of receipt of material. 5.7.3 CURRENT TRANSFORMERS
5.7.3.1 Construction: The core shall be high-grade non-aging electrical silicon-laminated steel of low hysterisis loss and high permeability to ensure high accuracy, at both normal and over current. The secondary terminals shall be brought into a compartment on one side of current transformer for easy access. The secondary terminals shall be provided with short circuiting arrangements. The secondary taps shall be adequately reinforced to withstand normal handling without damage. The current transformer shall be suitable for mounting on steel structure or concrete pedestals. The necessary flanges, bolts, etc for the base of current transformer shall be supplied and these shall be galvanized. The current transformer tank and other metal parts shall be galvanized. The various ratios of Current Transformers shall be obtained by changing the effective number of turns on the secondary. The magnetization curves for secondary cores shall be invariably furnished with the tender specifically marking the point on the curve at which knee point voltage is obtainable and also the corresponding excitation current. The secondary terminals shall be adequately reinforced to withstand normal handling without damage. The current transformers shall be designed to carry continuously a current of at least 125% of the rated current.
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All windings of Current Transformers shall be made of double paper covering insulation and the manufacturing of the units shall be done in completely closed and airconditioned room. Fiberglass insulation sleeves are to be provided for primary winding. Details of winding and core shall be furnished. The current transformers shall be complete in all respect with filling of oil confirming to IS:335 and with oil level indicator with minimum/maximum oil levels. 5.7.4 NAME/RATING PLATE: Each Current Transformer/Potential Transformer shall have the following particulars indelibly marked on it or on a label permanently secured to it or its casing. a) b) c) d) e) f) g) Manufacturers Name Manufacturers Sl.No. and/or type of designation. Rated transformation ratio Rated frequency Highest system voltage Insulation level and Rated short time thermal current with the associated rated time and rated dynamic current for CTs.
The purchase order number and date and year of supply and the words APEPDCLJBIC-II must be etched on the nameplate. 5.8 5.8.1 SCHEDULE OF EQUIPMENT: CIRCUIT BREAKERS: The Circuit breaker complete with suitable epoxy painted steel support structure (with anchor bolts & nuts) for outdoor shall have 1 No. Vacuum Circuit Breaker - 3 poles, Mechanism box, control and relay panels and current transformers. Note: -Earth strips as per relevant Standards shall be provided for proper earthing of equipment. -Earth bar of copper (suitable for termination of 2 Nos. 50 x 6 mm Flats) shall be provided on Circuit breaker support structure. -Connecting cable from breaker to control panel and breaker to CT are to be provided. -For HV/LV breakers, collecting cable from breaker to CTs 6 core cable of 5 m length from each CT i.e., total 3 x 5 = 15 m. Breaker and from Breaker to control panel 10 core cable of 10 m length. -Size of control cable is 2.5 Sqmm (armourded stranded copper cable) -Metallic sealing bellows are to be provided at the bottom of the all pole assemblies. 5.8.2 MECHANISM BOX CONTAINING: a) b) c) Operating mechanism Mechanical indicator for ON and OFF coupled to the circuit breaker operating mechanism. Mechanical close and trip ( with protective flap ) lever/push button.
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d) e) f) g) h) i) j) k) l) m) n) 5.8.3
Terminal blocks for control wiring and a spare terminal block (with 20% of he active terminals). Operation Counter. Operating handle for manual charging of springs. 2 Nos. cable glands over and above those provided for control cables with suitable dummies. Not less than four numbers normally open and four numbers normally close spare auxiliary contacts over and above those required for normal operation. 230V single phase AC Motor / Manual operated spring charging mechanism complete with electrical spring release coil, 2Nos. shunt trip coils and 1 No. closing coil. Local - Remote selector switch. Earth bar ( suitable for termination of 2 Nos. 50 X 6mm class ) 6 Nos. Terminal connectors for incoming and outgoing connectors for outdoor VCB. Set of 2 poles MCBs for AC and DC supply with different colours. 1 No. EE/ABB/Jyothi make Anti-pumping relay
A. CONTROL AND RELAY PANEL FOR 11KV VCB: Weather proof, vermin proof control and relay panel mounted on the breaker structure having equipped as follows: a) b) c) d) e) f) g) h) i) j) Control circuit cables and auxiliary supplies (AC & DC) with suitable dummies. 3 Digit LED display digital AC volt meter with selector switch One set alarm bell and push button for acceptance of alarm. 2 Nos. AC & DC MCBs for control circuit. Set of fine wiring with ferrules with standard code number of respective terminals and with suitable terminal connectors. 240V three pin socket with plug & switch Test terminal block with CT and PT terminals with links for testing ammeter and static trivector meter. Stud terminal blocks (Bolt and nut type) for CT and PT control cables suitably wired with 6Nos. spare terminals. One suitable copper earth strip of 12x3 mm size with adequate number of holes with suitable nuts and bolts for outdoor VCB. For 11KV VCBs provision for mounting the static trivector meter of standard size, flush of panel type shall be made. The meter will be provided by the purchaser at the time of erection. Additional locking arrangement to the panel door to be provided.
5.8.3
B. CONTROL AND RELAY PANEL FOR 33KV VCB: Weather proof, vermin proof control and relay panel mounted on the breaker structure having equipped as follows:
a) b) c)
3 Digit LED display CT Operated digital AC Ammeter to suit the CT ranges indicated in Section IV. (Schedule of materials) shall be AE/IMP make. One ammeter selector switch with R, Y, B, Neutral and OFF positions. One Heavy duty pistol grip type control switch for VCB trip/Neutral/Close positions with spring return to neutral position.
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d)
One Red and one Green indicating lamps for indicating Close and Open positions respectively. e) One yellow Lamp for healthy trip indication with push button control. f) One white lamp for spring charged indication. g) One amber lamp for auto-trip indication. h) Numerical relays shall be EE make/ABB make/ER make/ L&T make with the following features. i) IDMT relays with 3 poles arranged for O/L and one pole for E/L with min. 5% setting. j) Two Nos. cable glands over and above those provided for control CT and PT cables, control circuit cables and auxiliary supplies (AC & DC) with suitable dummies. k) 3 Digit LED display digital AC volt meter with selector switch for 33KV circuit breakers One set alarm bell and push button for acceptance of alarm. l) 2 Nos. AC & DC MCBs for control circuit. Set of fine wiring with ferrules with standard code number of respective terminals and with suitable terminal connectors. m) 240V three pin socket with plug & switch n) Test terminal block with CT and PT terminals with links for testing ammeter and static trivector meter. o) Stud terminal blocks (Bolt and nut type) for CT and PT control cables suitably wired with 6Nos. spare terminals. p) One suitable copper earth strip of 12x3 mm size with adequate number of holes with suitable nuts and bolts for outdoor VCB. q) For 33KV VCBs provision for mounting the static trivector meter of standard size, flush of panel type shall be made. The meter will be provided by the purchaser at the time of erection. r) Additional locking arrangement to the panel door to be provided. s) One suitable copper earth strip of 12x3mm size with adequate number of holes with suitable nuts and bolts for outdoor VCB. Note: All the instruments and relays to be provided on control panel shall be flush mounted. The relays are to be worked on one amp secondary current of Current Transformers and with DC voltage of 24V. The current and potential transformers shall be mounted in such a manner that their secondary terminal connections are accessible for testing and maintenance purposes. --The terminals for CTs shall be provided with shorting links. -All indicating lamps are of extended LED type only. -1 No. push button for trip circuit for healthy check up -1 No. plug point with switch (10 A, 230 V AC) -1 No. Illuminator lamp with switch (40W, 230 VAC) -1 No. panel space heater with heater switch thermostat -Complete wiring is to be done with ring type copper lugs with proper crimping. 5.8.4 CURRENT TRANSFORMERS: Three numbers Current Transformers as specified. Terminal connectors suitable for Panther conductor for 11KV & 33KV shall be supplied for Circuit Breaker (6Nos.) and CT Terminals (6Nos.). Suitable inter connection between circuit breaker terminals and CT terminals are to be provided for
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outdoor VCBs. Terminal connectors should have contact area of above 300 Sq.mm when connected to VCB & CTs and must be bushing type. Note: Other standard accessories which are not specifically mentioned but supplied with breakers of similar type and rating for efficient and trouble free operation shall be provided. Special Guarantee: The vacuum bottles shall be guaranteed for satisfactory operation for period of five years from the date of commissioning, including vacuum bottles mechanism box and all bushings etc. Guaranteed Technical Particulars: The bidder shall indicate the technical particulars guaranteed in the proforma given in Annexures. I(A) & I(B). 6.0 6.1 6.1.1 6.1.2 TESTS: The type, acceptance and routine tests and tests during manufacture, shall be carried out on the vacuum circuit breaker as per the IEC 62271-100 -2001 and current transformers as per IS 2705 (with latest revision). The standards and norms to which these tests will be carried out are listed in ISS/IEC mentioned above. For all type and acceptance tests, the acceptance values shall be the values guaranteed by the supplier in the proforma for Guaranteed Technical Particulars furnished in this specification or acceptance value specified in this specification, whichever is more stringent for that particular test. Test certificate of not more than three years old, from a recognized national laboratory with NABL accreditation shall be furnished. TYPE TESTS: The circuit breakers and current transformers shall be fully type tested by the bidder as per the relevant standard including the type tests mentioned below in Cl. 6.2.1 & 6.2.2. The type tests must have been conducted on 11KV Vacuum Circuit Breakers and current transformers from recognized NABL accredited test laboratories not earlier than 3 years from the date of bid opening. The bidder shall furnish two sets of type test reports as per relevant standards along with the bid.
BIDS WITHOUT THE FOLLOWING TYPE TEST REPORTS WILL BE TREATED AS NON-RESPONSIVE.
6.1.3 6.2
6.2.1
CIRCUIT BREAKERS: IS13118/IEC62271 a) b) c) d) e) f) g) h) i) a) Temperature rise test for the main circuits. Measurement of resistance of the main circuit. Operation tests. Mechanical endurance tests. Impulse voltage tests. One minute power frequency voltage dry withstand tests. One minute power frequency voltage wet withstand tests. Tests for short circuit conditions. Tests for short time current. Verification of terminal markings and polarity.
6.2.2 CURRENT TRANSFORMERS: IS 2705
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b) c) d) e) f) g) h)
High voltage power frequency test on primary windings. High voltage power frequency test on secondary windings. Over voltage inter-turn test. Determination of error according to the requirements of appropriate accuracy class. Short-time current Temperature rise test. Impulse voltage test for current transformers for services in electrically exposed installations.
6.2.3 ACCEPTANCE AND ROUTINE TESTS : 6.2.3.1CIRCUIT BREAKERS: a) Measurement of resistance of the main circuits. b) Operation tests. c) One minute power frequency voltage dry withstand test on the circuit breakers d) One minute power frequency voltage dry withstand test on auxiliary circuits. 6.2.3.2 CURRENT TRANSFORMERS: a) b) c) d) e) Verification of terminal markings and polarity. High voltage power frequency test on primary windings. High voltage power frequency test on secondary windings. Over voltage inter-turn test. Determination of error according to the requirements of appropriate accuracy class. All acceptance and routine tests stipulated in the relevant standards shall be carried out by the supplier in presence of purchasers representative. The employer reserves the right to insist for witnessing the acceptance/routine testing of the bought out items to pass tests. 6.2.3.3Tests during manufacture: The Bidder shall furnish details of tests carried out during the process of manufacture and end inspection by the bidder to ensure the desired quality of the equipment to be supplied. 6.3 6.3.1 ADDITIONAL TESTS: The purchaser reserves the right of having at his own expenses any other tests(s) of reasonable nature carried out at Bidders premises, at site, or in any other place in addition to the aforesaid type, acceptance and routine tests, to satisfy himself that the material comply with the specifications. In case of failure in any type test, the supplier is required to modify the design of the material and the material shall be type tested again for the modified design, without any extra cost to the purchaser. No delivery extension shall be given for this additional testing. The entire cost of testing for the acceptance and routine tests and tests during manufacture shall be treated as included in the quoted unit price. TEST REPORTS / TEST CERTIFICATES: Record of routine test reports shall be maintained by the Bidder at his works for periodic inspection by the purchasers representative.
6.3.2
6.3.3 6.4 6.4.1
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The Bidder shall maintain test certificates of tests conducted during manufacture. These shall be produced for verification as and when desired by the purchaser. 6.5 TEST FACILITIES: The tests shall be carried out as per relevant Standards and test certificates shall be furnished for approval. The Bidder shall indicate the details of the equipment available with him for carrying out the various tests as per relevant Standards. The bidder shall indicate the sources of all materials. He shall indicate the name of the supplier and make of vacuum interrupters, meters, relays, conductor, insulating oil, electrical steel laminations constructional steel etc. Note: The Meters used for conducting tests shall be calibrated periodically at reputed Government Accredited Test Laboratories and test certificates shall be available at works for verification by employers representative. Tests as per applicable standards should be carried out in respect of porcelain bushings, galvanization, relays and meters. 7.0 7.1 INSPECTION: The purchasers representative shall, at all times, be entitled to have access to the works and at all places of manufacture where equipment offered shall be manufactured and the representative shall have full facilities for unrestricted inspection of the bidders works, raw materials and process of manufacture and conducting necessary tests as detailed herein. The Bidder shall keep the purchaser informed in advance of the time of starting and of the progress of manufacture of the offered equipment in its various stages so that arrangements can be made for inspection. The supplier shall give 15 days advance intimation to enable the purchaser to depute his representative for witnessing acceptance and routine tests. No material shall be dispatched from its point of manufacture before it has been satisfactorily inspected and tested, unless the inspection is waived off, by the purchaser in writing. The acceptance of any quantity of material shall in no way relieve the Bidder of any of his responsibilities for meeting all requirements of the specification, and shall not prevent subsequent rejection if such material is later found to be defective. APEPDCL may its option get the materials inspected stage wise by the 3rd party on each unit/units offered for inspection along with a APEPDCLs representative, if it feels necessary. If a 2nd time inspection becomes necessary the inspection charges shall be borne by you. The bidder shall indicate the name(s) of reputed inspection agencies and the inspection charges clearly for each lot. The inspection charges will be borne by the purchaser. However the purchaser reserves the right to appoint at its cost any inspection agency to carry out the inspection.
7.2
7.3 7.4
7.5
7.6
7.7
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7.8 8.0
The APEPDCL reserves the right to insist for witnessing the acceptance routine testing of the bought out items. WARRANTY: The general terms and conditions the warranty clause applicable to Vacuum Circuit Breakers of this specification is as follows. The period of warranty will be 5 years (five years) from the date of commissioning. All similar materials are removable parts of similar equipment shall be interchangeable with each other.
9.0 9.1
DOCUMENTATION: All drawings shall conform to International Standards Organisation (ISO) À series of drawings sheet/India Standards Specifications IS:656. All drawings shall be in ink and suitable for micro filming. All dimensions and data shall be in S.I.Units. LIST OF DRAWINGS AND DOCUMENTS: The bidder shall furnish four sets of following drawings along with his offer. General outline drawing showing plan, elevation and end view dimensions, assembly and constructional drawings of the equipment. Name plate & schematic drawings. Operation manuals, leafless literature etc.
9.2
9.2.1
The successful Bidder shall, within 2 weeks of placement of order, submit three sets of final versions of all the above said drawings for purchasers approval. The purchaser shall communicate his comments/approval on the drawings to the supplier within four weeks. The supplier shall, if necessary, modify the drawings and resubmit three copies of the modified drawings for their approval. The supplier shall within two weeks, submit 23 prints and two good quality report copies of the approved drawings for purchasers use. Six sets of the type test reports, duly approved by the purchaser, shall be submitted by the supplier for distribution before commencement of supply. Adequate copies of acceptance and routine test certificates, duly approved by the purchaser, shall accompany the dispatch consignment. The manufacturing of the equipment shall be strictly in accordance with the approved drawings and no deviation shall be permitted without the written approval of the purchaser. All manufacturing and fabrication work in connection with the equipment prior to the approval of the drawing shall be at the suppliers risk. Two set of nicely printed bound volumes of operation, maintenance and erection manuals and approved drawings in English language shall be supplied along with each circuit breaker, in addition to the five sets to be sent directly to the purchaser. Approval of drawings/work by purchaser shall not relieve the supplier of his responsibility and liability for ensuring correctness and correct interpretation of the drawings for meeting the requirements of the latest revision of application standards,
9.2.2
9.2.3
54
rules and codes of practices. The equipment shall conform in all respects to high standards of engineering, design, workmanship and latest revisions of relevant standards at the time of ordering and purchaser shall have to power to reject any work or materials which, in his judgment is not in full accordance therewith. ANNEXURE-I - A GUARANTEED TECHNICAL PARTICULARS OF 33KV & 11kV VCBs ---------------------------------------------------------------------------------------------------------------Sl. No. CHARACTERISTICS ----------------------------------------------------------------------------------------------------------------(A). 1. RATED VALUES AND CHARACTERISTICS No. of Poles Rated Normal current Rated symmetrical short circuit breaking current (kA) Rated short circuit making current Opening time and break time. Closing time. Degree of Vacuum maintained in the Vacuum chamber. 2. Minimum Clearance in Air: Between poles Between live parts to earth. 3. Whether circuit breaker is trip free. Electrical service life Rated current (times) Rated interruptions current (times) Whether type test reports enclosed. Whether the special guarantee for vacuum bottles for five years is accepted. (B). Class Rated Voltage Rated Insulation level One minute power frequency withstand voltage Impulse withstand voltage One minute power frequency withstand voltage on auxiliary wiring. Rated frequency. Rated cable charging current Rated (Single) capacitor breaking current Rated small inductive breaking current Rated short circuit making current Rated duration of short circuit Rated transient recovery current. Rated operating sequence. Gap between the contacts in vacuum. Area of contacts. The voltage to which the circuit breaker shall be capable of withstanding indefinitely across open contacts. Weight of Complete Circuit Breaker : Operating Mechanism of Circuit Breaker and Associated Equipment.
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Type of closing mechanism No. and type of auxiliary contacts. (No. of spare normally open contacts and No. of spares normally closed contacts are to be indicated.). Power requirement : Closing Coil. Opening Coil Heaters at different locations (240V-50c/s AC) IR values of the pole assembles with 5KV Megger a. R Phase live part to body b. R Phase incoming to outgoing terminals. ii. a. Y Phase live part to body. b. Y Phase between incoming to outgoing terminals iii. a. B Phase live part to body b. B Phase between incoming to outgoing terminals. -----------------------------------------------------------------------------------------------------------i. ANNEXURE-I-B
GUARANTEED TECHNICAL PARTICULARS OF 33KV & 11KV CTs
-----------------------------------------------------------------------------------------------------------Sl. No. CHARACTERISTICS -----------------------------------------------------------------------------------------------------------A. Current Transformers: 1. Rated primary current 2. Rated secondary current Core I Core-II 3. No. of cores (Secondary core details) Core I Core-II 4. Rated output in VA Core I Core-II 5. Class of Accuracy Core I Core-II 6. Accuracy Limiting Factor Core I Core-II 7. One second short time factor times rated current 8. Weight of oil Kg 9. Total Weight Kg 10. Whether type test reports for breakers and CTs are enclosed. (B). 1. 2. 3. 4. 5. 6. 7. Type Manufacturers type and designation Rated Voltage Method of ratio change and secondary connections details and connection diagram Secondary voltage Core I, Core-II, Secondary limiting voltage Core I, Core-II, Rated current dynamic (peak value)
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8. 9. 10. 11. 12. 13.
Rated continuous thermal current temperature rise over ambient One minute power frequency dry/wet withstand voltage kV(rms) 1/50 micro second impulse withstand test voltage kV (peak) One minute power frequency withstand test voltage on secondaries kV (rms) Magnetisation curve of CT curve Mounting details Overall dimensions IR values of Primary with 5 KV Megger IR values of Secondary with 1 KV Megger
------------------------------------------------------------------------------------------------------------
Schedule of Requirements
33KV VCB with CTs & CR panel: Sl. No. 1. Description of Material 33KV, 3 Pole, 1250A, 50 Hz, 25 kA porcelain clad vacuum circuit breakers with Outdoor control and relay panels having 3 O/L & E/L numerical relays with following current transformers ratios with control voltage 24V DC conforming to IEC 62271-100-1/2001 and as per the technical particulars described in Section-V with 3 Nos. Current Transformers of ratio 200-100 / 1-1-1A for HV control VCBs.
11KV VCB with CTs & CR panel: Sl. No. 1.
Description of Material
11 kV, 3 Pole, 630 A,50 Hz,20 kA porcelain clad vacuum circuit breakers with outdoor control and relay panels & current transformers with control voltage-24V DC suitable for outdoor installation conforming to IEC 62271-100-1/2001 and as per the technical particulars described in Section-V with the following. 1. Control and Relay panels with 2 O/L & 1 E/L IDMT numerical Relays with auxiliary relays along with 3Nos. current Transformers of ratio 400-200-100 / 1-1A. 2. Control and Relay panels with 3 O/L & E/L IDMT numerical Relays with auxiliary relays along with 3Nos. current Transformers of ratio 400-200-100 / 1-1A for LV control VCBs. 3. Control and Relay panels with 3 O/L & E/L (restricted Earth Fault) IDMT numerical with auxiliary relays & differential Relay for protection of Power Transformer along with 3Nos. current Transformers of ratio 600-300 / 1-1-0.5775A for LV control VCBs.
ACRONYMS
-----------------------------------------------------------------------------------------------------------Reference Abbreviations Name and Address
-----------------------------------------------------------------------------------------------------------IEC International Electro Technical Commission Bureau Central de la Commission Electro Technique International, Rue de verembe Geneva, Switzerland ISO International Organisation for Standardisation, Danish Board of Standardisation Aurehoegyej-12, DK-2900, heel prup, DENMARK.
ISS
Indian Standard Bureau of Indian Standards, Nank Bhavan, 9, Bahadur Shah Zafar Marg, New Delhi 110 002, INDIA. ------------------------------------------------------------------------------------------------------------
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TECHNICAL SPECIFICATION FOR 33 kV & 11 kV AB SWITCHES (ISOLATORS)

1.0 SCOPE This specification covers design, engineering, manufacture, assembly, stage testing inspection and testing before supply and delivery at site of the following: a) b) c) 33 kV 800 A Air Break Switches (Isolators) with solid core insulators 11 kV 400 A Air Break Switches (Isolators) / Horizontal type with post type insulators 11 kV 200 A horizontal type Air Break Switches (Isolators) with solid core insulators.
1.1 It is not the intent to specify completely herein all the details of the design and construction of equipment. However the equipment shall conform in all respects to high standards of engineering, design and workmanship and shall be capable of performing in continuous commercial operation up to the Bidder's guarantee, in a manner acceptable to the purchaser, who will interpret the meanings of drawings and specification and shall have the power to reject any work or material which, in his judgment is not in accordance there with. The offered equipment shall be complete with all components necessary for their effective and trouble free operation. Such, components shall be deemed to be within the scope of Bidder's supply irrespective of whether those are specifically brought out in this specification and/or the commercial order or not. 2.0 STANDARDS The materials shall conform in all respects to the relevant Indian Standard Specifications with latest amendments indicated below. Indian Standard Title International & Internationally recognized standard IEC 62 271-102-2001 Alternating Current disconnectors (isolators) for voltages from 1kV to 52kV
IS-9920/1985 Part Switches & Switch isolators for Voltages I to IV above 1000 V IS-9921/1985 Alternating Current disconnectors Parts I to IV (isolators) and earthing switches for voltage above 1000 Volts. IS-1881/1972 IS-2544/1973 IS-5350/1970 Alternating current Isolators (disconnectors) and Earthing Switches Porcelain Post Insulators for systems with normal voltage greater than 1000 V Dimensions of Indoor and Outdoor Porcelain Post Insulators and Post Insulator Units for Systems with nominal Voltage greater than 1000 V Methods of Testing and Uniformity of coating of zinc coated articles Mild steel tubes, tubular & other rod steel fittings and pipe fittings
IS-2633/1986 IS-1239/1990
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2.2
CONFLICT OF STANDARDS:
Equipment conforming to other internationally accepted standards, which ensure equal or higher quality than the standards mentioned above would also be acceptable. In case the Bidders who wish to offer material conforming to the other standards, salient points of difference between the standards adopted and the specific standards shall be clearly brought out in relevant schedule. Four copies of such standards with authentic English Translations shall be furnished along with the offer. In case of conflict the order of precedence shall be (i) IS (ii) IEC (iii) Other standards. In case of any difference between provisions of these standards and provisions of this specification, the provisions contained in this specification shall prevail. 3.0 CLIMATIC CONDITIONS:
The Voltage Transformers to be supplied against this Specification shall be suitable for satisfactory continuous operation under the following climatic conditions. Sl. Location At various locations in the No. state of Andhra Pradesh i) Max. ambient air temperature (deg.C) 50 ii) Min. ambient air temperature (deg.C) 7.5 iii) Average daily ambient air temperature (deg.C) 35 iv) Max. Relative Humidity (%) 100 v) Max. altitude above mean sea level (Meters) 1000 vi) Average Annual rainfall (mm). 925 vii) Max. wind pressure(kg/sq.m.) 200 viii) Isoceraunic level (days per year) 50 ix) Seismic level (Horizontal accn.) 0.3 g. The equipment shall be for use in moderately hot and humid tropical climate, conducive to rust and fungus growth. 4.0 4.1 PRINCIPAL PARAMETEERS : Ratings: The Air Break Switches shall have the following ratings Nominal System Voltage 33 kV 11 kV Rated Voltage 36 kV 12 kV Insulation levels for isolation As per B.I.S As per B.I.S Rated impulse withstand voltage 170 kV 75 kV Rated frequency Rated Current (for isolator only) Rated peak short circuit current Rated short-time withstand current Rated maximum duration of Short circuit Load break capacity 50 Hz +2% -5% 800 A 50 kA 20 KA 1 Sec 40 A 50 Hz +2% -5% 400 A 40 kA 16 kA 1 Sec 20 A
11 kV 12 kV As per B.I.S 75 kV 50 Hz +2% -5% 200 A(Horizontal) 25 kA 10 kA 1 Sec 16 A
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5.0 TECHNICAL REQUIREMENTS FOR 11kV & 33kV AIR BREAK SWITCHES (ISOLATORS) 5. 1 GENERAL TECHNICAL REQUIREMENTS:-
5.1.1 Construction: Air Break Switches (Isolators) shall be 3 poles, gang operated, single or double break type, without earthing contact blades. All Ferrous metal parts, except those of stainless steel shall be hot dip galvanised and the uniformity of the Zinc coating shall satisfy the requirements of relevant standard specification. The parts shall be galvanised after machining. The finished galvanised surface shall be smooth. Bearing housing shall be weather proof. Facility shall be provided for lubrication of bearings. 5.1.2 Phase separation:
The phase separation for the different rated voltages shall be as given below: Rated Voltage Phase separation 5.1.3 Blades: 36 kV 1524 mm 12 kV (400 A) 914.4 mm 12 kV (200 A) (Horizontal type) 600 mm
The blades shall be made from a single length of rolled/extruded electrolytic grade copper flat for 11 KV-200 Amps, and extruded hollow copper tube of adequate size matching with current capacity, for 11KV 400Amps (double break) AB switches and 33 KV-800Amps Air Break Switches. These shall be capable for carrying rated current continuously and fault current safely. The contact end shall be tin or silver coated. 5.1.4 Fixed Contact:
The fixed contact element shall be made of rolled electrolytic grade copper flat and with flexible ends, where required shall be made of soft electrolytic grade copper sheet. The contact element shall be tin or silver coated. The contacts assembly shall be so designed that while carrying the rated continuous current, the temperature rise does not increase beyond the value specified in relevant standards. The contact shall be self-relevance jaw-type and suitable stainless steel SPRING of sufficient pressure shall be provided to ensure proper contact in the closing position. 5.1.5 Arcing Horns:
The AB (Air Break) Switches shall be provided with 3 sets of removable spring controlled rod type arcing horns with Make Before and Break After feature Arcing Horns of GI material, one set for each phase, shall be provided. The diameter of the arcing horn rods shall be not less than 6 mm for 11 kV and 10 mm for 33 kV. 5.1.6 Terminal & Connector: The terminal shall be made of rolled/extruded electrolytic grade copper flat having a cross sectional area equal to that of the blade. It shall be so constructed that an intimate contact with
61
the contact elements ensured. The connector should be suitable for ACSR Conductor up to Panther. The Aluminum Alloy Connectors shall be supplied for each end and for each phase of the switch. The terminal shall preferably be tin or silver coated 5.1.7 Bearing: The operating shaft shall be supported with ball bearings, guide bearing and universal joint in order to ensure smooth operation. Each rotating insulator stack shall have thrust roller bearings and shall rotate into gunmetal bush bearings contained in a suitable weatherproof housing. The housing shall be fitted with the greasing nipple. 5.1.8 Phase Coupling Bar: The bar is required for coupling the rotation of the 3 phases and should be fixed in a manner to permit the smooth movement for operation of the switches. 5.1.9 Operation Mechanism: The operating mechanism shall be suitable for normal operation by one man without undue effort. This shall comprise of operating pipe of diameter 32 mm (Nominal Bore) for 11 kV and 40 mm (Nominal Bore) for 33 kV and length 6 m with intermediate coupling and operating handle. The mechanism shall provide adequate mechanical leverage with minimum of loose/lost motion. The pipe shall conform to class 'B GI pipe as per relevant standards. For single break switches, the rotating blades shall be connected to the line side through a flexible copper connection of sufficient length so that the strain on the live jumpers is avoided. These copper connectors shall be made of tinned of braided copper strips. There should be adequate clearance between HG fuse and AB switches operating handle when the switch is erected on a transformer structure. 5.1.10 Mechanical strength: The isolating switches shall be capable of withstanding the rated mechanical terminal loads and electromagnetic forces, without affecting the operation and current carrying properties. The switches, with or without earthing blades, complete with the operating mechanism should not come out of their own in closed position due to the effect of gravity, wind pressure, vibrations reasonable shocks. Their construction should be such that they do not open under the influence of the short circuit current. 5.1.11 Galvanising: All ferrous parts should invariably be hot dip galvanised except the bolts, nuts, washers spring washers and split pins, which shall be electro-galvanised, conforming to relevant IS. 5.1.12 Locking Arrangements: The Air Break Switches shall be constructed in such a manner to permit pad locking in both open and close position. 5.1.13 Bolts and Nuts: The required bolts and nuts (hot dip galvanised) for assembling the complete air-break switch and for fixing the same to the structures shall be supplied with the equipment at no extra cost. Bolts and nuts shall be provided with lock washers and lock nuts wherever required. The
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switches shall be so designed that the leakage current will pass to earth and not between terminals of the same pole or between poles, when the insulators are fixed. A reliable earthing terminal having a clamping bolt of at least 12 mm dia provided on the frame at one end of the isolator, it shall be marked with the earth symbol in delible manner on or adjacent to the terminal 5.1.14 Insulators: Solid core Insulators for 33 kV 800 A and 11 kV 200 A (Horizontal type ) AB switches and post type insulator for 11 kV 400 A AB switches conforming to the relevant standards shall be supplied along with equipment. 6.0 TESTS FOR 11 kV & 33kV AB SWITCHES (ISOLATORS) :
6.1.1 The tests indicated in IS : 9920 Part I to IV / IS-9921-1985 Part I to IV / IEC 62 271102-2001 with latest amendments shall constitute the type tests. The certificates of type tests already not carried out (not more than 2 years old ) on the day of bid opening by the tenderer in their lab or from any accredited test house on the AB SWITCHES (ISOLATORS) identical in all respects being quoted against this specification must be furnished by the manufacturer along with this quotation as an evidence of compliance of this specification. In case the tender is not accompanied by the type test certificate board/power utility reserves the right of cancel/reject the tender. 6.1.2 The AB SWITCHES (ISOLATORS) shall be fully type tested by the bidder as per the relevant standard including the type tests mentioned in the above standards. The type tests must have been conducted on 11kV & 33kV AB SWITCHES (ISOLATORS) from recognized NABL accredited test laboratories. The bidder shall furnish two sets of type test reports as per relevant standards along with the bid. BIDS WITHOUT THE FOLLOWING TYPE TEST REPORTS WILL BE TREATED AS NON-RESPONSIVE. 6.2 ACCEPTANCE AND ROUTINE TESTS :
6.2.1 All acceptance and routine tests stipulated in the relevant standards shall be carried out by the supplier in presence of purchasers representative 6.2.2 The purchaser reserves the right to insist for witnessing the acceptance/routine testing of the bought out items to pass tests. 6.2.3 Tests during manufacture : The Bidder shall furnish details of tests carried out during the process of manufacture and end inspection by the bidder to ensure the desired quality of the equipment to be supplied. 6.3 ADDITIONAL TESTS : 6.3.1 The purchaser reserves the right of having at his own expenses any other tests(s) of reasonable nature carried out at Bidders premises, at site, or in any other place in addition to the aforesaid type, acceptance and routine tests, to satisfy himself that the material comply with the specifications. 6.3.2 In case of failure in any type test, the supplier is required to modify the design of the material and the material shall be type tested again for the modified design, without any extra cost to the purchaser. No delivery extension shall be given for this additional testing.
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6.3.3 The entire cost of testing for the acceptance and routine tests and tests during manufacture shall be treated as included in the quoted unit price. 6.4 TEST REPORTS / TEST CERTIFICATES:
Record of routine test reports shall be maintained by the Bidder at his works for periodic inspection by the purchasers representative. The Bidder shall maintain test certificates of tests conducted during manufacture. These shall be produced for verification as and when desired by the purchaser. 6.5 TEST FACILITIES :
The tests shall be carried out as per relevant Standards and test certificates shall be furnished for approval. The Bidder shall indicate the details of the equipment available with him for carrying out the various tests as per relevant Standards. The bidder shall indicate the sources of all materials. He shall indicate the name of the supplier and make of vacuum interrupters, meters, relays, conductor, insulating oil, electrical steel laminations constructional steel etc. NOTE : The Meters used for conducting tests shall be calibrated periodically at reputed Government Accredited Test Laboratories and test certificates shall be available at works for verification by purchasers representative. 7.0 INSPECTION :
7.1 The purchasers representative shall, at all times, be entitled to have access to the works and at all places of manufacture where equipment offered shall be manufactured and the representative shall have full facilities for unrestricted inspection of the bidders works, raw materials and process of manufacture and conducting necessary tests as detailed herein. The Bidder shall keep the purchaser informed in advance of the time of starting and of the progress of manufacture of the offered equipment in its various stages so that arrangements can be made for inspection. The supplier shall give 15 days (for Group A & B suppliers)/30 days (for Group C Suppliers) advance intimation to enable the purchaser to depute his representative for witnessing acceptance and routine tests. No material shall be dispatched from its point of manufacture before it has been satisfactorily inspected and tested, unless the inspection is waived off, by the purchaser in writing. The acceptance of any quantity of material shall in no way relieve the Bidder of any of his responsibilities for meeting all requirements of the specification, and shall not prevent subsequent rejection if such material is later found to be defective. 7.6 NOTE FOR FOREIGN BIDDERS :
The bidder shall indicate the name(s) of reputed inspection agencies and the inspection charges clearly for each lot. The inspection charges will be borne by the purchaser. However the purchaser reserves the right to appoint at its cost any inspection agency to carry out the inspection.
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8.0
DOCUMENTATION :
8.1 All drawings shall conform to International Standards Organisation (ISO) A series of drawings sheet/India Standards Specifications IS:656. All drawings shall be in ink and suitable for micro filming. All dimensions and data shall be in S.I.Units. 8.2 LIST OF DRAWINGS AND DOCUMENTS : The bidder shall furnish four sets of following drawings along with his offer: General outline drawing showing plan, elevation and end view dimensions, assembly and constructional drawings of the equipment. Name plate & schematic drawings. Operation manuals, leafless literature etc. 8.2.1 The successful Bidder shall, within 2 weeks of placement of order, submit three sets of final versions of all the above said drawings for purchasers approval. The purchaser shall communicate his comments/approval on the drawings to the supplier within four weeks. The supplier shall, if necessary, modify the drawings and resubmit three copies of the modified drawings for their approval. The supplier shall within two weeks, submit 23 prints and two good quality report copies of the approved drawings for purchasers use. 8.2.2 Six sets of the type test reports, duly approved by the purchaser, shall be submitted by the supplier for distribution before commencement of supply. Adequate copies of acceptance and routine test certificates, duly approved by the purchaser, shall accompany the dispatch consignment. 8.2.3 The manufacturing of the equipment shall be strictly in accordance with the approved drawings and no deviation shall be permitted without the written approval of the purchaser. All manufacturing and fabrication work in connection with the equipment prior to the approval of the drawing shall be at the suppliers risk. 8.2.4 Two set of nicely printed bound volumes of operation, maintenance and erection manuals and approved drawings in English language shall be supplied along with each circuit breaker, in addition to the five sets to be sent directly to the purchaser. 8.2.5 Approval of drawings/work by purchaser shall not relieve the supplier of his responsibility and liability for ensuring correctness and correct interpretation of the drawings for meeting the requirements of the latest revision of application standards, rules and codes of practices. The equipment shall conform in all respects to high standards of engineering, design, workmanship and latest revisions of relevant standards at the time of ordering and purchaser shall have to power to reject any work or materials which, in his judgment is not in full accordance therewith. 9.0 PACKING & FORWARDING:
9.1 The equipment shall be packed in crates suitable for vertical/horizontal transport as the case may be, and suitable to withstand handling during transport and outdoor storage during transit. The supplier shall be responsible for any damage to the equipment during transit, due to improper and inadequate packing. The easily damageable material shall be carefully packed
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and marked with the appropriate caution symbol. Wherever necessary, proper arrangement for lifting, such as lifting hooks etc., shall be provided. Supplier without any extra cost shall supply any material found short inside the packing cases immediately. 9.2 Each consignment shall be accompanied with a detailed packing list containing the following information. Name of the consignee. Details of consignment. Destination. Total weight of consignment Handling and packing instructions. Bill of Material indicating contents of each package. 9.3 The supplier shall ensure that the purchaser before dispatch approves the packing list and bill of material. 9.4 The packing shall be done as per the manufacturers standard practice. However, he should ensure the packing is such that, Rail/Road should not damage the material during transit. 9.5 The marking on each package shall be as per the relevant standards and shall also contain JBIC. 10.0 QUANTITY AND DELIVERY REQUIREMENTS:
The quantity and delivery requirement are indicated in Section-V 11.0 SUPERVISION SERVICES: The Purchaser will arrange for unloading of the consignments. 12.0 MANDATORY SPARES & TOOLS:
The manufacturer shall provide all necessary mandatory spares like fuses, spanners, etc., free of cost. 13.0 TECHNICAL DEVIATIONS:
Any deviation in Technical Specification as indicated in Section-III shall be specifically and clearly indicated in the enclosed Technical deviation format as per Annexure II or in the schedule of deviation format Schedule A. 15.0 GUARANTEED TECHNICAL PARTICULARS
The Bidder shall furnish the guaranteed Technical Particulars as per Annexure I, enclosed and submit the same with the Tender. ANNEXURE I GUARANTEED TECHNICAL PARTICULARS FOR AIR BREAK SWITCHES
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Sl.No Details Air Break Switches (Isolators) A B C d e f g
Guaranteed particulars 33 kV 11 kV 11 kV 800 A 400 A 200A(Horizontal)
h i j k l m n o p q r s T U V W
X 2 a
Name(s) of Manufacturer(s) Whether single break or double break No. of poles Voltage rating Frequency Current rating in Amps. i. Normal ii. Max. with duration Temperature rise of the following at full rated current in Deg. C over ambient temperature i. Copper contacts with coating ii. Terminal of switches intended to be bolted to the external conductors Whether contracts are silver coated or tin coated along with thickness of coating in mm Voltage drop across terminals of poles Short time current and duration Material of fixed contact Material of moving blade Material of terminal connector Type, diameter and length of operating handle Material of arcing horns Size and length of mounting channel Whether the Air break switch is complete with all accessories Whether dimensional drawing is enclosed with the bid Minimum clearance between phases (The centre distance between the insulators of adjacent phases in assembled position of switch) Centre to centre distance between insulators of the constructive poles of the same phase in the assembled position of switch (in mm) Whether mechanical interlock has been provided for 33 kV 11 kV 11 kV EARTH Switches 800 A 400 A 200A (Horizontal) Type of bearings used in i. Rotating insulator stack ii. Operating shaft Impulses withstand voltage with 1/50 Micro Sec. wave positive and negative polarity i. Across isolating distance ii. To each and between poles One minute power frequency withstand voltage across isolating distance to earth and between poles Insulators Type of Insulator
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b c d e 2.1 a b c d e f
2.2 2.3 a b c d 2.4 a b 2.5
Name of Manufacturer of insulators Height of the insulators Diameter of the largest shell No. of units per stack Electrical characteristics (for one insulator) Flash over voltage Dry power frequency Wet power frequency Impulse voltage of 1/50 Micro-seconds (+ve) Impulse voltage of 1/50 Micro-seconds (-ve) Withstand voltage i. Dry voltage ii. Wet voltage iii.Impulse voltage of 1/50 Micro-seconds (+ve) iv. Impulse voltage of 1/50 Micro-seconds (-ve) Power frequency puncture withstand voltage of unit Mechanical characteristics Cantilever strength upright Cantilever strength under hand Torsional strength Tensile strength General characteristics Min. creepage distance Weight of complete unit Standard to which insulator conforms
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TECHNICAL SPECIFICATIONS FOR 3Ph, 11KV VOLTAGE TRANSFORMERS SCOPE: This specification covers the manufacture, assembly stage testing, inspection and testing before supply and delivery at site of 11KV outdoor oil cooled vacuum impregnated (metering) Voltage Transformers, suitable for mounting externally. 1.1 It is not the intent to specify completely herein all the details of the design and construction of equipment. However the equipment shall conform in all respects to high standards of engineering, design and workmanship and shall be capable of performing in continuous commercial operation up to the Bidders guarantee, in a manner acceptable to the purchaser, who will interpret the meanings of drawings and specification and shall have the power to reject any work or material which, in his judgment is not in accordance there with. The offered equipment shall be complete with all components necessary for their effective and trouble free operation. Such, components necessary for their effective and trouble free operation. Such, components shall be deemed to be within the scope of Bidders supply irrespective of whether those are specifically brought out in this specification and / or the commercial order or not. 2.0 STANDARDS: 2.1. The materials shall conform in all respects to the relevant Indian Standard Specifications / IEC Standards, with latest amendments indicated below. Indian Standard IS 3156 ( Parts I & II) IS- 335/1983 IS 2099 IS 2633 IS 10601 Title International Internationally standard & recognized
Specification for Voltage Transformers Specification for New insulating IEC 71 ( For CTs) oils Electrical Clearances Specification for H.V. Porcelain Bushings Specification for Galvanization Specification for Primary Terminals
2.2. CONFLICT OF STANDARDS: Equipment conforming to other internationally accepted standards, which ensure equal or high quality than the standards mentioned above would also be acceptable. In case the Bidders who wish to offer material conforming to the other standards, salient points of difference between the standards adopted and the specific standards shall be clearly brought out in relevant schedule. Four copies of such standards with authentic English Translations shall be furnished along with the offer. In case of conflict the order of precedence shall be (i) IS (ii) IEC (iii) Other standards. Incase of any difference between provisions of these standards and provisions of this specification, the provisions contained in this specification shall prevail.
3.0 CLIMATIC CONDITIONS:
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The Voltage Transformers to be supplied against this specification shall be suitable for satisfactory continuous operation under the following climatic conditions. Sl.No. Location i) ii) iii) iv) v) vi) vii) viii) ix) Max. ambient air temperature ( deg.C) Min. ambient air temperature ( deg.C) Average daily ambient air temperature ( deg.C) Max. Relative Humidity (%) Max. altitude above mean sea level (Meters) Average Annual rainfall (mm). Max. wind pressure ( kg. sq.m) Isoceraunic level ( days per year) Seismic level ( Horizontal accn. At various locations in the state of Andhra Pradesh 50 7.5 35 100 1000 925 200 50 0.3 g.
The equipment shall be for use in moderately hot and humid tropical climatic, conducive to rust and fungus growth. 4.0 PRINCIPAL PARAMETERS: 4.1 The rating of 11kV Voltage Transformers at a frequency 50 Hz shall be as follows: Sl.No. 1 2 3 PARAMETERS Rated voltage No. of phases / connection Insulation Level: i) Nominal System voltage ii) Highest System voltage iii) Standard Impulse withstand Voltage iv) One minute Power Frequency withstand Voltage Primary Secondary v)Rated voltage factor and corresponding rated time Rated transformation ratio i) Class of accuracy ii) Rated burden / phase Type of Transformer Number of windings / phase RATING 11kV Three Phase / Star Star 11kV 12kV 75kV 28kV 3kV 1.2 0.5 100 VA ------- Earthed-------Two
4 5 6
4.2. Voltage transformer shall be capable of carrying without injury continuous burden of 50% above the rated burden in respect of 11kV PTs. The PTs shall have adequate protection with fuses on primary and secondary side.
NOTE:1. Marking on primary and secondary terminals of P.T. shall be clearly marked for different C.T. Ratios.
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2. A provision shall be made to fix the PTs on M.S. Channel with necessary slotted holes on the base of the PTs. 3. A provision for inserting suitable cable shall be made in the secondary cover of the P.T. 4. The top cover of the PT shall be made such that no rain be stocked on the surface and no entry of rain water in to the PT. 5. Only copper winding shall be used. 6. The voltage transformer shall be offered with first filling of oil conforming to relevant standards. 5.0 TECHNICAL REQUIREMENTS FOR 11kV VOLTAGE TRANSFORMERS 5.1. GENERAL TECHNICAL REQUIREMENTS: Porcelain Housing:The porcelain housing shall be of single piece construction without any joint. The housing shall be made of homogeneous, vitreous porcelain of high mechanical and dielectric strength. Glazing of porcelain shall be uniform brown or dark brown colour with a smooth surface arranged to shed away rainwater or condensed water particles ( fog.) 5.1.2. Details of attachment of metallic flanges to the porcelain pressure release valve and primary / secondary terminals shall be brought out in the offer. 5.1.3.The metal tank shall be fabricated from mild steel having thickness of minimum 3.15 mm for sides and 5mm for top and bottom. The thickness of tank should be specified clearly. The metal tanks shall be coated with at least two coats of zinc rich epoxy paint externally and inside shall be painted with oil resistant white enamel paint. All the ferrous hardware, exposed to atmosphere, shall be hot dip galvanized. All other fixing nuts, bolts, washers in the electric current path shall be made out of stainless steel. The clear height of porcelain housing for 33kV instrument transformers shall be at least 430mm. OIL IMMERSED EQUIPMENTS:5.2.1. INSULATING OIL:Insulating oil required for first filling of the instrument transformers shall be covered in tenderer scope of supply. The oil shall meet the requirements of latest edition of IS 335. Use of other insulating material such as quartz sand is not permitted. 5.2.2. PREVENTION OF OIL LEAKAGES & ENTRY OF MOISTURE:The tenderer shall ensure that the sealing of instrument transformers is properly achieved, so as to avoid leakages of oil. In this connection the arrangement provided by tenderer at various locations including the following ones shall be supported by sectional drawings. Locations of emergence of primary and secondary terminals. Interface between porcelain housing and metal tanks. Cover of the secondary terminal box.
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5.2.3. Nuts and bolts or screws used for fixation of the interfacing porcelain bushings for taking out terminals shall be provided on flanges cemented to the bushings and not on the porcelain. If gasketed joints are used, nitrite butyle rubber gaskets shall be used. The gasket shall be fitted in properly machined groove with adequate space for accommodating the gasket under compression. OIL LEVEL INDICATORS: 5.3.1. Each Instrument Transformer shall be provided with prismatic type oil sight window at suitable location so that oil level is clearly visible with naked eye to an observer standing at ground level. 5.3.2. For compensation of variation in volume of the oil due to temperature variation nitrogen cushion or stainless steel bellows shall be used. Rubber diaphragms shall not be permitted for this purpose. 5.3.3. The units shall be vaccum filled with oil after processing and thereafter hermetically sealed to eliminate air and moisture from entering the tank. Oil filling and / or oil sampling cocks if provided to facilitate factory processing shall be permanently sealed before despatch of the instrument transformers. EARTHING: Metal tank of the instrument transformer shall be provided with two separate earthing terminals of size 16mm dia x 30mm length H.D.G. with one plane washer and one nut for connection to station earth-mat. The earth terminal shall be marked with sign for identification. LIFTING ARRANGEMENT:Instrument transformers shall be provided with suitable lifting arrangement to lift the entire unit. Lifting arrangement (lifting eye) shall positioned in such a way so as avoid any damage to the porcelain housing, primary terminals or the tanks during the process of lifting for installation / transport. The general arrangement drawing shall show clearly the lifting arrangements provided such as lifting eye guide etc., NAME / RATING PLATE: 5.6.1. Each Voltage Transformer shall have the following particulars indelibly marked on it or on a label permanently secured to it or its casing. Manufacturers Name Manufacturers Sl. No. and / or type of designation. Rated transformation ratio Rated frequency Highest system voltage Insulation level and
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Rated short time thermal current with the associated rated time and rated dynamic current for PTs. 5.6.2. The instrument transformer shall be provided with non-corrosive legible plate with the information specified in relevant standards duly engraved punched on it. 5.7. MOUNTING DETAILS:5.7.1. The voltage transformers shall be suitable for mounting on steel structures or concrete pedestals. The necessary flanges, bolts etc. for the base of PT shall be supplied and galvanized. 5.7.2. The terminal connectors suitable for panther ASCR conductors shall be supplied. Suitable earth connectors for earthing connections shall also be supplied. 5.7.3. Enamel, if used for conductor insulation, shall be either polyvinyl acetate type or amide type and shall meet the requirement of IS 4800. Polyster enamel shall not be used. Double cotton cover, if used shall be suitably covered to ensure that it does not come in contact with oil. 5.7.4. The secondary terminals shall be brought out in a weatherproof terminal box. The terminal box shall be provided with removable gland plate and glands. The cable glands shall be suitable for 1100/3300 volts glands, PVA insulated. PVC Sheathed multicore 6sq.mm stranded copper or 10 sq.mm aluminium conductor PVC cable. The terminal box shall be dust and vermin proof. The dimensions of the terminal box and its opening shall be adequate to enable easy access and working space with use of normal tools. 5.7.5. Polarity shall be invariably marked on each primary and secondary terminal. 5.7.6. The P.T. shall be provided with a rating plate with dimensions and markings as per IS 3156 or equivalent international standards. The markings shall be punched metal photo and not painted. 5.7.7. The serial number and code of the supplier shall also be punched on tank on identify the unit case of loss or damage to the rating plate. 5.7.8. The casting of base, collar etc. shall be diecast and tested before assembly to detect cracks and voids if any. 5.8.CORE: The core shall be high grade non-ageing electrical silicon laminated steel of low hystresis loss and high permeability to ensure high accuracy, at both normal and over current voltage. 5.9. WINDING: All windings shall be insulated high- grade electrolytic copper wire. Conductors used for the primary winding shall be rigid, unavoidable joints in the primary winding shall be welded
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type preferably lap type. The details of such welded joints shall be indicated in the drawings submitted with the offer. 5.10. PRIMARY TERMINALS: Primary terminals of PTs to which the line connections are made shall have dimensions as per IS 10601/1983. The primary terminals shall be heavily tinned electrolytic copper of 99.9% conductivity. The minimum thickness of tinning shall be 15 microns. 5.11. SECONDARY TERMINALS:Secondary terminal studs shall be provided with atelast three nuts and two plain and two spring washers for fixing the leads. The studs, nuts and washers shall be of brass, duly nickel plated. The minimum out side diameter of the studs shall be 6mm. The horizontal spacing between centers of the adjacent studs shall be atleast 45 mm. 5.12. The following accessories / fittings shall be supplied along with the instrument transformers. Pressure release device Oil level indicator Lifting lugs 5.13. SEALING: Provision for sealing secondary terminal compartment and task effectively such that no fraud etc. such as tampering of circuit ( current) is possible. The holes provided for the sealing provision shall be of adequate size to pass the sealing wire of about 14 SWG. 5.14 The purchase order number and date and year of supply and the words APEPDCL JBIC must be etched on the nameplate. TESTS FOR 11kV VOLTAGE TRANSFORMERS: 6.1. The tests indicated in IS : 3156 with latest amendments shall constitute the type tests. The certificates of type tests already not carried out ( not more than 5 years old) on the day of bid opening by the tenderer in their lab or from any accredited test house on a Voltage Transformer identical in all respects being quoted against this specification must be furnished by the manufacturer along with this quotation as an evidence of compliance of this specification. In case the tender is not accompanied by the type test certificate board / power utility reserves the right of cancel / reject the tender. 6.1.2. The Voltage Transformers shall be fully type tested by the bidder as per the relevant standard including the type tests mentioned below clause 6.2. The type tests must have been conducted on 11kVthree phase Voltage Transformers from recognized NABL accredited test laboratories not earlier than 5 years. The bidder shall furnish two sets of type test reports as per relevant standards along with the bid. BIDS WITHOUT THE FOLLOWING TYPE TEST REPORTS WILL BE TREATED AS NON-RESPONSIVE.
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6.2. TYPE TEST: The following tests constitute the type tests: Verification of terminal marking and polarity. High voltage power frequency wet withstand voltage test. Power frequency dry withstand tests on primary windings. Power frequency dry withstand tests on secondary windings. Determination of errors according to the requirements of the appropriate accuracy class. Temperature rise test. Impulse voltage test. ACCEPTANCE AND ROUTING TESTS: The following tests constitute the acceptance and routine tests: Verification of terminal making and polarity. Power frequency / dry withstand tests on primary windings. Power frequency dry withstand tests on secondary windings. Determination of errors according to the requirements of the appropriate accuracy class. The supplier shall carry out all acceptance and routine tests stipulated in the relevant standards in presence of purchasers representative. The purchaser reserves the right to insist for witnessing the acceptance/ routing testing of the bought out items to pass tests. Tests during manufacture:- The bidder shall furnish details of tests carried out during the process of manufacture and end inspection by the bidder to ensure the desired quality of the equipment to be supplied. 6.4. ADDITIONAL TESTS :
6.4.1 The purchaser reserves the right of having at his own expenses any other tests(s) of reasonable nature carried out at Bidders premises, at site, or in any other place in addition to the aforesaid type, acceptance and routine tests, to satisfy himself that the material comply with the specifications. 6.4.2 In case of failure in any type test, the supplier is required to modify the design of the material and the material shall be type tested again for the modified design, without any extra cost to the purchaser. No delivery extension shall be given for this additional testing. The entire cost of testing for the acceptance and routine tests and tests during manufacture shall be treated as included in the quoted unit price. 6.5 TEST REPORTS / TEST CERTIFICATES:
6.5.1 Record of routine test reports shall be maintained by the Bidder at his works for periodic inspection by the purchasers representative. Test certificates of tests conducted during manufacture shall be maintained by the Bidder. These shall be produced for verification as and when desired by the purchaser.
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6.6
TEST FACILITIES :
The tests shall be carried out as per relevant Standards and test certificates shall be furnished for approval. The Bidder shall indicate the details of the equipment available with him for carrying out the various tests as per relevant Standards. The bidder shall indicate the sources of all materials. He shall indicate the name of the supplier and make of vacuum interrupters, meters, relays, conductor, insulating oil, electrical steel laminations constructional steel etc. NOTE : The Meters used for conducting tests shall be calibrated periodically at reputed Government Accredited Test Laboratories and test certificates shall be available at works for verification by purchasers representative. 7.0 INSPECTION :
7.1 The purchasers representative shall, at all times, be entitled to have access to the works and at all places of manufacture where equipment offered shall be manufactured and the representative shall have full facilities for unrestricted inspection of the bidders works, raw materials and process of manufacture and conducting necessary tests as detailed herein. 7.2 The Bidder shall keep the purchaser informed in advance of the time of starting and of the progress of manufacture of the offered equipment in its various stages so that arrangements can be made for inspection. 7.3 The supplier shall give 15 days advance intimation to enable the purchaser to depute his representative for witnessing acceptance and routine tests. 7.4 No material shall be dispatched from its point of manufacture before it has been satisfactorily inspected and tested, unless the inspection is waived off, by the purchaser in writing. The acceptance of any quantity of material shall in no way relieve the Bidder of any of his responsibilities for meeting all requirements of the specification, and shall not prevent subsequent rejection if such material is later found to be defective. 7.6 NOTE FOR FOREIGN BIDDERS :
The bidder shall indicate the name(s) of reputed inspection agencies and the inspection charges clearly for each lot. The inspection charges will be borne by the purchaser. However the purchaser reserves the right to appoint at its cost any inspection agency to carry out the inspection.
8.0
DOCUMENTATION :
8.1 All drawings shall conform to International Standards Organisation (ISO) À series of drawings sheet/India Standards Specifications IS:656. All drawings shall be in ink and suitable for micro filming. All dimensions and data shall be in S.I.Units. 8.2. LIST OF DRAWINGS AND DOCUMENTS :
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The bidder shall furnish four sets of following drawings along with his offer. General outline drawing showing plan, elevation and end view dimensions, assembly and constructional drawings of the equipment. Name plate & schematic drawings. Operation manuals, leafless literature etc. 8.2.1 The successful Bidder shall, within 2 weeks of placement of order, submit three sets of final versions of all the above said drawings for purchsers approval. The purchaser shall communicate his comments/approval on the drawings to the supplier within four weeks. The supplier shall, if necessary, modify the drawings and resubmit three copies of the modified drawings for their approval. The supplier shall within two weeks, submit 23 prints and two good quality report copies of the approved drawings for purchasers use. 8.2.2 Six sets of the type test reports, duly approved by the purchaser, shall be submitted by the supplier for distribution before commencement of supply. Adequate copies of acceptance and routine test certificates, duly approved by the purchaser, shall accompany the dispatch consignment. The manufacturing of the equipment shall be strictly in accordance with the approved drawings and no deviation shall be permitted without the written approval of the purchaser. All manufacturing and fabrication work in connection with the equipment prior to the approval of the drawing shall be at the suppliers risk. Two set of nicely printed bound volumes of operation, maintenance and erection manuals and approved drawings in English language shall be supplied along with each voltage transformer, in addition to the five sets to be sent directly to the purchaser. 8.2.5 Approval of drawings/work by purchaser shall not relieve the supplier of his responsibility and liability for ensuring correctness and correct interpretation of the drawings for meeting the requirements of the latest revision of application standards, rules and codes of practices. The equipment shall conform in all respects to high standards of engineering, design, workmanship and latest revisions of relevant standards at the time of ordering and purchaser shall have to power to reject any work or materials which, in his judgment is not in full accordance therewith. 9.0 PACKING & FORWARDING :
9.1 The equipment shall be packed in crates suitable for vertical/horizontal transport as the case may be, and suitable to withstand handling during transport and outdoor storage during transit. The supplier shall be responsible for any damage to the equipment during transit, due to improper and inadequate packing. The easily damageable material shall be carefully packed and marked with the appropriate caution symbol. Wherever necessary, proper arrangement for lifting, such as lifting hooks etc., shall be provided. Any material found short inside the packing cases shall be supplied immediately by supplier without any extra cost. 9.2 Each consignment shall be accompanied with a detailed packing list containing the following information. Name of the consignee.
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Details of consignment. Destination. Total weight of consignment Handling and packing instructions. Bill of Material indicating contents of each package. 9.3 The supplier shall ensure that the packing list and bill of material are approved by the purchaser before dispatch. The packing shall be done as per the manufacturers standard practice. However, he should ensure the packing is such that, the material should not get damaged during transit by Rail/Road. 9.4. The marking on each package shall be as per the relevant standards and shall also contain APEPDCL - JBIC. 10.0 QUANTITY AND DELIVERY REQUIREMENTS :
The quantity and delivery requirement are indicated in Section - V 11.0 SUPERVISION SERVICES : The Purchaser will arrange for unloading of the consignments. 12.0 MANDATORY SPARES & TOOLS :
The manufacturer shall provide all necessary mandatory spares like fuses, spanners, Breaker cranking handle etc., free of cost. 13.0 TECHNICAL DEVIATIONS :
Any deviation in Technical Specification as indicated in Section-V shall be specifically and clearly indicated in the enclosed Technical deviation format as per Schedule VII. 14.0 GUARANTEED TECHNICAL PARTICULARS The Bidder shall furnish the guaranteed Technical Particulars as per Annexure I, enclosed and Schedules IA to IE shall also be filled and submit the same with the Tender.
ANNEXURE 1 GUARANTEED TECHNICAL PARTICULARS 11KV THREE PHASE POTENTIAL TRANSFORMERS Sl. Manufacturers Guaranteed Description No. particulars 1 Name and address of manufacturer 2 Manufacturers type and designation 3 Nature of service
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4 5 a) b) c) d) e) 6 7 8 9 10 11 12 13 14 15 16 17 a) b) c) d) 18 19 20 21 a) b) 22 23 24
Type of cooling System Characteristics Rated System Voltage Highest system voltage Rated system frequency Nature of neutral earthing Standard system voltage Rated voltage transformation ratio No. of phases No. of windings per phase Winding connections Type of transformer Rated burden per phase Class of accuracy Polarity Rated voltage factor and time Limits of ration and phase angle error Temperature rise of top oil at 1.1 times rated primary voltage with rated secondary H.V. Insulation characteristic of porcelain bushing. Type Make Electrical characteristics Total creepage distance One minute power frequency and wet withstand test on primary windings. One minute power frequency withstand test on secondary windings High voltage impulse withstand on primary windings. Oil Specification Quantity for first filling Total weight of PT with oil Reference specification to which the equipment conform Outline dimensional drawings on mounting details 15. Warranty: The supplier will warrant for the satisfactory functioning of the material / equipment as per specification for a period of Five (5) years from the date of commissioning. EPDCL reserves the right to claim the financial loss incurred / suffered due to the failure of voltage transformer during the guarantee period
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SPECIFICATION OF 24V 40 AH BATTERY WITH CHARGER
(SMF LEAD ACID BATTERIES)

1.0 SCOPE: This specification covers the design, manufacture, testing before dispatch supply and delivery of SMF 24V 40 AH Batteries with chargers suitable for out door applications (with rack). The Batteries are intended to be used for operating 33kV, 11kV SF6/Vac. Circuit Breakers with auto reclosing feature and for VHF sets. The rating of closing and opening coils is 400 Watts (operating time is 100 ms.) and the rated operating sequence is 3 Min. Co-3 Min. Co or 0-0.3 Sec. Co.-3 Min.-Co. The Batteries should have a capacity sufficient to operate 2 Nos. ( in case of 24V) 11kV Vac/SF6 Circuit Breakers simultaneously for about 25 closing operations on each when used without a charger. 2. STANDARDS i) IS 1885 ( part VIII) ii) IS 1651 1991 iii) ID 8320 1982 iv) IS 1069/ 1964 : : Electro Technical Secondary cells and batteries Stationery Cells & Batteries Lead Acid Battery with tubular positive plates. : Sulphuric Acid General requirements and methods of test for lead acid storage batteries. : Water for storage batteries.
Materials meeting any other equivalent International standards which ensures equal or better quality than the standards mentioned will be acceptable. In such cases the copy of the standards ( English version) adopted should be enclosed to the tender. 3. CLIMATE CONDITIONS: The climate conditions under which the equipment shall operate satisfactorily are as indicated in clause 23.1 page 13 of General and Financial terms and conditions for supply of materials. 4. RATINGS of 24V-40AH Batteries 4.1. BATTERY : 24 Volts 4.1.1. TYPE : Sealed and Maintenance Free Lead Acid Battery 4.1.2. Nominal Voltage of the : 24 Volts complete Bank 4.1.3. Voltage / CELL : 2.0 V (The cell Voltage shall not exceed 2.25 with a continuous low rate floating charge and shall not be less than 1.75V at the end of the emergency discharge). 4.1.4. Capacity of Batteries : 40 AH (in Amp. Hours at 10 Hour rate to an end voltage of 1.75V per cell).
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4.2 BATTERY CHARGER: 4.2.1. TYPE 4.2.2. Input Voltage 4.2.3. Charger output 4.2.3.1. Float Voltage 4.2.3.2. Boost Voltage 4.2.3.3. Regulation 4.2.3.4. Charger current 4.2.3.5. Ripple 4.2.3.6. Efficiency 4.2.3.7. Current limit 4.2.4. Insulation : Constant Voltage and Current limiting charger : 415V, 50 HZ, 3ph. / 240V,50HZ, 1 Ph. shall work satisfactorily for voltage range of 30% to + 10% with frequency variation + or 5%. : : 27V + or 5% : 29V + or 5% ( Max.) : + or 1% :5A : < 2% rms : Not less than 75% at full rated load : 105% of rated load : Not less than 5 mega Ohms. between DC output terminals and AC input terminals. Between AC input terminals and earth
5.0 GENERAL REQUIREMENTS: 5.1. BATTERY: The Batteries required under this specification are for supplying aux. D.C. supply to control circuits of Circuit Breakers. The battery shall be capable of withstanding large discharge currents for operating 11kV SF6/Vaccum Circuit Breakers and for VHF sets. It shall be of rugged construction designed for long life and for working satisfactorily under the severest operating conditions and shall conform to the relevant Indian / International standard of latest issue. The battery shall be supplied complete with all required accessories for their efficient operations and such parts / accessories shall be deemed to be within the scope of this specification, whether specifically mentioned or not. The rating of the Batteries is specified at 27 deg.C. However, the battery shall be capable of operating satisfactorily in outdoor applications when it is housed in a Cubicle between 5 deg. C and 50 deg.C ( at reduced capacities) and in locations where the relative humidity between 12% and 100%. All parts particularly removable once shall be interchangeable with each other. The separators shall be micro porous absorbent glass material with high porosity. All connections shall be of lead plated copper. All inter cell and nuts and bolts shall be brass and lead plated. The lead plating shall be adequate and tenacious. The cells shall be suitably marked as per I.S.S. The D.C. Battery shall be operated without intentional ground. 1 No. cell testing center zero volt. Meter with suitable range shall form part of the supply.
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5.2. BATTERY CHARGER ( FLOAT CUM BOOST): The battery shall be offered with suitable charger requiring low maintenance. The charger shall be of full wave semi controlled thyrister bridge rectifier type with automatic voltage regulator unit and with necessary printed circuit boards, transformer and relays etc. The charger shall be provided with a regulator to facilitate controlling of the cell voltage and to stabilize the output voltage within + or 1% of the set D.C. value, for AC mains supply voltage variation of 10% or 30% and frequency variation of + or 5% and D.C. load variation of 0-100% and also when all the three variations occur simultaneously. The charger shall be provided with an automatic current limiting facility such that when charger output current exceeds 10% above the rated current. The charger output current does not exceed the set value. Spike suppressors preferably on both primary & secondary side) and surge arresters are to be provided. Peak inverse voltage of all thyristors / diodes shall be rated for minimum of 600V. Screening circuit to be incorporated for reducing transfer surges. The charger shall be provided with a low voltage cut off arrangement. A manual and automatic changeover arrangement from quick to trickle and vice versa shall be provided. Provision should be made to vary the charging current of Trickle high charge in manual mode also. In the event of A.C. supply failure, when the battery is on boost charge, the available battery capacity shall be automatically connected to the DC load. The charger should include AC ON / OFF switch preferably MCB of suitable capacity, fuse protection for AC and DC, Battery reverse polarity protection, with Power On, Charger on, Boost Charge lamp indications. A bell to be provided for giving alarm with indication in case or AC supply failure / charging failure. The equipment shall also include a push button, a dual range moving coil ammeter (with center zero) of show quick / trickle charging currents and discharge current of battery. The indicating instruments shall be of flush mounting type with dust tight covers. The instruments shall be approximately 96 mm square with 270 Degree scale or alternatively black numbers and lettering. The make of the Ammeters, voltmeters to be provided should be got approved before supply. The charger shall have suitable indicators to visually know its mode of operation. The battery charging equipment shall be complete with all parts that are necessary for their efficient operation. Such parts shall be deemed to be within the scope of this specification whether specifically mentioned or not. The internal wiring of the charger shall be carried out with PVC insulated 650V grade standard copper conductor. The contact wiring shall be carried out with 2.5 Sq.mm copper conductors. All wiring for external connections shall be brought to 650V grade single piece mounted terminal blocks with barriers. Suitable vertical terminable blocks shall be provided. Terminal connections provided for wiring shall be stud type and not screw type. The D.C. output shall be terminated at D.C. terminals, with facility to receive the battery wires and the load cable, with similar arrangements for A.C. input terminals for receiving A.C. wiring cable. All the external cables to be connected to the charger shall be arranged for bottom / side entry with proper cable glands.
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The service manuals with component details & ckt diagrams are to be supplied with each charger. All the important component of the charger must be easily accessible for maintenance, repair, replacement in case of trouble without giving interruption to the total D.C. supply as far as possible. 5.2.1. SYSTEM BOX ( FOR 24V BATTERY AND CHARGER) The 24V Battery and charger shall be housed in self supporting outdoor cubicle designed with good ventilation to cool the components so as to take care of the temperature effects. The units will be located in OUTDOOR YARD by the side of vaccum circuit breaker, which are mounted on a suitable angular or tabular structure. The cubicle housing trickle charger along with electrical instruments / components in the upper compartment and the battery in the lower compartment, shall be completely wheather proof & vermin proof. A suitable hood shall be provided to protect the equipment from rain. The cubicle shall be made of suitable M.S. Angles and sheets of not less than 16 SWG to withstand the weight of charger and battery cells and shall be of robust construction. The door covering the entire unit shall be provided in the front facilitating reading of instruments inspection / service and maintenance of battery cell and charger components periodically. The door shall be fixed using screws so as to observe all meter readings and indications without opening the door through a prospect sheet. Suitable provision shall be made for the escape of flames emanating from the cells and heat from charger components. Suitable anti corrosive, acid resistive paint is to be provided to interior side of the box. No. Cell testing center zero voltmeter with suitable range shall form part of the supply. 6.TESTS & TEST CERTIFICATES: The batteries and chargers are to be tested as per relevant I.S. and the type test certificates are to be furnished for approval. End cell voltage shall be as per relevant I.S. A copy of the test certificates issued by any National Laboratory shall accompany the tender. The date of type test shall not be later than 5 years. 7. DRAWING & LITERTURE: Detailed Drawings, Circuit details and technical literature of batteries shall be enclosed to the offer. Tenders not accompanied by the above are liable for rejections, 2 copies of these drawings circuit details and literature are to be supplied along with each unit in the event of order. Trouble shooting charts shall be supplied with each unit to trace faults in the charger with voltage and resistances to be measured at various test joists. 8. PAINTING:
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Before painting, all ungalvanised parts shall be completely cleaned and made free from rust, scale and grease and all external rough surface cavities and casting shall be filled by metal deposition. The interior parts and internal structural steel work shall be cleaned of all scale and rust by sand blasting or other approved method. All external surfaces shall received a minimum of 3 coats of paint. Anticorrosive / Acid resistant paint is to be provided for interior side of the system box. The paint shall be guarantee by 5 years from the date of receipt of material. 9. INSPECTION: 9.1. All routine tests and inspection shall be made at the place of manufacturer unless otherwise especially agreed upon by the manufacturer and purchaser at the time of purchase. The manufacturer shall afford the inspector representing the purchaser all reasonable facilities, without charge, to satisfy him that the material is being furnished in accordance with this specification. 9.2. The purchaser has the right to have tests carried out to suppliers cost by an independent agency wherever there is a dispute regarding the quality of supply. 10. PACKING: The equipment shall be delivered suitably packed. Although the method of packing is left to the discretion of the manufacturer, it should be robust for rough handling, that is occasioned during transportation by rail / road. 11. GUARANTEED TECHNICAL PARTICULARS: The guaranteed technical particulars shall be furnished by the bidder as per Section V Annexure. 12.0 WARRANTY: The general terms and conditions the warranty clause applicable to 24, 40AH battery with charger of this specification is as follows. The period of warranty will be 5 years (five years) from the date of commissioning. EPDCL reserves the right to claim the financial loss incurred / suffered due to the failure of 24, 40AH battery with charger during the guarantee period. ANNEXURE GUARANTEED TECHNICAL PARTICULARS For 24V 40 AH Batteries. A) TENDERS: 1. Type of Designation as per ISS 2. Manufacturers type designation 3. Amphere hour capacity at 10 Hrs. rate of discharge to 1.75V. 4. Total No. of plates per cell 5. Nominal cell voltage (Volts) : : : : :
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6. No. of Cells in each bank 7. No. of spare cells if any in each bank 8. Internal resistance for each Cell ( micro ohms) 9. Resistance of the battery including interconnection between the Cells (ohms)
: : : :
10. Cell discharge rate in Amperes : ( from rated voltage to final discharge voltage) 5 Hrs. Discharge rate in Amp. 2 Hrs. Discharge rate in Amp. 1 Hr. Discharge rate in Amp. 30 Min. Discharge rate in Amp. 10 Min. Discharge rate in Amp. 1 Min. Discharge rate in Amp. 30 Sec. Discharge rate in Amp. 1 Sec. Discharge rate in Amp. (Please furnish a graph showing Amps. against time for the type of battery offered) 11. Short Circuit current (Amps) : 12. i) Material of Cell containers : ii) Material used for battery box : 13. Thickness, type and material of separators: 14. Constructional Details and Dimensions : i) Positive plate : ii) Negative Plate : iii) Surface area of placed sq.mm : 15. i) Ampere hour efficiency % : ii) Watt hour efficiency % 16. i) Recommended float charge : current and voltage ii) Recommended float charge current and : voltage 17. Time required for boost charging from : from discharged condition 18. i) Max. charging current / Cell : ii) Nominal charging rate : 19. i) Whether explosion provisions or vent : plugs provided ii) Whether vent is spill proof : 20. Type of intercell connection and whether : they are covered with plastic sleeves. 21. i) Dimensions of each 12V Block / Cell : Length mm: Width mm: Height mm: Thickness of container mm: ii) Net weight of the cell complete :
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with acid 12V block (Kg.) 22. Expected life span of battery 23. Accessories provided 24. Special conditions if any B. For CHARGERS: 1. i) Charger Type ii) Type of Rectifier 2. No. of units 3. Manufacturers type Designation 1 4. A.C. Supply 5. Rated D.C. Output (KW) 6. Rated D.C. Output Voltage (Voltage) 7. Rated D.C. Output Current (Amps) : 8. D.C. Output voltage regulation from No load to full load (Volts)
: : : : : : : : : : :
9. Maximum ripple current : 10. Changeover from boost to trickle : ( Automatic / Manual) 11. Protection over voltage, under voltage : protection reverse polarity protection etc. provided. 12. Maximum permissible temperature rise : over an ambient temperature of 50 degree C. 13. Overall efficiency 14. Load limiting feature 15. Unit dimensions i) Width ii) Height iii) Depth 16. Unit shipping weight 17. Recommended spares C. SYSTEM BOX / RACK i) SYSTEM BOX a) Dimension of box b) Weight of box c) Guage of material d) Painting details ii ) RACK a) Dimension & Weight b) Description c) Material D. DISTRIBUTION BOARD : : : :
: : : : : : : : : : : :
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a) Double Pole Rotary Switch for Incoming : D.C. Supply b) HRC Fuses for the above : c) Double Pole 10A ON / OFF : Rotary switches d) HRC Fuses for the above
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TECHNICAL SPECIFICATION FOR 63 KVA CONVENTIONAL CRGO DISTRIBUTION TRANSFORMERS OF 11/0.433 KV CLASS 1.0 SCOPE: This specification covers design, engineering, manufacture, assembly stage testing, inspection and testing before supply and delivery at site of 11 KV /433V 63 KVA CRGO Conventional Distribution Transformers. 1.1 It is not the intent to specify completely herein all the details of the design and construction of material. However, the material shall conform in all respects to high standards of engineering, design and workmanship and shall be capable of performing in continuous commercial operation in a manner acceptable to the purchaser, who will interpret the meanings of drawings and specification and shall have the power to reject any work or material which in his judgment is not in accordance therewith. The material offered shall be complete with all components necessary for its effective and trouble free operation. Such, components shall be deemed to be within the scope of bidders supply irrespective of whether those are specifically brought out in this specification and / or the commercial order or not. 2.0 STANDARDS: 2.1 The materials shall conform in all respects to the relevant Indian/International Standards specifications, which shall mean latest revisions, amendments/changes adopted and published, unless otherwise specified herein before. International and Internationally recognized standards to which these standards generally correspond are also listed below: Indian Standard No. ISS-1180 Title Outdoor Distribution Transformer upto and including 100 KVA BS 148, ASTM D1275, D-1473, D-1533, 1934 IEC Pub 296-1969 IEC Pub 296-1969 DIN 42531 to 33 ASTM B-49 ASTM B-233 IEC 60 099-1 IEC 60 076 IEC-554 IEC-641 International & Internationally Recognized Standard
1SS-335/1993 REC specification Specification for Oil 39/1993 ISS-2099/1973 ISS-7421/1976 ISS-3347 ISS-12444 ISS-5484 ISS-1747/1973 ISS-3070/1974 ISS-5/1961 No.632 ISS-6600/1972 ISS-9335 ISS-1576 Specification for High Voltage Porcelain bushings Specification for Low Voltage Bushings Specification for Outdoor Bushings Specification for Cu wire rods Specification for Al wire rods Specification for commercial grade Nitrogen Specification for metal Oxide Lightning Arrestors Specification for colors for ready mixed paints Guide for loading of oil immersed transformers Specification for Insulating Kraft paper Specification for Insulating press board
Material conforming to other internationally accepted standards, which ensure equal or higher quality than the standards mentioned above would also be acceptable. In case the Bidders who
wish to offer material conforming to the other standards, salient points of difference between the standards adopted and the specific standards shall be clearly brought out in relevant schedule. Four copies of such standards with authentic English Translations shall be furnished along with the offer. Incase of conflict the order of precedence shall be (i) IS (ii) IEC (iii) Other standards. In case of any difference between provisions of these standards and provisions of this specification, the provisions contained in this specification shall prevail. 3.0 PRINCIPAL PARAMETERS: The Transformers shall be suitable for outdoor installation with three phase, 50 c/s, 11 KV system in which the neutral is effectively earthed and they should be suitable for service under fluctuations in supply voltage upto + 20 % to 30%. The transformer shall conform to the following specific parameters Sl.No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Item Continuous rated capacity System Voltage (max.) Rated Voltage HV Rated Voltage LV Line current HV Line current LV Frequency No. of phases Connection HV Connection LV Vector group Type of cooling Tap changing arrangement Over fluxing limit Noise level at rated voltage and frequency Permissible temperature rise over ambient i) Of top oil measured by thermometer ii) Of winding measured by resistance Minimum clearances in air 17 i)HV phase to phase/Phase to earth(mm) ii) LV phase to phase/Phase to earth(mm) Specification 63 KVA 12 KV 11 KV 433V-250V 3.306A 84.0A 50 c/s +/- 5% Three Delta Star (Neutral brought out) Dyn-11 ONAN Not applicable 12.5% 45 db 40 Deg. C 45 Deg. C ---- As per IS-1180 latest as per latest---- 255/140-------75/40-------
4.0 TECHNICAL REQUIREMENTS: 4.1 DESIGN PARAMETERS: 4.1.1. LOSSES : The bidder should quote maximum losses at rated voltage and rated frequency permitted at 75 deg. C. No load Voltage ratio Full load losses in watts CORE losses in watts KVA rating (V) (Max) (Max)
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11000/433 11000/433
63 63
CRGO Amorphous
180 W 45 W
(No positive allowed) 1235 W 968 W
tolerance
4.1.2. Percentage Impedance: The percentage impedance at rated frequency is given below: KVA Rating 63 Percentage Impedance (Subject to tolerance as per IS-2026) 4.5%
Bids not meeting the limits indicated above will be treated as NON-RESPONSIVE 4.1.3. TEMPERATURE RISE: The temperature rise over ambient shall not exceed the limits described below: Top oil temperature rise measured by thermometer : 40 deg. C Winding temperature rise measured by resistance : 45 deg. C Bids not meeting the above limits of temperature rise will be treated as NON-RESPONSIVE. 4.1.4. PENALTY FOR EXCESSIVE LOSSES: During testing, if it is found that the actual measured losses are more than the values quoted by the bidder penalty shall be recovered from the bidder at double the loss rate as specified below: 1. No load losses: 2. Load losses: Rs.2,17,515 per KW Rs.28,772 per KW
For fraction of a KW, proportionate penalty will be recovered. 4.1.5. TRANSFORMERS WITH TEMPERATURE RISE AND IMPEDENCE BEYOND GUARANTEED VALUES: Purchaser reserves the right to reject any transformer during the test at suppliers works, if the temperature rise exceeds the guaranteed values. Purchaser reserves the right to reject any transformer during the test at suppliers works, if the impedance values differ from the guaranteed values including tolerance Purchaser also reserves the right to retain the rejected transformer and take it into service until the Bidder replaces it with a new transformer at no extra cost. The delivery as per contract will be counted when the manufacturer provides the new transformer as per specification. 4.1.6. INSULATION MATERIAL & CLEARANCES: Materials: Electrical grade insulation Kraft paper of standard make and Press Board of standard make or shall be used in manufacturing transformers, All spacers ,axial wedges/runners used in windings shall be made of pre-compressed Pressboard- solid, conforming to type B 3.1 of IEC 641-3-2. All spacers shall be properly
sheared and dovetail punched to ensure proper locking. All axial wedges/ runners shall be properly milled to dovetail shape so that they pass through the designed spacers freely. Insulation shearing ,cutting milling and punching operations shall be carried out in such a way, that there should not be any burr and dimensional variations c) Clearances: i) Radial Clearance of LV coil : Not less than 3.5 mm to core (bare conductor) ii) Radial Clearance between HV & LV : Not less than 11.0 mm iii) Phase to phase clearance between HV : Not less than 10 mm for 11 KV with a conductors minimum of 2x1 mm press board to cover the tie rods iv) The minimum electrical clearance : Not less than 30 mm between the winding and body of the tank (between inside surface of the tank and outside edge of the winding) v) Minimum end Insulation to earth : Not less than 25 mm vi) (a) No. of coils HV/Phase : 4 (min) vii) Thickness of locking spacers : 10 mm (min). between HV coils viii) No. of axial wedges between : Shall be 8 (min) LV & HV winding equi-spaced ix) Tap lead insulation : 1.5 mm thick with paper (minimum) Note: 1. Manufacturing drawing showing various clearances shall be got approved before commencement of supplies. 2. The design calculations with reference to guaranteed values along with watt loss curves/tables shall be furnished along with the Bid. 4.1.7. OVER LOAD CAPACITY : The tenderer should state clearly the percentage overload the transformers can take for a continuous period of 1 hour. The transformers shall suitable for loading as per IS-6600/1972. 4.2. CONSTRUCTION: 4.2.1. CRGO Core a) Material : The core shall be generally of high grade cold rolled grain oriented annealed steel lamination having low loss and good grain properties, coated with hot oil proof insulation, bolted together and to the frames firmly to prevent vibration or noise. All core clamping bolts shall be effectively insulated. The complete design of core must ensure permanency of the core losses with continuous working of the transformers. The value of the maximum flux density allowed in the design and grade of lamination used shall be clearly stated in the offer. b) The transformer core shall be suitable for over fluxing (due to combined effect of voltage and frequency) upto 12.5% without injurious heating at full load conditions and shall not get saturated. The bidder should furnish necessary design data in support of this.
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c) The operating flux density shall be such that there is a clear safe margin over the over fluxing limit of 12.5%. d) Flux density should not be more than 1.55 weber/meter (Tesla).
e) No load current shall not exceed 3% of full load current upto 63 KVA and will be measured by energizing the transformer at 433 Volts, 50 c/s on the secondary. Increase of voltage of 433 volts by 12.5% shall not increase the no load current by maximum 6% of fulload current. Test for magnetic balance by connecting the LV phase by phase to rated phase voltage and measurement of an, bn, cn voltages will be carried out. f) Only prime quality CRGO sheets should be used in the transformers and no Second/Defective/Scrap CRGO finds way into transformers. Therefore regarding quality control following documents are to be furnished before giving the inspection offer. Invoices of supplier Mills test certificate Packing list. Bill of landing Bill of entry certificate by custom Description of material, electrical analysis, Physical inspection, certificate for surfacedefects, thickness and width of the material. Subjecting to at least 10% of the transformers to routine tests and no load and load loss measurement. It is to note that, using seconds/defective CRGO sheets or load losses found to be more than stipulated limit, heavy penalty will be imposed or the suppliers will be black listed. g) Core Clamping: a) b) c) d) e) f) g) h) i) MS channel (75 mm x 40 mm) of adequate size shall be used on top and bottom. Number of steps of core shall be minimum of 5 Nos. Diameter of core should not be less than 100 mm . Effectiveness of core area should not be less than 70 sq.mm . High tensile bolts of 2 x 12 mm to be used in parallel at each end. Channel on LV side to be reinforced at equidistance, if holes/cutting is done for LT lead in order to avoid bending of channel. MS channels shall be painted with varnish or oil-resistant paint. Tie-rods : 4 Nos. of 12 mm diameter size of high tensile steel rods shall be effectively insulated. a) All top and bottom yoke nuts & bolts and tie rods shall be painted with oil and corrosion resistant paint before use. b) Core base and bottom yoke shall be supported with MS channel (75 x 40 mm) with proper bolting. Flat or cut channels will not be accepted.
Note: The tenderer shall furnish the design details of the core construction along with their offer with references to the losses quoted. 4.2.2. WINDINGS:
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a) b) c) d) e)
Material: Double paper covered insulated electrolytic Aluminum Current density for HV and LV should not be more than 1.5A/Sq.mm for Aluminium Conductor. HV cross section shall not be less than 1.539 sq.mm. LV cross section shall not be less than 56 sq.mm. LV winding shall be in even layers so that neutral formation will be at top.
Formation of Delta on HV side shall be with 13 SWG super enameled copper wire with multi layered (not less than 13 layers) paper insulation. Necessary resin bonded paper insulation tubes or backlight bits may be used through. This shall be done with ferrules and crimping. The HT jumpers from winding to the HT bushing (fuse link) inside the transformer should be provided with lugs to bolts and nuts. The jumper wire should pass through resin bonded paper cylinders and fiber glass sleeves. Vertical ducts and spacers shall be provided within each coil for HV & LV windings. Dovetail spacers shall be used in between HV coils and they shall be fixed to the vertical ducts which are provided between HV & LV. iv) f) g) h) Wedges of 3.2 mm shall be provided at 50% turns of the HV coils Inter layer insulation shall be Epoxy dotted Kraft paper. Proper bonding of inter layer insulation with the conductor shall be ensured. Test for binding strength conducted. Dimensions of winding coils are very critical. Dimensions tolerance for winding coils shall be within limits as specified in GTP
4.2.3. OIL: The transformer shall be supplied complete with first filling of oil and the same shall comply with ISS-335/1983. The characteristics of the oil shall be as follows: Sl.No. 1 2 3 4 5 6 7 8 Characteristic Electric strength (breakdown voltage) Electric dissipation factor (tan delta) at 90 degree C Specific resistance (resistivity) at 27 degree C Specific resistance (resistivity) at 90 degree C Flash point (PM closed) Interfacial tension at 27 degree C Neutralisation value (total acidity) Water content Specified value 30 KV (rms) (min) 0.01 (max) 1500 x 10 ohm-cm (min) 35 x 10 ohm-cm (min) 140 degree C 0.03N/m (min) 0.05Mg KOH/g (max) 35 PPM (max)
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Test report for each batch of oil shall be submitted 4.2.4. TANK : a) The transformer tank shall be of robust construction rectangular in shape and shall be built up of tested MS sheets of the following minimum thickness. i) Side walls : 3.15 mm thickness ii) Top and bottom plates : 5.0 mm thickness b) The internal clearance of tank shall such that ,it shall facilitate easy lifting of core with coils from the tank without dismantling LV bushings. c)Manufacturer should carry out all welding operations operations as per the relevant relavant ASME standards and submit a copy of the welding procedure qualifications and welder performance qualification certificate to the customer. d) All joints of tank and fittings shall be oil tight and no bulging should occur during service. The tank design shall be such that the core and windings can be lifted freely. The tank plate shall be of such strength that the complete transformer when filled with oil may be lifted bodily by means of lifting lugs provided. Inside of tank shall be painted with varnish. e) U shaped pressure relief vent of 2 diameter pipe with 0.025 mm copper shim sheet as diaphragm shall be provided on the top of the cover of the tank such that the pressure released should be directed to the ground. The other end of the vent pipe shall be guarded with wire mesh for preventing the entry of worms and nesting. The diaphragm shall burst at pressure of 0.76 to 0.95 kg/sq.cm. f) The tank shall be fitted with round cooling tubes minimum of 38 mm outer dia and 1.25 mm thick bent and directly welded on both sides i.e. Inside and outside of the tank. The cooling tubes shall not be provided underneath the LV bushing to avoid puncturing of the tubes due to falling down of LV lead on them. A minimum of 4 tubes shall be provided for each transformer Or The Transformer tank can be with radiator fins or made of corrugated panels g) Heat dissipation by tank walls excluding top and bottom should be limited to 500W/Sq.mt upto the oil level, 250 Watts/Sq.mt above oil level and 300W/Sq.mt. for cooling tubes the transformers shall be capable of giving continuous rated output without exceeding the specified temperature rise. Tenderer shall submit the calculation sheets. i) Total minimum weights Sl.No. Rating KVA Core Lamination min. in Kgs. Winding with insulation Min in Kgs. 1 63 KVA 145 55 j) Lifting lugs: 4 Nos. welded heavy duty lifting lugs of MS Flat 8 mm thick (min.) suitably reinforced by vertical supporting flat welded edgewise below the lug on the side wall. k) Pulling lugs: 4 Nos. of welded heavy duty pulling lugs of MS plate 8 mm thick (min.) shall be provided to pull the transformer horizontally. l) Top cover fixing bolts of G.I. 12 mm diameter spaced at 100 mm apart, 6 mm continuous (without any joints) Neoprene Nitrile rubber gaskets conforming to IS 4352 Part-II
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will be placed between tank and cover. The bolts outside tank shall have 2 flat washers & one spring washer. m) All transformers shall be capable of giving their continuous rated output without exceeding the specified temperature rise. n) Sand blasting or chemical treatment method shall be used inside of the tank before tanking. o) Gaskets & Sealing washers: 5mm thick oil and heat resistant Neoprene rubberized cork sheets, conforming to type B/C/ Part-II, IS-4253 will be placed between the tank and cover plate. Accordingly sealing washers for items like drain plug etc are to be provided. CONSERVATOR The total volume of conservator shall be such as to contain 10% of total quantity of oil. Normally 3% quantity of the total oil will be contained in the conservator. Dimension of the conservator shall be indicated in the General Arrangement Drawings. Oil level indicator with minimum oil level marking shall be provided on the side which will be with fully covered detachable flange with single gasket and tightened with MS nut-bolt. The conservator shall be provided with the drain plug and a filing hole (30 mm dia) with cover). The cover of the main tank shall be provided with air release plug to enable trapped air to be released unless the conservator is so located as to eliminate the possibility of air being trapped within the main tank. The pipe from conservator tank connecting to main tank shall be of 30mm to 50mm dia, according to the capacity of the transformer. The inside diameter of the pipe connecting the conservator to the main tank shall be within 30 mm to 50 mm according to the capacity of the transformer and it should project into the conservator in such a way that its end is approximately 20mm above the bottom of the conservator so as to create a sump for collection of impurities. The minimum oil level corresponding to (-) 5 Degree C, should be above the sump level.
SURFACE PREPARATION AND PAINTING GENERAL 4.2..5 1. All paints shall be applied in accordance with the paint manufacturers recommendations. Particular attention shall be paid to the following: a) Proper storage to avoid exposure as well as extremes of temperature.
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b) Surface preparation prior to painting. c) Mixing and thinning d) Application of paints and the recommended limit on time intervals between coats. e) Shelf life for storage. 4.2.5.2 All paints, when applied in a normal full coat, shall be free from runs, sags, wrinkles, patchiness, brush marks or other defects. 4.2.5.3 All primers shall be well marked into the surface, particularly in areas where painting is evident, and the first priming coat shall be applied as soon as possible after clearing. The paint shall be applied by airless spray according to manufacturers recommendations. However, where ever airless spray is not possible, conventional spray be used with prior approval of purchase. 4.2.5.4 The Supplier shall, prior to protect nameplates, lettering gauges. Sight glasses, light fittings and similar such items. 4.2. 6 Cleaning and Surface preparation 4.2.6.1 After all machining, forming and welding has been completed, all steel work surfaces shall be thoroughly cleaned of rust, scale, welding slag or spatter and other contamination prior to any painting. 4.2.6.2 Steel surfaces shall be prepared by Sand / Shot blast cleaning or Chemical cleaning by Seven Tank process including Phosphating to the appropriate quality. 4.2.6.3 The pressure and volume of the compressed air supply for blast cleaning shall meet the work requirements and shall be sufficiently free from all water contamination to ensure that the cleaning process is not impaired. 4.2.6.4 Chipping, scraping and steel wire brushing using manual or power driven tools cannot remove firmly adherent mill-scale shall only be used where blast cleaning is impractical. Manufacturer to explain such areas in his technical offer clearly. 4.2..7 Protective Coating As soon as all items have been cleaned and within 4 hours of the subsequent drying ,they shall be given suitable anti-corrosion protection 4.2.8 .Paint Material Followings are the types of pain that may be suitably used for the items to be painted at shop and supply of matching paint to site: 4.2.8.1. Heat resistant paint (Hot oil proof) / Varnish for inside surface. 4.2.8.2. For external surface one coat of Thermo Setting paint or 1 coat of Zinc chromate primer followed by 2 coats of Polyurethane base paint. These paints can be either air drying or stoving. 4.2..8.3.The color of the finishing coats shall be dark admiral gray conforming to No. 632 of IS 5 of 1961.
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4.2.9. Painting procedure 4.2.9.1. All painting shall be carried out in conformity with both specification and with the paint manufacturers recommendation. All paints in any one particular system, whether shop or site applied, shall originate from one paint manufacturer. 4.2..9.2. Particular attention shall be paid to the manufacturers instructions on storage, mixing, thinning and pot life. The paint shall only be applied in the manner detailed by the manufacturer e.g. brush, roller, conventional or airless spray and shall be applied under the manufacturers recommended condition. Minimum and maximum time intervals between coats shall be closely followed. 4.2..9.3. All prepared steel surfaces should be primed before visible re-rusting occurs or within 4 hours, whichever is sooner. Chemical treated steel surfaces shall be primed as soon as the surface is dry and while the surface is till warm. 4.2.9.4. Where the quality of film is impaired by excess film thickness (wrinkling, mud cracking or general softness) the Supplier shall remove the unsatisfactory paid coating and apply another. As a general rule, dry film thickness should not exceed the specified minimum dry film thickness by more than 25%. In all instances where two or more coats of the same paid are specified, such coatings may or may not be of contrasting colours. 4.2.9..5. Paint applied to items that are not be painted shall be removed at suppliers expense, leaving the surface clean, unstained and undamaged. 4.2.10. Damaged paintwork 4.2..10.1. Any damage occurring to any part of a painting scheme shall be made good to the same standard of corrosion protection and appearance as that originally employed. 4.2.10.2. Any damaged paint work shall be made good as follows: The damaged area, together with an area extending 25 mm around its boundary, shall be cleaned down to bare metal. A priming coat shall be immediately applied, followed by a full paint finish equal to that originally applied and extending 50 mm around the perimeter of the original damage. The repainted surface shall present a smooth surface. This shall be obtained by carefully chamfering the paint edges before and after priming. 4.10.11 Dry Film Thickness 4.10.11.1To the maximum extent practicable the coats shall be applied as a continuous film of uniform thickness and free of pores. Overspray, skips, runs, sags and drips should be avoided. The different coast may or may not be of the same colour. 4.10.11.2 Each coat of paint shall be allowed to harden before the next is applied as per manufacturers recommendation.
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4.10.11.3 Particular attention must be paid to full film thickness at edges. 4.10.11.4The requirements for the dry film thickness (DFT) of paint and the materials to be used shall be as given below: Sl. No. 1 2 Paint type Thermo setting paint. Area to be painted inside outside No. of coats 01 01 01 02 01 Total Dry film thickness 9min.) 20 microns 60 microns 30 microns 25 microns each 35 / 10 microns
Liquid paint Zinc chromate (primer) outside Polyurethene (Finish coat) outside Hot oil paint / Varnish inside
4.10.12. Tests 4.10.12.1 The painted surface shall be tested for paint thickness. 4.10.12.2The painted surface shall pass the Cross Hatch Adhesion test, Salt spray test and hardness test as per the relevant ASTM standards. NOTE: Supplier shall guarantee the painting performance requirement for a period of not less than 5 years 5.1 BUSHINGS: a) The porcelain portion of HT and LT bushings shall be of standard make and confirm to IS-2099/1973 (HV), Specification for High voltage porcelain bushings and IS-7421/1976 for LV IS-3347 shall be outdoor with a minimum creepage distance of 270 mm. The bushing rods and nuts shall be made of brass material 12 mm diameter for both HT & LT. The bushings shall be fixed to the transformers on sides with straight pockets and in the same plane. The tests as per IS-2099/1962 shall be conducted on the transformer bushings as detailed below. Dry flashover voltage Wet flashover voltage Dry I min. withstand voltage Wet half min. withstand voltage Impulse withstand voltage (1.2/50 micro seconds positive wave) b) For 11 KV, 17.5 KV class bushings shall be used and for 0.433 KV, 1.1 KV class bushings shall be used. Bushings of plain sheds as per IS-3347 shall be mounted on the side of the Tank and not on top cover. c) Dimensions of the bushings of the voltage class shall conform to the standards mentioned below: A minimum phase-to-phase clearance of 75 mm for LV (upto 1.1 KV bushing) and 255 mm for HV (3.3KV and above) bushings shall be obtained with the bushing mounted on the transformer.
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d) The bushings shall be fixed on side with pockets in the same plane. Arcing horns shall not be provided and instead brass caps shall be provided. e) Brazing of all inter connections, jumpers from winding to bushing shall have cross section larger than the winding conductor. For aluminum, Standard make Aluminium Brazing rods shall be used. f) In the case of LV bushing, the internal busing shall be made of tough insulating material like epoxy and shall have embedded stem and a strong coupling connection (screwed) properly secured with a split pin shall be used, between stem of the internal and external bushings. g) The LV bushings shall be so located that even under the hottest conditions the level of the transformer oil shall be below the opening meant for fixing the LV bushings. The LV jumpers and bushing materials shall be selected and designed for this condition. h) The design of the internal bushing for LV shall be such as to provide adequate earth clearance as stipulated in clause No.10, 2.1 of IS 1180 part I and creepage distance as per clause No.7.1 of IS 2029. All other tests as per relevant standards shall be applicable. i) The bushings shall be of reputed make supplied by those manufacturers who are having manufacturing and testing facilities for manufacture of HT insulators. The terminal arrangement shall not require a separate oil chamber not connected oil in the main tank. k) The LV bushing and HV bushing stems shall be provided with suitable non detachable terminal connectors so as to connect the jumper without disturbing the bushing stem. High voltage phase windings shall be marked both in the terminal boards inside the tank and on the outside with capital letters 1U, 1V, 1W and low voltage winding for the same phase marked by corresponding small letters 2u, 2v, 2w. The neutral point terminal shall be indicated by the letter 2n. l) Internal HV fuses on the HT side of transformer:
Specification for the HT fuses : Expulsion/any other suitable type of fuse placed in series with the primary winding. This fuse is mounted normally inside of the primary bushing for all three phases and is connected to the high voltage winding through a terminal block. This has to protect that part of the electrical distribution system which is ahead of the distribution transformer from faults which occur inside the distribution transformer i.e. either in the windings or some other part of the transformer. It shall be ensured that this fuse does not blow for faults on the secondary side (LT side) of the transformer m) The Name plate with vector diagram shall clearly indicated the method adopted for marking the terminals both outside and interior. 5.2 LIGHTNING ARRESTERS:
9KV, 5kA metal Oxide Lightning Arrester with minimum creepage distance of 270 mm and with disconnector as per IS-3070/Part-I/1974 and IEC-99-1 (latest version), one number per phase shall be fitted with the HV bushings with GI earth strip of 25 x 4 mm connected to the body of the transformer with necessary clamping arrangements. The metal oxide lighting arresters with disconnector shall be reputed make.
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5.3 FASTENERS: All bolts, studs, screw threads, pipe threads, bolt heads and nuts shall comply with the appropriate Indian Standards for metric threads, or the technical equivalent. Bolts or studs shall not be less than 6 mm in diameter except when used for small wiring terminals. All nuts and pints shall be adequately locked. Wherever possible bolts shall be fitted in such a manner that in the event of failure of locking resulting in the nuts working loose and falling off, the bolt will remain in position. All ferrous bolts, nuts and washers placed in outdoor positions shall be treated to prevent corrosion, by hot dip galvanizing, except high tensile steel bolts and spring washers which shall be electro-galvanized / plated. Appropriate precautions shall be taken to prevent electrolytic action between dissimilar metals. Each bolt or stud shall project at least one thread but not more than three threads through the nut, except when otherwise approved for terminal board studs or relay stems. If bolts nuts are placed so that they are inaccessible by means of ordinary spanners, special spanners shall be provided. The length of the screwed portion of the bolts shall be such that no screw thread may form part of a shear plane between members. Taper washers shall be provided where necessary. Protective washers of suitable material shall be provided front and back or the securing screws. 5.4 MOUNTING ARRANGEMENT: The under base of all transformers shall be provided with two 75 x 40 mm channels 460 mm long as shown in REC specification 2/73 with holes to make them suitable for fixing on a platform or plinth. FITTINGS: The following standard fittings shall be provided. Rating and terminal marking plates non-detachable 1 No. Earthing terminals with lugs - 2 Nos. Lifting lugs 4 Nos. for main tank & 2 Nos. for Top cover. Thermometer pocket with cap 1 No. HT fuse links 3 Nos. U shaped Pressure relief vent to direct the oil to the ground with 0.025 mm copper diaphragm on the top of the top cover for breaking at a pressure of 0.76 to 0.95 kg. HV bushing 3 Nos. with bimetallic terminal connectors. LV bushings 4 Nos. with bimetallic terminal connectors. Pulling lugs 4 Nos. Stiffener angle minimum 40 x 40 x 5 mm and vertical strip of 50 x 5 mm flat. Cooling tubes No. & length may be mentioned (minimum 4 Nos. shall be provided) Disconnector type Metal oxide lightning Arrestors (3 Nos.) with G.I. earth strip 25x4 mm of 12 feet length. Base channel 75x40 mm Rating plate indicting I)Tank & over all dimensions II)Wt content of (a) Core (b) Windings (c) Tank & fittings (d) Wt/Qty. of oil (e) overall Weight 5 years guarantee embossed plate welded below name plate
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16)Oil filling provision 17)Oil level gauge indicating the positions of oil marked as follows Min (-5 Deg. C) 30 deg. C Max (90 deg. C) 18)Drain cum sampling valve. 19)Silicagel breather. (Note: The terminal connector arrangement can also be integral part of bushing rod) The bidder shall furnish cost analysis for each rating of transformer. 6. TESTS: 6.1. The type, acceptance and routine tests and tests during manufacture, shall be carried out on the Distribution Transformers as per the IS-2026 and IS-1180 latest revision. 6.1.1. The standards and norms to which these tests will be carried out are listed in ISS mentioned above. 6.1.2. For all type and acceptance tests, the acceptance values shall be the values guaranteed by the supplier in the proforma for Guaranteed Technical Particulars furnished in this specification or acceptance value specified in this specification, whichever is more stringent for that particular test. 6.2 TYPE TESTS: The bidder will furnish Type Test Results. The following type tests must have been conducted on the material offered as per the relevant IS in recognized laboratory as per the latest revision of the Technical Specification and the date of type test will not be later than 3 years. The Bids received without type test reports will be treated as Non-Responsive. Measurement of winding resistance (IS 2026 (part-I) :1977) Measurement of voltage ratio and check of voltage vector relation ship (IS 2026 (part-I) :1977) Measurement of Impedance voltage/short circuit impendence and load loss (IS 2026 (part-I) : 1977) Measurement of No Load loss and current (IS 2026 (part-I) :1977) Measurement of Insulation resistance (IS 2026 (part-I) :1977) Measurement of over voltage with stand test(IS 2026 (part-3) :1981) Separate source voltage withstand test(IS 2026 (part-3) :1981) Impulse voltage test: (IS-2026 (Part-III)/1981 Temperature rise tests(IS 2026 (part-II) :1977) Short Circuit test (IS 2026 (part-I) :1977) Air pressure test ( IS-1180/Part-I/1989.) Permissible flux density and over fluxing ( IS-1180/Part-I/1989.) ACCEPTANCE AND ROUTINE TEST: All transformers shall be subjected to routine tests at the manufacturers works. The following routine tests shall be carried out in accordance with the details specified in IS:1180 (Part-I) and IS:2026 or as agreed upon between the EPDCL and the manufacturer. Measurement of winding resistance (IS 2026 (part-I) :1977) Measurement of voltage ratio and check of voltage vector relation ship (IS 2026 (part-I) :1977) Measurement of Impedance voltage/short circuit impendence and load loss (IS 2026 (part-I) : 1977)
Measurement of No Load loss and current (IS 2026 (part-I) :1977) Measurement of Insulation resistance (IS 2026 (part-I) :1977) Measurement of Induced over voltage with stand test(IS 2026 (part-3) :1981) Separate source voltage withstand test(IS 2026 (part-3) :1981) 8. Measurement of no load current at 112.5% of rated voltage. 9. Checking of di-electric strength of transformer oil. 10. Checking of weights, dimensions fittings and accessories, tank thickness, oil quantity, material, finish and workmanship as per purchaser order and contract drawings. 11. Physical verification of core coil assembly and measurement of flux density of one unit of each rating, in every inspection with reference to short circuit test report. 12. Checking of name plate and marking on the tank.. The purchaser reserves the right to insist for witnessing the acceptance/routine testing of the bought out items. The supplier shall give 15 days for local supply/30 days in case of foreign supply advance intimation to enable the purchaser to depute his representative for witnessing the acceptance and routine tests. Tests during manufacture: The Bidder shall furnish details of tests carried out during the process of manufacture and end inspection by the bidder to ensure the desired quality of the Distribution Transformers to be supplied. TESTS AT SITE: The purchaser reserves the right to conduct all tests on Transformer after arrival at site and the manufacturer shall guarantee test certificate figures under actual service conditions. If the losses measured at site are found more than the guaranteed losses penalty will be levied on all the transformers of the purchase order as per clause number 4.41. 6.4 ADDITIONAL TESTS:
The purchaser reserves the right of having at his own expenses any other tests (s) of reasonable nature carried out at Bidders premises, at site, or in any other place in addition to the aforesaid type, acceptance and routine tests, to satisfy himself that the material comply with the specifications. 6.4.1 SPECIAL TEST : Special tests as specified in IEC 60 076 1993 in clause 10.1.3 shall also be undertaken with an agreement between the manufacturer and the purchaser. 6.4.2 In case of failure in any type test, the supplier is required to modify the design of the material and the material shall be type tested again for the modified design, without any extra cost to the purchaser. No delivery extension shaft be given for this additional testing. 6.4.3 The entire cost of testing for the acceptance and routine tests and tests during manufacture shall be treated as included in the quoted unit price. 6.5 TEST REPORTS:
6.5.1 Record of routine test reports shall be maintained by the Bidder at his works for periodic inspection by the purchasers representative.
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6.5.2 The Bidder shall maintain test certificates of tests conducted during manufacture. These shall be produced for verification as and when desired by the purchaser. The supplier shall get one transformer tested for impulse and short circuit tests for every 100 transformers supplied or part thereof. The transformer to be tested in a batch of 100 transformers will be randomly selected by APEPDCL. 6.6 TEST FACILITIES:
The following test facilities shall be available at bidders works. Ratio, polarity and phase sequence & winding resistance. No load current and losses at service voltage and normal frequency. Load losses at rated current and normal frequency. Impedance Voltage test. Resistance of windings cold (at or near the test bed temp.) Insulation resistance. Induced over voltage withstand test. Separate source voltage withstand test. NOTE: The Meters used for conducting tests shall be calibrated periodically at reputed Government Test Laboratories and test certificates shall be available at works for verification by purchasers representative. 6.7 DRAWINGS & LITERATURE: a) Completely dimensioned drawings indicating general arrangements and details of fittings, clearances and winding details shall accompany the tender. Drawings of internal constructional details, fixing details of the core and coils should also indicated. Tank dimensions, position of internal, fittings, clearances between leads within the transformer, core area grade of laminations, distance of core centers, area of conductor bare and with insulation. No. of coils, No. of turns per coils material of bushing metal parts conservator details heat dissipation calculations etc., shall also be furnished with tender. 6.8 TOLERANCES: unless otherwise specified herein the test value of the transformers supplied should be within the tolerance permitted in the IS: 2026 on the guarantee values. 6.9 FINISHING: The exterior of the transformer and other ferrous fittings shall be thoroughly cleaned, scraped and given a primary coat and the two finishing coats of durable oil and weather resisting paint of enamel. The colour of the finishing coats shall be dark admiral gray confirming to No.632 of IS 5 of 1961 colour for ready mixed paints. 7.0 INSPECTION: APEPDCL shall arrange 3rd party agency at EPDCLs cost for inspecting each unit/units offered for inspection. 3rd party inspecting agency of A.P.E.P.D.C.L. shall have access to you or your sub-contractors works at any time/stage during working hours for the purpose of inspecting the materials during manufacturing of the plant and equipment as well as active part inspection during acceptance tests for testing and may select test samples from the materials going into plant and equipment.
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You shall provide the facilities for testing such samples at any time. The supplier shall keep this office informed 15 days in advance about the manufacturing programme, so that arrangements can be made for inspection. As soon as the materials are ready, you shall duly advise APEPDCL with the routine test certificates along with all particulars in proof of satisfying the clause No. 5.12 regarding CRGO core laminations and clause No.8.0 Quality Assurance Plan to carryout the tests before 3rd party inspecting agency of APEPDCL. The despatches shall be made only after the inspection is completed by 3rd party inspecting agency, accredited representative of APEPDCL to A.P.E.P.D.C.L.s satisfaction. The A.P.E.P.D.C.L. reserves the right to insist for witnessing the acceptance of routine tests of the bought out items. 10% of the offered quantity for inspection will be inspected at the premises of the supplier by 3rd party inspecting agency. DOCUMENTATION: All drawings shall conform to International Standards Organization (ISO) A series of drawings sheet/India Standards Specifications IS:656. All drawings shall be in ink and suitable for microfilming. All dimensions and data shall be in S.I. Units. PACKING & FOR WARDING: The equipment shall be packed in creates suitable for vertical/horizontal transport as the case may be, and suitable to withstand handling during transport and outdoor storage during transit. The supplier shall be responsible for any damage to the equipment during transit, due to improper and inadequate packing. The easily damageable materials shall be carefully packed and marked with the appropriate caution symbol. Wherever necessary, proper arrangement for lifting, such as lifting hooks etc., shall be provided. Supplier without any extra cost shall supply any material found short inside the packing cases immediately. Each consignment shall be accompanied with a detailed packing list containing the following information. Name of the consignee. Details of consignment Destination. Total weight of consignment Handling and packing instructions. Bill of material indicating contents of each package. The supplier shall ensure that the purchaser before despatch approves the packing list and bill of material. The packing shall be done as per the manufacturers standard practice. However, he should ensure the packing is such that, Rail/Road should not damage the material during transit. The marking on each package shall be as per the relevant standards and shall also contain APEPDCL JBIC
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11.
WARRANTY:
The general terms and conditions the warranty clause applicable to Distribution Transformers of this specification is as follows. The period of warranty will be 5 years (five years) from the date of commissioning. EPDCL reserves the right to claim the financial loss incurred / suffered due to the failure of DTR during the guarantee period. 12. GUARANTEED TECHNICAL PARTICULARS: The tenderer shall furnished Annexures of IA, IB, II & III. 13. TECHNICAL DEVIATIONS:
Technical deviations to Section-V Technical specification shall be specifically and clearly indicated. ANNEXURE IA GUARANTEED & OTHER PARTICULARS FOR DISTRIBUTION TRANSFORMERS (To be furnished by the Manufacturer) Sl. No. 1 2 3 4 5 Description Make & Manufacturer Place of Manufacture Voltage Ratio Voltage per turn (Volts) Rating in KVA Core Material used and Grade Flux density Over fluxing without saturation (Curve to be furnished by the Manufacturer in support of his claim) Thickness of core plates Power factor of magnetizing current (lag. Max.) Maximum temperature rise of a) Windings by resistance method b) Core by Thermometer c) Oil by Thermometer Magnetising (No load) current at Normal Voltage Maximum Voltage Core loss in watts at 75 deg. C 63KVA Shall be M-4/ superior grade Not more than 1.55 weber/sq.mm Not more than 12.5% Shall be furnished 0.2 45C Max. over an ambient of 45C Shall be furnished 40C Max. over an ambient of 45C Not to exceed 3% of F.L. current Shall be furnished 63 KVA To be furnished by the manufacturer - do 11000V/433 250V
7 8
10 11
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Sl. No.
Description Normal Voltage Maximum Voltage Resistance of windings at 20 Deg. C (with 5% tolerance) HV Winding (ohms) LV winding (ohms) Reactance of winding/phase % of end turn reinforcement Full load losses (watts) at 75 Deg. C Full load current HV : LV : Current density used for HV winding LV winding Clearances Core & LV LV & HV HV Phase to phase (with a min. of 2 x 1 mm press board to cover tie rods) End insulation clearance to Earth Any point of winding to tank % Impedance at 75 Deg. C Radiation: 1) Heat dissipation by tank walls exclusive top & bottom 2) Heat dissipation by cooling tube 3) Dia & thickness of cooling tube 4) Whether calculation sheet enclosed for selecting cooling and area to ensure that the transformer is capable of giving continuous rated output without exceeding temperature rise is enclosed. Inter layer insulation provided in design for 1) Top & Bottom layer 2) In between all layer 3) Details of end insulation 4) Whether 3.2 mm wedges are provided at 50% turn of the HV coil Insulation materials provided For Conductors (1) HV (2) LV For Core Particulars of metal oxide Lightning arrestor Medium of free space above oil level.
63 KVA 180 W for CRGO/45 W Amorphous Shall be furnished Shall be furnished To be furnished 1235 W for Amorphous 3.306 A 84 A 1.5 A/sq.mm 1.5 A/ sq.mm with 5% tolerance 3.5 mm 11 mm 10 mm 25 mm 30 mm 4.5 CRGO/968W for for
12 13 14 15 16
17
18
19
Shall be furnished. 38 mm Dia 1.25 mm thickness(min) Shall be furnished
20
Shall be furnished
21
Shall be furnished Shall be furnished Shall be furnished
22 23 24
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ANNEXURE I B GUARANTEE & OTHER PARTICULARS FOR DISTRIBUTION TRANSFORER (To be furnished by the Manufacturer) Sl. No. 1 2 3 4 Description 63 KVA
6. 7 8 9
10
Make & Manufacturer To be furnished by the manufacturer Place of Manufacture - do Voltage Ratio 11000V/433 250V Rating in KVA 63 KVA Efficiency at 75 Deg. C Shall be furnished Unity P.F. & The transformer shall be designed to 0.8 P.F. obtain maximum efficiency at 75% 125% load load. 100% load 75% load 50% load 25% load Regulation at Unity P.F. Shall be furnished 0.8 P. F. at Deg. C Flash Test Shall be confirmed HV 28 kV/50Hz for 1 minute LV 3 kV/50Hz for 1 minute Over potential Test Double Voltage & Double Shall be confirmed frequency for 1 minute Impulse test AS per IS to be confirmed Weight content of Core lamination 145 Kgs. for CRGO/ Shall be furnished for Amorphous Windings 55 Kgs. Shall be furnished Tank & Fittings Shall be furnished Oil in litres Shall be furnished Total Weight
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Sl. No.
Description Oil Data 1) Qty. for first filling (min.) 2) Grade of oil used
63 KVA Shall be furnished EHV grade confirming to latest version IS 335 (Grade shall be furnished) Shall be furnished Shall be furnished
11
3) Makers name 4) BDV at the time of filling Transformer 1) Overall length x breadth x height 2) Tank length x breadth x height 3) Thickness of plates for Side plate (min.) Top & bottom plate (min.)
12
Shall be furnished Shall be furnished 3.15 5
13
Size of the wire used 1) HV a) SWG/mm b) Dia Area (sq.mm) 2) LV a) Strip size b) No. of conductors in parallel c) Total area of cross section (sq.mm)
Shall be furnished (current density for HV & LV should not be more than 1.5 Amp/sq.mm (with a tolerance of 5% for LV)
14
15
16
Is the name plate gives all particulars are required in Shall be furnished tender Particulars of Bushings HV/LV Shall be furnished 1) Makers name 2) Type IS-3347/IS-1180 3) Rating as per I.S. 4) Dry flash over voltage kV at 50 C/s 5) Wet flash over voltage kV at 50 C/s Shall be furnished HT Fuse links
ANNEXURE II ADDITIONAL DETAILS Sl. No. 1 2 3 4 5 6 Description 63 KVA Core Grade Core diameter (Should not be less than 100 mm) Mm Gross Core area Net core area (Effective ness of core area should not cm be less than70 sq. mm) Flux density (1.55 Tesla max.) Tesla Wt. Core (minimum 145 Kgs)
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7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
Loss per Kg. of core at the specified Flux Density Core window height Center to center distance of the core No. of LV Turns No. of HV Turns Size of LV conductor bare/covered Size of HV conductor bare/covered No. of parallels Current density of LV winding (Max. 1.5A/sq.mm with 5% tolerance) Current density of HV winding (max 1.5A/sq.mm) Wt. Of the LV winding for transformers Wt. Of the HV winding for transformers No. of LV coils/phase (Wt. both for HV & LV wdg. Should not be less than 55 Kgs.) No. of HV coils/phase (minimum 4 Nos.) Height of LV Winding Height of HV winding ID/OD of LV winding ID/OD of HV winding Size of the duct in LV winding Size of the duct between HV & LV HV winding to LV clearance (minimum 11 mm) HV winding to tank clearance (minimum 30 mm) Calculated impedance (4.5%) HV to earth creepage distance LV to earth creepage distance
Watts mm mm mm
Kg. Kg.
mm mm mm mm mm mm mm % Mm mm
ANNEXURE III SOURCE OF MATERIALS/PLACES OF MANUFACTURE, TESTING AND INSPECTION Sl. No. 1 2 3 4 Item Laminations Aluminium Core plates Steel Castings/sections Source Material of Place Manufacture of Place of testing and inspection
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5 6 7 8 9 10 11
Tank Insulating Cylinders HT Fuse Links Bushing HV/LV Oil Insulated winding wire Las SCHEDULE OF REQUIREMENT
Sl. No.
Description of Material 11KV/433 250V 63 KVA Oil immersed naturally cooled three phase, 50 Hz double wound, outdoor type, CRGO core Conventional Distribution Transformers top cover fixed with nut and bolt and neoprene gasket arrangement with double paper covered aluminium winding, with 0.025 mm Cu diaphragm pressure relief vent generally conforming to IS-1180/part-I & II of 1979 & IS-2026/1977 latest versions where specified otherwise with first filling of oil generally as per IS-335/1983 (latest version) and as per specification.
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TECHNICAL SPECIFICATION OF ALL ALUMINIUM ALLOY CONDUCTORS SCOPE: This specification provides for the manufacture, testing before despatch, supply and delivery of All Aluminium Alloy (Aluminium + Magnesium +Silicon) Standard Conductors for overhead Power Transmission purposes. STANDARD The conductors shall comply in all respects with the latest version of REC 33/84 R (1991) specification and IS 398 (Part-IV) 1994. CLIMATIC CONDITIONS: i) Peak ambient temperature in shade 50 deg.C ii) Maximum average ambient temperature over a 24 Hour period in shade 40 deg.C iii) Maximum temperature attainable by an object exposed to sun. 70 deg.C iv) Minimum ambient temperature 7.5 deg.C v) Maximum relative humidity 100 % vi) Average number of thunderstorm days per annum 50 vii) Average number of dust storms 10 viii) Average number of rainy days per annum 90 ix) Average rainfall per annum 925 mm x) Number of months of tropical monsoon conditions 4 months xi) Maximum wind pressure 260 kg/sqm. xii) Altitude not exceeding 100 meters above MSL MATERIALS: The material offered shall be of best quality and workmanship. The conductors shall be constructed of heat treated Aluminium-Magnesium Silicon alloy wires containing approximately 0.5% Magnesium and o.5% Silicon and having the mechanical and electrical properties specified in Appendix I enclosed. The wires shall be smooth and free from all imperfections such as spills and splits. The surface of conductor shall be free from points, sharpedges, abrasions or other departures from smoothness on uniformity of surface contour that would increase radio interference and corona losses. When subject to tension up to 50% of the ultimate strength of the conductor. The surface shall not depart from the cylindrical form nor any part of the component parts or strains move relative to each other in such a way as to get out of place and disturb the longitudinal smoothness of the conductor. 5. SIZE AND PROPERTIES: The sizes and properties of Aluminium Alloy Conductors of various sizes shall be as given in Appendix I and Appendix II enclosed which also indicates the values of resistance and weights.
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TOLERANCE: The following tolerances shall be permitted on nominal diameter of Tolerance on nominal diameter of aluminium alloy wires - 1 percent 7. a) The Co-efficient of linear expansion per deg.C shall be 23.0x10-6 b) Final modulus of elasticity (Practical) 0.6324 x 10-6 Kg/Sq.mm 8. JOINT IN WIRES: No joints are permitted in seven strand conductors. STRANDING: 9.1. The wires used in construction of a stranded All Aluminium Alloy Conductor (AAAC) shall, before stranding, satisfy all requirements of REC 33/84 (R_1991) and IS 398 (Part-IV) 1994 with latest amendment thereof. The lay ratio shall be within the limits given under Col.10 below:9.2. The lay of the stranding shall be right handed. The wires shall be evenly and closely stranded. LAY-RATIO: The lay ratio of different layers shall be within the limits given below:No. of wires in conductors 7 PACKING AND MARKING: 11.1 The conductor shall be wound in non-returnable reels or drums conforming to IS: 1961 Specification for reels and drums for bare wire or the latest version thereof. The drums shall be marked with the following:Manufacturers Name: Trade Mark, if any: Drum number on identification number Size of conductor Number and lengths of piece of conductor in each drum Gross mass of the packing Net mass of conductor 11.2. The reels shall be such construction as to ensure delivery of conductor in the field free from displacement and damage and should be able to withstand all stresses due to handling and the stringing operation so that conductor surface is not dented, scratched or damaged in any way during manufacture, transport and erection. The conductor shall be properly lagged on the drums and the method of lagging to be employed may be clearly stated in the tender. It should be notched to suit the reel and held in place by steel strapping. Lagging shall not be nailed or bolted in place. 6 wire layer Min. Max. 10 14
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11.3. The conductor drum should be suitable for wheel mounting. Before reeling, the cardboard or other suitable materials shall be secured to the drum and inside flanges of the drums. After reeling the conductor the exposed surfaces should be wrapped with suitable soft material to protect the conductor from dirt and grit. 11.4. The gross weight of each package shall not exceed the following limits, subject to a tolerance of + 10%. For 100 sq.mm Al.Alloy area (7/4.26mm AAAC) 2000 Kg. For 55 sq.mm Al.Alloy area (7/3.15mm AAAC) 1500 Kg. 11.5.The standard length for AAAC shall be as noted below. Longer length shall be acceptable. Short lengths of not less than 50% of the standard length shall be acceptable to the maximum extent of 10% of the quantity ordered for each size. 100 sq.mm 55 sq.mm TESTS: The following tests shall be carried out on wires used for AAAC as per detailed procedures given in the IS 398 Part-IV/1994. i) ii) iii) Breaking load test Elongation test Resistance Conductor Conductor 1.1 KM 1.7 KM
The rejection and retest procedure shall be followed as stipulated in IS: 398/Part-IV 1994, or any other later amendments there of. 13. INSPECTION:
All tests and inspection shall made at the place of manufacturer unless otherwise specifically agreed up on by the purchaser. The manufacturers shall afford the Inspector representing the purchaser all reasonable facilities, without charge, to satisfy him that the material is being furnished in accordance with this specification. The purchaser has the right to have the tests carried out at his own cost by an Independent agency whenever in dispute regarding the quality of supply. CHECKING AND VERIFICATION OF LENGTH OF CONDUCTORS: The supplier/manufacturer of conductor should arrange for the inspection by the representative of the purchaser specially authorized for this purpose. Atleast 5% of the total number of drums of conductors taken at random should be checked to ascertain the length of conductor adopting the following method. the drum with the AAA conductor shall be weighed, four or five empty reels normally used for winding the AAAC shall also be weighed. Net weight of the AAAC shall be calculated by subtracting average weight of the empty reel from the Gross weight of the drum containing AAAC. Having known the weight of the AAA Conductor and other parameters of the conductor its length can be computed.
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ALTERNATIVELY Transfer the AAAC from one reel to the other while at the same time measuring the AAAC so transferred by means of a meter. Arrangements should be made available in the works of the manufacturer for transferring the conductor from one reel to another at the same time measuring the length of conductor so transferred by means of a meter. GUARANTEED TECHNICAL PARTICULARS:The Bidder shall furnish the guaranteed technical particulars as per Appendix III enclosed and submit the same with his tender.
WARRANTY: The general terms and conditions the warranty clause applicable to conductor of this specification is as follows. The period of warranty will be 5 years (five years) from the date of commissioning. EPDCL reserves the right to claim the financial loss incurred / suffered due to the failure of conductor during the guarantee period. APPENDIX I SIZE AND PROPERTIES OF ALUMINIUM ALLOY WIRES USED IN THE CONSTRUCTION OF STRANDED ALL ALUMINIUM ALLOY CONDUCTOR Diameter Nominal Size Mm 1 Mm 2.00 2.50 3.15 4.26 Min. mm 2 mm 1.98 2.47 3.12 4.22 Max. mm 3 mm 2.02 2.53 3.18 4.30 Cross Sectional Mass area of Nominal Kg./ km diameter 4 5 Sq.mm Kg./Km. KN 3.142 4.909 7.793 14.25 8.482 13.25 21.04 38.48 Minimum breaking load after stranding 6 Resistanc e at 20 deg.C Maximu m 7 ohm/KM 10.653 6.790 4.290 2.345
Standard 8 Ohm/KM 10.344 6.620 4.170 2.280
0.92 1.44 2.29 4.18
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APPENDIX II PROPERTIES OF ALUMINIUM ALLOY STRANDED CONDUCTORS Nominal Aluminiu m area 1 Sq.mm 100 55 34 22 Stranding Sectional and wire area dia 2 Mm 7/4.26 7/3.15 7/2.50 7/2.00 3 Sq.mm 99.77 54.55 34.36 21.99 Approxim Approxim ate over all ate Mass dia 4 Mm 12.78 9.45 7.50 6.16 5 Kg./KM 272.86 149.20 94.00 60.16 Calculated resistance at 20 deg.C standard 6 Ohm/KM 0.3390 0.6210 0.9900 1.541 Approximate calculated breading load 7 KN 29.26 16.03. 10.11 6.45
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GUARANTEED TECHNICAL PARTICULARS FOR ALL ALUMINIUM ALLOY CONDUCTORS S.No. 1. 100 Sq.mm Makers Name and Address Aluminium alloy rods Complete Alloy Strand Stranding and diameter of Aluminium Alloy Strand Approx. Overall diameter of conductor in mm Standard nominal Aluminium Alloy area in Sq.mm Calculated Aluminium Alloy area in Sq.mm Minimum ultimate tensile strength of Aluminium alloy wire strand in Kg Guaranteed ultimate tensile strength of conductor in Kg Minimum breaking load in Kg For Aluminium Alloy Strand Aluminium Alloy conductor Maximum working tension of conductor Apprx. Weight in kg per KM of Aluminium Alloy conductor Resistance in Ohm per KM at 20 Deg. C Continuous maximum current rating of conductor in still air at 45 deg. C ambient temperature Temperature rise for the above current(Deg.C) Modulus of Elasticity of Aluminium Alloy conductor (Kg./Sq.mm) Co-efficient of linear expansion per degree centigrade for Aluminium Alloy Strand Alloy conductor Standard length of each piece in KM Approx. Dimension of the reel in Cms Gross weight of the reel including weight of the conductor Kg (with tolarance of +10%) Standard according to which the conductor will be manufactured and tested Other particulars 55 Sq.mm
: HINDALCO /BALCO : M/s Arrow Cables Ltd., : 7/4.26 mm 7/3.15 mm : 12.78 : 100 : 99.77 : 30 : 31.30 : : : : 4.40 29.26 746 272.86 9.45 55 54.55 30 32.70 2.41 16.03 409 149.20
2. 3 4. 5 6. 7. 8. 9. 10. 11. 12.
: 0.339 0.6210 : As per IS 398 (Part-IV) 1994 : As per IS 398 (Part-IV) 1994 : 0.6324 x 106 0.6324 x 106
13 14
15. 16. 17 18 19.
: : : : :
23.0 x 10-6 23.0 x 10-6 1.2 +/-5% 1200x520x485 755
23.0 x 10-6 23.0 x 10-6 1.8 +/-5% 1200x520x485 700
: IS: 398 (Part IV) 1994 : ---
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TECHNICAL SPECIFICATION FOR 33 KV & 11 KV LINES

ERECTION OF 33 KV LINE OVER 9.1Mtr./280 Kg WL PSCC POLES & ERECTION OF 11KV LINE OVER 8.0Mtr./200 Kg WL PSCC POLES
1.0 SCOPE: The works of erection of 33KV and 11KV lines is on partial turnkey basis. The 33KV line is to be erected on 9.1Mtr./280Kg PSCC poles with 100Sqmm AAA conductor at an average span of 65Mtrs. The 11KV line is to be erected on 8.0Mtr./200 Kg PSCC poles with 55Sqmm AAA conductor at an average span of 65Mtrs. The scope covers the survey of the proposed route, tree clearance wherever necessary, transport of material to the locations, erection of the line, testing of the line and handing over to the A.P.E.P.D.C.L. as per specification. Materials such as steel, cement, PSCC poles, top, cleats, clamps, washers, earth-wires. H.B.G. metal, sand, water, cost of bolts and nuts etc., as given in Annexure-1 (A) are to be procured by the contractor cost of which shall be included in the bid. 2.0 GENERAL: The contractor should be well acquainted with the I.E. Rules 1956 as amended from time to time and with the Indian Telegraph Act 1889 so that the necessary provisions therein may be followed. 3.0 SURVEY OF THE ROUTE: The tentative route map of the line to be erected will be furnished by the APEPDCL to he contractor along with the copy of the concluded agreement. The contractor is required to carry out the detailed survey of the route of the line and fix up the locations at the average span indicated in the schedule and mark the locations and submit a detailed route map to the Engineer in charge of the work within 30 days for approval. In the course of surveying by the contractor, any conspicuous variations in the change and physical feature to those indicated in route map and as actually existing as noticed, the deviations must be brought to the notice of the APEPDCLs Engineer. The APEPDCLs Engineer if considered necessary shall make alterations to the route map and communicate the same to the contractor in writing. As such alterations shall be carried out accordingly and the APEPDCLs Engineer, after inspecting the surveyed route and the revised route map shall be given for final approval by the Engineer in charge in writing to the contractor. 4.0 WAY LEAVES AND TREE CUTTINGS: The contractor shall submit proposals for way leaves and right of way. Permission will be obtained by the APEPDCL within reasonable time for the contractor shall give which due notices. The contractor shall arrange for tree cuttings or tree branches cutting also. The width of tree clearance to be adopted for the lines of various voltages is as detailed below: 11 KV line (Normal Line):
All growth within 4.572 M (15ft) on either side from center line of support and all trees that may fall and foul the line. In the case of beetle leaf garden all growth within 3.048 Meters (10ft.) on either side of the line. 11/33 KV (trunk lines): All growth within 6.096 M (20ft) from the centre line of support and all trees which may fail and foul the line. The contractor shall take all possible steps to see that standing crops etc., are not damaged while attending to tree cutting. When such damage is inevitable the compensation will be borne by the APEPDCL provided the damage is with the prior concurrence of the Engineer. The contractor shall bear the compensation for damage caused by the gangs without prior concurrence of the Engineer concerned. trees shall be cut until APEPDCL has made necessary arrangement with the authorities concerned and permission is given to the contractor to fell such tree. The contractor shall arrange to remove the obstacles as soon as possible.
No
At time however, it may not possible for the APEPDCL to arrange right-of-way for excavation of pole pits or erecting the poles of stringing the line. At all such times, the contractor shall shift his gangs to other areas. The rates quoted shall cover all such contingencies and no extra payments shall be claimed for such contingencies. 5.0 EXCAVATION OF POLE /STAY/STRUT/ DP PITS: After the final survey of the line and after marking the pole locations with pegs, excavation work has to be commenced in accordance to the approved route map. Excavation is generally done by pick axes, crow V-bars and showers although some times earth augers are used. Excavation of pole pits in very hard or rocky soil or in rock beds may involve blasting of rock by suitable explosives. The pits for the supports are excavated in the direction of the line as this will facilitate the erection of support, in addition to giving greater lateral stability, the depth of the foundation to be excavated for pole shall be in accordance with relevant sketch for the erection of pole or strut or D.P etc. Excavation rates for poles, struts and D.P. pits shall be quoted by the contractor for the following types of soil including dewatering of pits and shoring and shuttering wherever necessary. No quotation for extra rate for dewatering during excavation and shoring and shuttering will be entertained. All Soils other than hard rock: Hard rock: Hard Rock will be that which requires drilling and blasting by any method. The cost of drilling and blasting shall be included in the quoted rates. In certain cases, when the area around the location happens to be an inhabited area consequent to which blasting cannot be restored to, the excavation may have, to be dug with or by the process of drilling wedging, hammering and splitting or by the process of heating and splitting by sudden cooling. The rate quoted shall take into consideration such contingencies also. Whenever blasting is resorted to, the contractor shall make
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adequate arrangements of safety precautions. The A.P.E.P.D.C.L. will not be responsible for any damages or accidents arising out of process of blasting. Note: For soils other than hard-rock excavation rate to be quoted shall include back filling the pits with excavated soils after concreting wherever necessary. For soils covered by hard rock variety, the excavation rate shall be including back filling with excavated rock bits and borrowed earth duly reamed after laying the designed rock foundation. No extra charges shall admissible for the removal of the fallen earth in the pit, when once excavated. The quoted rates should cover all contingencies during the process of excavation. For any reasons what so ever, no extra claim will be accepted. 6.0 FOUNDATION: Classification of Foundation: Depending on the type of soils, the subsoil water table and the presence of surface water, four types of foundation designs will be used for each locations classified in the following manner. 1) Wet type: To be used for locations: Where sub-soil waters is wet at 1.5 meters or more below the ground level. Which are in surface water for long period with water generation not exceeding one meter below the ground level e.g. the paddy fields. 2) In black cotton soils. a) Partially submerged type: To be used at locations where sub-soils water table is met at more than 0.75 meters from the ground level. b) Fully submerged type: To be used at locations where sub-soil waters is met at less than 0.75 meters from the ground level. 3) Rocky type: To be used at location where hard rock is met with and where the bond strength between the rock and the concrete will be very high. 7.0 ERECTION OF SUPPORTS 8.0Mtr poles as struts are to be used mostly and wherever required stays also can be used. After the excavation of pits is completed the supports to be erected may be brought to the pit location. Then the pole may be erected inside the pit. Wooden support may be utilized to facilitate lifting of the pole at the pit locations.
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Before the pole is put into the pit, RCC padding may be laid below the pole to increase the surface contact between the pole and the soil. The padding will distribute the density of the pressure due to weight of the pole on the soil. Having lifted the pole, the same should be kept in a vertical position with the help of manila rope of 25 mm dia. using the rope as a temporary anchor. As the poles are being erected say from the pole already erected to the next location where the pole is being erected the alignment of the poles are to be checked and set right by visual check. The verticality of the poles is to be checked with a spirit level on both transverse and longitudinal directions. Having satisfied that the verticality and alignment are all right earth filling or concreting is to be done. In swampy and special locations, however, before earth filling, the poles are to be concreted up-to ground level of the pit. After the poles have been set the temporary anchors are to be removed. The supports shall be buried to a depth as per sketch enclosed.
8.0 ERECTION D.P STRUCTURES FOR ANGLE LOCATIONS (11 KV/ 33KV LINES):
8ft(2440mm)/5ft(1500mm) line DPs for 33/11KV respectively are to be erected one for each Km and AB switch on the DP are to be erected at angle points. One AB switch to be erected at every 3 or 4 KM and depending on angle point as per field conditions and as per the direction of the engineer. Generally, for angles of deviation more than 200 double pole structures of spacing 8ft may be erected. The pits are to be excavated as per the bisection of the angle of deviation. After the poles of DP are erected, the horizontal/cross bracings should be fitted and the supports held in a vertical position with the help of temporary guys of manila rope at least 25 mm dia. Ensuring that the poles are held in a vertical position (this can be checked with a spirit level) the concreting of the poles with cement, granite chips of size 20/30 mm mesh and sand in the ratio M400 conforming to ISS is to be done from the bottom of the support to the ground level. Before lifting the pole in the pit, concrete padding of not less than 75 mm thickness may be put for the distribution of the load of the support on the soil. After the concreting is done, the pit may be filled with earth after the curing of the concrete is completed. Four stays/ or 2 struts & 2 stays along the line, two in each direction and two stay/struts along the bisection of the angle of deviation, are to be provided. Stay/Strut concreting may be done with M 400 mixture. The D. P. shall be erected as per the sketch enclosed.
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9.0
ANCHORING AND PROVIDING GUYS FOR SUPPORTS: Guys are to be provided to the supports at the following places (I) Angle locations, (ii) Dead and locations, (iii) Tee-off points, (iv) Steep gradient locations to avoid uplift on the poles. The installation of guy will involve the following works: Excavation of pit and fixing of stay rod. Fastening guy wire to the support. Tightening guy wire and fastening to the anchor. The marking of the guy pit for excavation, the excavation of pits and setting of the anchor rod must be carefully carried out. The stay rod should be placed in the position such that the angle of inclination of the rod with the vertical face of the pit is as the case may be. The concreting of the stay at the bottom should then be carried out. The back filling and ramming must be well done thereafter, and allowed to set for at least 7 days. The free end of the guy wire is passed through the eye of the anchor rod, bent back parallel to the main portion of the guy and bound after inserting the G.I. thimble. The G.I. thimble protects the loop where it hears on the anchor rod. Where the existence of guy wire proves hazardous, it should be protected with suitable asbestos pipe, filled with concrete, of about 2Mtrs. length above the ground level, duly painted with white and black stripes so that it may be visible at night. The turn buckle shall be mounted at the pole end of the stay and guy wire so fixed that the eye bolt turn buckle is half way in the working position thus giving the maximum movement for tightening or loosening. Guy insulators are placed to prevent the lower part of the guy from becoming electrically energized by a contact of the guy when the conductors snap and fall on them or due to leakage. No guy insulator shall be located less than 2.6Mtrs. from the ground. The anchoring and providing guys for supports (Single guy Bow guy an fly guy) shall be done as per sketch 3 enclosed. Bow guy and fly guy shall have to be provided as per the field conditions.
10.0
FIXING OF CROSS ARMS AND INSULATORS After the erection of supports and providing guys, the next step would be mount the cross arms on the support. The cross arm is to be mounted after the support is erected. The lineman should climb the support having requisite tools with him and the cross arm is then tied to a hand line and pulled up by the ground man, through a pulley till the cross arm reaches the linemen. The ground man should station himself well to one side so that if any material drops from the top of the pole it may not strike him. All the materials required should be lifted or lowered by means of the hand line. In no case, the material or the tools should be dropped or thrown from the pole top. The fixing of 33 KV and 11 KV cross arms shall be in accordance to spacing detailed in Sketch G.I. bolts and nuts and spring washers of good quality only shall be used which have to be procured by the contractor. Back Clamps:
10.1
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10.2
The back clamps for fixing of the V cross arms will have to be procured by the contractor and shall be in accordance with sketch enclosed and the clamp shall be fabricated with 75 X 8mm M.S.Flat for 33 KV and 50 X 6 mm M.S Flat for11 KV. Top Cleats: The top cleat shall be got fabricated with M.S. channel of 100x50mm and MS angle of 65x65x6mm for 33 KV and 11KV respectively shall be in accordance with sketches enclosed.
11. INSULATORS The pins for insulators shall be fixed in the holes provided in the cross arms and the pole top brackets. The insulators shall be mounted in their places over the pins and tightened. In the case of strain or angle supports, where strain fittings are provided for this purpose, on strap of the strain fittings is placed over the cross arm before placing the bolts in the hole of the cross arms. The nut of straps is so tightened that the strap can move freely in horizontal direction, as this is necessary to fix the strain insulator. Note: The insulators shall be cleaned and examined for defects before fixing. It shall be ensured that all the current carrying parts are smooth and without dirt, cracks or chips. 12.0 STRINGING OF THE LINE CONDUCTORS: For the guidance of the contractor in handling the conductor and in stringing certain Dos and Donts are given below, before the workmen actually commence the stringing work. 12.1 Dos and Donts Dos: -Use proper equipment for handling aluminum conductors at all times. -Use skids, or similar method for lowering reels or coils from transport or ground. -Examine reel before unreeling for presence of nails or any other object, which might damage the conductor. -Rotate the reel or coil while unwinding conductor. -Grip all strands while pulling out the conductor. -Control the unreeling speed with a suitable braking arrangement. -Use wooden guards of suitable braking arrangement. -Use long straight, parallel jaw grip with suitable liners when pulling conductor thus avoiding nicking or kinking of the conductor. -Use free-running sleeves or blocks with adequate grooves for drawing/paving conductors. -Use proper sag charts. -Mark conductors with crayons or adhesive tape of such (other) material which will not damage the strand. -Make all splicing with the proper tools. -Use a twisting wrench for twisting the joints. -Chromate or graphite conducting oxide-inhibiting grease should be applied before cleaning with wire brush. Donts: -Do not handle conductors without proper tools at any stage. -Do not pull conductors without ensuring that there is no obstruction on the ground. -Do not pull out excess quantity of conductor than required.
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12.2
-Do not make jumper connections on dirty or weathered conductor. Clean the conductor using sand paper or wire brush. -Do not handle aluminum conductors in a rough fashion but handle it with care it deserves. Conductor Erections: -The erection of overhead line conductor is a very important phase in construction. -The erection of conductors can be sub-divided into 4 separate parts as follows: -Transport of conductors to work site. -Paving and stringing of conductors. -Tensioning and sagging of conductors. -Jointing of conductors. At important crossing of roads, canals, navigable rivers, railways etc., flagmen should be in attendance to ensure that normal services are not unduly interrupted. These crossings should only be carried out in conjunction with and with the approval of the proper authorities concerned. The conductor drums shall be transported to the tension point without injuring the conductor. If, it is necessary to roll the drum on the ground for a small distance, it should be slowly rolled in the direction of the arrow marked on the drum. The drum should be so supported that it can be rotated freely. For this purpose the drum should either be mounted on the cable drum supports or jacks or hung by means of chain pulley of suitable capacity, suspended from a tripod. In case if it is not possible to raise the conductor drum by any of the above methods, a trench of suitable depth slightly bigger than the conductor drum may be dug, so as to facilitate free rotations of the drum when it is suspended in the trench by means of M.S. Shaft. While paving, care should be taken to see that conductor does not rub against any metallic fitting of the pole or on the bad/rocky ground. Wooden tussles should be used for this purpose to support the conductor. The conductor should be passed over the poles on wooden or aluminum snatch pulley blocks provided with low friction bearings. While conductor is being paved out slowly, some braking arrangements should be made so that the rotation of the drum may be stopped in emergency. In case the length of one piece of the conductor is less than the length of the section in which conductor paving is being done, it is easy to stretch one length of all phases from one end and the remaining length from another end of the section and thereafter jointing the two ends of the conductor where they meet on no account any part of the conductor shall be left at a height of less than 5 meters. Above the ground over night and the work shall be so arranged that before the end of the day, the conductor shall be raised to minimum height of 5 meters above the ground by rough sagging.
12.3
Mid Span Jointing of Conductors The mid span jointing of conductors should be carried out by using 2Nos. aluminum ferrules of required size, one inner and one outer ferrule and the crimping of the ferrules is to be done by using proper crimping tools. Aluminum tape is to be wound over the conductor before insertion into the ferrules to have better grip.
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12.4
Sagging and Tensioning On the completion of the paving of the conductors and making mid-span joints if any, tensioning operations will commence. Temporary stays will have to be provided for both the anchoring supports in the section where the stringing has to be done. At the tensioning end, one of the conductors is pulled manually up to a certain point and then come along clamp is fixed to the conductor to be tensioned. The grip to the come along clamp is attached to double sleeve pulley block or the pulley lift machine and gradually tensioned. The conductor should then be sagged in accordance with the sag-temperature chart for the particular conductor and span. The sag should then be adjusted in the middle span of the section. The Engineer will provide the sag chart. The stretch of the conductor has to be taken out before stringing in order to avoid the gradual increase in sag due to the setting down of the individual wires. There are ways of accomplishing this.
12.5
Pre Stressing: In this method the conductor is pulled up to a tension considerably above the correct figure, but never exceeding fifty percent of breaking load for a short period of say twenty minutes. As this method requires more time and involves the use of stronger tackle to secure the higher tension the other method of over-tensioning is commonly adopted.
12.6
Over tensioning: This method consists of pulling up the conductor to a tension a little above the theoretical tension for the prevailing temperature and fixed it up at that tension with correspondingly reduced sag. After a certain time the conductor will settle down to the correct sag and tension. A tension of five to eight percent more than the theoretical value has been found to be suitable for the sizes of ACSR and AAAC conductors standardized by REC. The ambient temperature during sagging may be recorded correctly. Conductors can be sagged correctly only when the tension is the same in each span through out the entire length of the section. Use of snatch blocks reduces the friction and chances of inequality of tension in various spans. Sagging can be accomplished by several different methods but most commonly used method is sighting. The sighting sag method of measuring sag is by the use of targets placed on the supports below the cross arms. The targets may be light strip of wood clamped to the pole at a distance equal to the sag below the conductor when the conductor is placed in snatch block. The lineman sees the sag from the next pole. The tension of the conductor is then reduced or increased, until, the lowest part of the conductor in the span coincides with the linemans line of sight. When sagging is completed, the tension clamps shall be fixed. The clamp can be fitted on the conductor without releasing the tension. A mark is made on the conductor at a
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distance from the cross arms equal to the length of complete strain insulator. Before the insulator sets is raised to position, all nuts should be free. Come along clamp is placed on the conductor beyond the conductor clamp and attached to the pulling unit. The conductor is pulled insufficiently to allow the insulator assembly to be fitted to the clamp. After the conductor is clamped to insulator, assembly unit may be released gradually. If the tension is released with a jerk, an abnormal stress may be transferred to conductor and support, which may result in the failure of the cross arms, stay or pole in some cases. After the stringing is completed, all poles, cross arms, insulators, fitting etc., are checked up to ensure that there have been no deformities etc. The next step is to place the conductor on the top of the pin insulator from the snatch block and removing snatch blocks. Conductors are then fastened to insulator by the use of aluminum wires. The following points should be observed: The length of tie wire should be sufficiently long for making complete tie including the end allowance for gripping with the ends. A good tie should provide a secure binding between the line conductor and insulator and should reinforce the conductor on either side of the insulator. The use of cutting pliers for binding the site wire should be avoided. The tie wire, which has been used, previously should not be re-used. Before tieing the conductor to the insulator two layers of aluminum tape should be wrapped over the conductor in the portion where it touches the insulator. The width and thickness of aluminum tape to be used for a specific size of conductors has been specified in handbooks of aluminum conductor manufactures and the same may be preferred to. The aluminum tapes should also be used at the tension clamp and for proper grip. Normally in straight runs of line, the conductors are run on the top of insulators, when there is small angle of deviation the conductor is placed inside groove and binded. Accordingly, there are two methods of tieing the conductors to insulators. The binding wire/tie wire has to be procured by the contractor and the bid price shall include the cost of this. The contractor shall entirely responsible for any damage to the supports, other accessories and conductor. He shall also be responsible for proper distribution of the conductor drums to keep number and lengths of cut pieces of the conductor to a minimum. 12.7 Conductor damage and repair: If the conductor is damaged for whatever reasons and damage is not repaired aluminum sleeves etc., it shall be brought to the notice of the Engineer and shall not be used without his approval. Even repairing of conductor surfaces shall be done only in case of minor damages, scuff marks etc. which are safe from both electrical and mechanical points of view. The final conductor surface shall be clean, smooth, without any
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projections, sharp points, cut or abrasion etc., giving satisfactory corona and R.I performance. No joint or splice be made in spans crossing over main roads, railways, small rivers or in tension spans. Not more than one joint per conductor shall be allowed in one span. The strength of the joint shall confirm to I.E rule 75. 12.8 Stringing rate: The stringing rate for stringing of the conductor per route length of line shall include paving, stringing, clamping, jointing, tensioning, strain disc binding, clamping and fitting of all necessary accessories. Wherever necessary ground clearance have to be measured to ensure obtaining adequate line clearance as per I.E. rule 77 (I). 12.9 Jumpering : The jumpering at all locations where it is required i.e. cut points and tapping points etc. Should be done by using aluminum T-Clamps of suitable size required for the conductor, and using aluminum tape over the conductor at the T-clamp location to have a better grip. The bolts of the T-clamps should be tightened to the required torque to prevent any loose contacts at the jumper locations. 13.0 13.1 EARTHING Pipe Earthing At D.P. Location pits are to be excavated, the steel and metal parts are to be earthed by pipe earthling as per the drawing of sketch enclosed to this specification. Duly filling the pits with bentonite compound and black cotton soil (in1:6 ratio) and shall be maintained up-to a distance of 300 mm from the pipe in all sides. The top edge of the pipe shall be at least 200 mm below the ground level. The steel strips shall be fixed not less than 300 mm deep from the ground level. The tenders shall quote the charges for earthing inclusive of the cost of bentonite compound and block cotton soil, excavation and back-filling. Pole Earthing: All supports shall be properly earthed with coil earthing. The earthing of DP structures should be done in the presence of Asst. Divisional Engineer/Construction only. CROSSINGS Guarding shall be erected as per standards and as per sketch a, b, c, enclosed for Railways, telephone lines and power lines. 14.0 EXECUTION OF WORKS RELATING TO POWER LINE CROSSINGS AND RAILWAY CROSSINGS:
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Work such as erection of support underneath an existing power line and paving out of conductors and earth-wire and stringing the power line crossing span or a railway crossing span, will have to be done only after receipt of line clear form APEPDCL authorities and approval from the concerned officer, which some times, may not match with program of the contractor. In such cases, the contractor shall execute such works as and when approvals are received. His rates for line erection and stringing shall take into consideration such contingencies also. 15.0 CONCRETING:
Note: All DP structures, vertical formations, single pole cut points and Angle locations should be concreted. The cement concrete used for the foundation shall be of ratio 1:3:6 using 40mm HBG metal. The sand used for the concrete shall be composed of hard silicon materials and well sieved. It shall be clear and a sharp angular grit type of and free from earthy or organic matter and deleterious salts. The aggregate shall be of clean broken hard granite or other stone specified or approved by the Engineer. It shall be hard, close grained quality. It shall also be as far as possible cube like preferably angular, but not flaky, perfectly clean and free from the earth organic or other deleterious matter, 40 mm aggregate shall be of size as will pass through 40 mm square mesh measured in the clear. The water used for mixing concrete shall be fresh and conform to ISI it should be clean and free from oil, acids and alkali. Saltiest or brackish water should not be used. The concrete should be mixed as stiff as the requirements of placing the concrete in the forms or moulds with as and the degree to which the concrete resists segregation will permit. Hence, the quantity of water used should not be too much. Proper forms of moulds adequately braced to retain proper shape while concreting should be used. The mould should be made watertight so that cement cream will not come out leaving only sand and jelly consequently forming honeycombing in the concrete. The rate for concrete should be made so that the works are not held up on this account. After concerting to the required height, the top surface should be finished smooth, with slight slope towards the outer edge to drain off the rainwater falling on the copings. These copings and muffing should be done after the stringing is completed in respect of tension locations and the Engineer at site may decide such other locations as. For such locations an adhoc reduction of Rs.100/- per location will be made while billing for concrete and this will be released after the coping and muffing are completed. In wet locations, the site must be kept completely dewatered both during the placing of the concrete and for 24 hours after completion. There should be no disturbance of concrete by water during this period. No extra rate will be paid for the dewatering and the rate for concrete shall be inclusive of dewatering charges. The forms of moulds shall not be removed before a lapse of about 24 hours after the completion of concreting. After removal of the form moulds, the concreted surface,
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wherever required, shall be repaired with a rich cement and sand motor in the shortest possible time. The full concreting for the poles if erected in excavated pit shall be done so that the complete block will be of the dimensions 0.6X0.6X1.5Mts up to ground level including base concreting of 75mm thick with 1:3:6 CC mix. If augur is used for making pole pits, ramming shall be done after erection of pole. 16. WORKMANSHIP The contractor shall entirely be responsible for the correct erection of all support as per the approved drawings, and their correct setting and alignment, as approved by the Engineer. If the supports and D. P. structures after the erection are found to differ from approved route maps and drawings or to be out of alignment, the contractor shall dismantle and re-erect them correctly at his own cost without extension of time. The supports must be truly vertical and in plumb after erection and so straining will be permitted to bring them to vertical position. Verticality of each support shall be measured by the contractor and furnished to the Engineer. 17. Location numbers for each pole shall be painted on the pole. Anti-climbing devices, and danger boards are to be provided at all railway crossings and road crossings and DP locations. No extra charges shall be admissible even though separate gangs may have to be sent by the contractor for fitting these accessories and attachments on the support at the appropriate time. 18. FINAL CHECKING, TESTING AND COMMISSIONING After the completion of the works final patrolling and checking of the line shall be done by the contractor to ensure that all the foundation works, pole erection and stringing have been done as approved by the Engineer, and also to ensure that they are complete in all respects. Contractor shall prepare pole schedules and hand it over to the Engineer. All works shall be thoroughly inspected keeping in view of the following main points. i) ii) iii) iv) v) vi) vii) Sufficient back filled earth is lying over each foundation pit and it is adequately compacted. Concreting and coping of poles are in good and finally shaped conditions. All the accessories and insulators are strictly as per the drawings and are free from any defects or damages, what so ever. All the bolts and nuts should be hot dip G.I. material and as per contractual provisions. The stringing of the conductor has been done as per the approved sag and desired clearances are available. No damage, minor or major to the conductor, earth wire, accessories and insulator strings will unattended are noticed. For all points double jumpers shall be provided to each phase. The jumpers provided at the cut points are connected rigidly to the tension hardware utilizing all the jointing bolts provided for the purpose.
The contractor shall submit a report to the above effect to the Engineer. In case, it is noticed later that some or any of the above are not fulfilled the engineer will get such items rectified through other agencies and recover the cost of such works from the bills
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payable to the contractor against that contract or any other contract executed by him for the APEPDCL After final checking, the lines shall be tested for insulation in accordance with tests prescribed by the Engineer. All arrangements for such testing or any other test desired by the Engineer, shall be done by the contractor and necessary labour, transport and testing equipment shall be provided by him. The contractor defects found out as a result of such tests, shall rectify any, forthwith, without any extra charges to the APEPDCL In addition to the above, the contractor shall be responsible for testing and ensuring that the total and relative sags of the conductors are within the specified tolerance. Such tests shall be carried out at selected points along the route as required by the Engineer and the contractor shall provide all necessary equipment and labour to enable the test to be carried out. After satisfactory tests on the line and approval by the Engineer the line shall be energized at full operating voltage before handling over. 19. Supply of materials by the contractor: The contractor has to make his own arrangements for procurement, supply and use of materials and compliance of the following should be ensured. These materials should conform to the relevant Indian Standard specification. These materials shall be supplied at least one month in advance of their requirement manufactures test certificate for these materials shall be submitted and got approved by Engineer before utilization. He shall guarantee the materials so supplied by the contractor for satisfactory performance up to the end of the maintenance and defects liability period. All materials to be supplied should fully conform to provisions under clause 3 of Instructions to Bidders. In procurement of these items the contractor shall follow all regulations of the APEPDCL/Government of India in respect of import license etc., if he chooses to procure these from imports. Further, the contractor shall be responsible for the payment of applicable duties and taxes, port clearance inland transportation etc. The materials for which advance is given by APEPDCL is to be insured by the contractor at his cost from the date of payment of advance to the date stated in the certificate of completion for the whole of the works. Material & Quality: All the material used in the works shall be of the best quality of their respective kinds as specified herein. They shall be obtained from sources and suppliers approved by the Engineer or his representatives, and shall comply strictly with the tests, specified herein after or, where tests are not specified in this specification, they should conform to the requirements of the latest issue of the relevant Indian standards herein after abbreviated to as (I.S.) or other approved National Standards authorized by the Engineer. The contractor has got the obligation of showing the proof of source of any material procured by him, to the APEPDCL on demand.
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Inspection and Testing: Any materials used in the works shall be subject to inspection and tests if required by the Engineer. Unless otherwise stated, the costs of all tests required by this specification shall be deemed to be included in the rates and prices named by the contractor in the bill (schedule) of quantities. Any material, which is prepared or manufactured without notice having been given in writing to the Engineer, may be rejected if the Engineer considers that his inspection was necessary during the process of manufacture of such material. Approvals: No material shall be used in the works unless the Engineer or his representative has first approved it. 20 INFORMATION AND DATA: The information furnished is the best available however, the APEPDCL does not guarantee the correctness or interpretations, deductions or conclusions which are given as supplementary information in the Bid Documents or in any reports, maps, drawings, diagrams or in other reference information available to the bidder from the APEPDCL of or otherwise. The information have been produced as found, communicated to ascertained or otherwise learned by the APEPDCL It will be the Bidders responsibility to satisfy himself from the Reference Information supplied and/or inspection of the site that sufficient quantities of construction materials required for the works shall exists in the designated borrow areas or quarry sites. The APEPDCL does not accept any responsibility either in handing over the quarries or procuring the materials or any other facilities. The Tenders will not be entitled for any extra rate or claim for the misjudgment on his part for the quantity and quality of materials available in the quarries. Failure by the Bidder to have done all the timings, which is in accordance with this condition he is deemed to have done, shall not relieve the successful Bidder of the responsibility for satisfactorily completing the works as required at the rates quoted by him. 21 CONSTRUCTION MATERIALS Cement: The contractor has to make his own arrangements for the procurement of cement to required specifications required for the works subjected to the followings: The contractor shall procure cement, required for the works only from reputed cement factories (Main producer) acceptable to the Engineer in-Charge. The contractor shall be required to furnish to the Engineer in-Charge bills of payment and test certificates issued by the manufactures to authenticate procurement of quality cement from the approved cement factory. The contractor shall make his own arrangement for adequate storage of cement.
a)
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b)
The contractor shall procure cement in standard packing of all 50Kg per bag from the authorized manufacturers. The contractor shall make necessary arrangement at his own cost to the satisfaction of Engineer-in-Charge for actual weighment of random sample from the available stock and shall conform with the specification laid down by the Indian Standard Institution or other standard foreign institutions as the case may be, Cement shall be got tested for all the tests as directed by Engineer-in-Charge at-least one month in advance before the use of cement bags brought and kept in site Godown. The Contractor free of cost shall supply cement bags required for testing. However, the testing charges for cement will be borne by the APEPDCL. If the tests prove unsatisfactory, then the charges will be borne by the Contractor.
c)
The Contractor should store the cement of 60 days requirement at least one month in advance to ensure the quality of cement so brought to site and shall not remove the same without the written permission of the Engineer-in-Charge. The Contractor shall forthwith remove from the works area any cement that the Engineer-in-Charge may disallow for use, on account of failure to meet with required quality and standard. The contractor shall further, at all times satisfy the Engineer-in-charge on demand, by production of records and books or by submission of returns and other proofs as directed, that the cement is being used as tested and approved by Engineer-in-charge for the purpose and the Contractor shall at all times, keep his records up to date enable the Engineer-in-charge to apply such checks as he may desire. Cement which has been unduly long in storage with the Contractor or alternatively has deteriorated due to in adequate storage and thus become unfit for use in the works will be rejected by the department and no claim will be entertained. The Contractor shall forthwith remove from the work area, any cement the Engineer-in-charge may disallow for use on work and replace it by cement complying with the relevant Indian Standards.
21.2
STEEL:
The Contractor shall procure mild steel reinforcement bars, high yield strength deformed (HYSD) bars, rods and structural steel etc., required for the works, only from the main or secondary producers manufacturing steel to the prescribed specifications of Bureau of Indian Standard or equivalent and licensed to affix ISI or other equivalent certifications marks and acceptable to the Engineer-in-Charge. Necessary ISI list certificates are to be produced to Engineer-in-Charge before use on works. The unit weight and dimensions shall be as prescribed in the relevant Indian standard specifications of steel. Note: The Contractor has to follow R.E.C. standard for the works wherever it is not specifically mentioned above.
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CONSTRUCTION STANDARDS FOR ERECTION OF 33/11KV SUBSTATION WORKS

1.0 Scope The scope of the specification covers the following Cleaning the site Civil works in the switchyard Construction of control house Erection of structures, Bus bars, equipment etc Electrification of control house. Testing of the equipment and handing over of the substation to the Employer (APEPDCL) as per specification. General The Contractor should be conversant with Indian Electricity Rules 1956 as amended from time to time. Site work: All works to be carried out in a workman like manner to minimize interference to others. In particular excavations must be guarded. Adequate precautions must be taken to prevent damage or injury to persons and live stock. No dogs or other animals shall be brought on or near to the site. Materials must be tidily stored. All waste material must be removed from site by the end of the working day. The Contractor is responsible for piping or channeling all pumped water from excavations to the nearest ditch, to avoid damage to neighboring land and they will be held responsible for the cleaning out the ditch should this become silted up due to pumping operations.
2.0
Animals: Storage: Pumping:
Public Relations: Particular attention should be paid by the Contractor and his workmen to maintain public relations. 3.0 Definitions: Contractor: Defect:: Employer: Equipment: Engineer: Materials: The Contractor is a person or corporate body whose bid to carry out the works has been accepted by the Employer. A defect is any part of the works not completed in accordance with the contract. The Employer (APEPDCL) is the party who will employ the contractor to carry out the works. Equipment is the Contractors machinery and Vehicles brought temporarily to the site for carrying out the works. The Engineer is a person appointed by the Employer (APEPDCL) who is responsible for supervising the Contractor, administering the Contract. Materials are all supplies, including consumables, used by the Contractor for incorporation in the works.
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Specification Specification means the specification of the works included in the Contract and any modification or addition made or approved by the Engineer. Subcontractor A sub contractor is a person or corporate body who has a contract with the Contractor to carry out a part of the work in the Contract, which includes work on the site. Works: 4.0 The works are what the Contract requires the Contractor to construct, install, and hand over to the Employer as defined in the Contract Data.
Cleaning up the Site: Before commencement of works, the site shall be cleaned and dressed with an approved weed killer. During construction, the Contractor shall keep the work site and storage area used by him free from accumulation of waste materials or rubbish and before completing the works, the Contractor shall at his own cost, remove or dispose off in a manner satisfactory to the Engineer in charge. All holes in the ground shall be filled in and the land restored to its original state and the entire premises should be kept in a neat and tidy condition of cleanliness as the Engineer may direct. Any damage done to the APEPDCL by the Contractor or his Sub-Contractor shall be made good at Contractors expense.
5.0
Civil works in Switchyard a) Excavations for i) Foundations ii) Retaining wall iii) Leveling iv) Cable laying, Earthing b) Cement concrete foundations for structures, transformers, Bolt type foundations for other equipment such as VCBs etc c) Leveling of substation site with borrowed gravel as per para 15 of the specification. d) Peripheral fencing and security fencing as per para 18 and 29 e) Construction of cable ducts as per para 17 f) Formation of roads as per para 28. Control House: The work involves providing foundations, plinth beam, columns and beams for super structure, laying R.C.C slab, providing brick work for walls, providing doors and windows, Flooring with polished stone, painting, providing water supply, sanitary arrangements etc.
6.0
7.0
Electrification of Control House: The work involves electrification of control room. The contractor shall design the illumination details for the control room and furnish to the Engineer for approval. The illumination level to be maintained shall conform to IS : 3646 (Part II)-1966, as mentioned below.
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3 pins sockets required for general purpose shall be provided with the approval of Engineer. Limi Average Sl. ting Particulars illumination No. glare level inde Control rooms Vertical control panels 300 19 Rear of control panels 150 19 1. Control Desks 300 19 Switch houses 150 25 Battery room 100 2. Carrier room 300 3. Office room 300 19 4. 5. 6. 7. 8. 8.0 Store room D.G. Set room Corridors Bath Room 100 150 70 100 16 -
Type of substation Construction For standard substation layouts as per the drawings enclosed the structures will be of 150x150mm H type Beams. The foundations of structures are 150 mm thick cement concrete with M150 grade at the bottom and mass concrete as per the approved drawings. Crosspieces are 100x50x6.4 mm M.S.Channel. All the bolts, nuts and washers etc. used in erection of 33/11KV substation should be hot dip galvanized conforming to IS: 2629 and IS: 2633. For non-standard layouts, structural design drawings with detailed design calculations are to be furnished by the contractor for the approval of Engineer. 33 KV & 11 KV buses in respective bays are strung type with 200Sqmm Panther AAAC/ACSR. A control house to be constructed as per the approved drawings at location shown by the Engineer.
9.0 10.0
Site Layout: A copy of the substation site layout will be furnished to the Contractor to have an idea of the quantum of work involved. Execution of Civil Works: Para 11.1 to 15.10 mentioned below are applicable to all civil works under the specifications including control house.
10.1
Excavation: This clause covers excavations to be done for all the civil works such as laying foundations for structures, equipment, retaining wall, buildings (control room) cable trenches etc. The rate quoted is applicable for all types of soils including hard rock.
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Blasting shall not be permitted with in the substation site. In rocky soils also excavation has to be carried out by using any method other than blasting. The Engineer shall approve the method of excavation. Back filling shall be done with approved back fill material. The Contractor shall provide a method statement detailing the proposal method of back filling for approval by the Engineer. 10.2 Filling Foundations and Basement Backfilling of foundations is to be done with river sand. Back filling includes watering and consolidating 150mm layers for all soils. Anti-termite and anti-wood treatment for foundations basement and flooring shall be provided. Precautions: Back fill shall not be dropped directly upon or against any structure or facility where there is danger of displacement or damage. Back fill shall be done in horizontal layers not exceeding 150mm layers, leveled, wetted and rammed properly before another layer is deposited. Trucks, tractors or heavy equipment for depositing or compacting back fill shall not be used with in 1.5 meters of the foundation / structures. While ramming around piping, care should be taken to avoid unequal pressures. Concrete: This clause is applicable for all the civil works under this specification. Rate for concrete shall include cost of shoring, shuttering and de-watering wherever necessary. 11.1 Code of Practice: All concrete and reinforced concrete work shall be carried out in accordance with IS:456, (code of practice for plain and reinforced concrete) and APSS No 402 and 403. 11.2 Concrete Proportion; The concrete shall be of nominal mix as specified in the drawings or in the schedule of quantities. 11.3 Consistency The quantity of water used shall be determined by slump test as per APSS No 402.9.1 and shall be sufficient to produce a dense concrete of adequate workability for the purpose, and will surround and properly grip all the reinforcement. 11.4 Water Potable water free from Chlorides, Sulphur, other salts and organic matter shall be used for mixing concrete grout and mortar and curing. Water used shall be as per APSS No 129. Cement
11.5
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Cement used shall be ordinary or rapid hardening Portland cement conforming to APSS No 112 and IS: 269 with the following properties Initial setting time: Not less than 30 minutes. Final setting time: Not more than 600 minutes Minimum compressive strength of standard Mortar Cube with graded sand as per IS: 650 1966. At 3 days 160 Kg / Cm2 At 7 days 220 Kg / Cm2 11.6 Sand Sand used shall be composed of hard silicon materials and of sharp angular grit. Only river sand free from Calcium Chloride or other Chlorides and Salts, which are likely to promote corrosion of steel, shall be used. Sand shall be screened before use and shall conform to APSS No 110. 11.7 Coarse Aggregate The coarse aggregate used in the concrete shall be machine crushed hard granite metal conforming to IS: 383 1970 (specification for coarse and fine aggregates from natural sources for concrete) and APSS No 108 and size shall be as mentioned in the relevant schedule of quantities and drawings. 11.8 Steel Steel used shall conform to APSS No 126 and APSS No 1101. The cost of reinforcement steel, binding wire and fabrication charges for all the works shall be included in the corresponding item of such schedules. 11.9 Mixing Concrete Mixing of concrete shall conform to APSS No 402. Hand mixing of concrete shall not be permitted. Concrete shall be thoroughly mixed to a uniform consistency in the motor operated mixing machines of approved types. The Contractor shall provide a method statement detailing the proposed method of concrete mixing for approval by the Engineer before commencement of work. 11.10 Samples The Engineer shall be approved samples of all materials to be used in the substation works. The materials used in the work shall be at least equal to the approved samples No material shall be used in the works unless the Engineer or his representative has first approved it. 11.11 Inspections and Testing:
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All materials used in the works shall be subject to inspection and tests if required by the Engineer. The cost of all such tests required by this specification shall be deemed to be included in the rates and prices quoted by the Contractor in the bill (schedule) of quantities. Any material, which is prepared or manufactured without the notice having been given in writing to the Engineer, may be rejected if the Engineer considers that his inspection was necessary during the process of manufacture of such material. 11.13 Concreting in Unsuitable Weather: In the event of rain, storms and other severe weather conditions arising, concreting shall be stopped and appropriate temporary stop ends vee-grooves etc., placed as may be necessary. To meet such circumstances, the contractor shall always have in readiness on the site, approved framed sheeting, tarpaulins etc., for the protection of newly placed concrete. Should any concrete be damaged due to rain, storms or other weather conditions the Engineer may order the cutting out / replacement of the damaged concrete at the expense of the Contractor. Form work: This clause is applicable to form work / centering etc., for all civil works under the specification. Before commencing the work the Contractor shall provide a method statement detailing the proposed method of form work he proposes to use for approval by the Engineer before commencement of work, but such approval shall in no way relieve the Contractor of any of his responsibilities for the sufficiency and efficiency of the work. For the guidance of the Engineer. The formwork shall conform to Clause 10 of IS: 456 and APSS No 403.5 The form work shall be designed and arranged so that it will not settle under the load and can be stripped and removed without causing any blemish or jar to the concrete. All forms shall be securely braced and supported to prevent any sagging or bulging during construction. In no circumstances wire ties shall be used. All forms shall be fixed to the proper line and tightened up immediately before depositing the concrete. All joints shall be close enough to prevent leakage of water from the concrete. Form work for all exposed faces of mass concrete and for all faces of reinforced concrete shall consist of approved material so finished as to produce the concrete surface without honey combing, bulges etc., strutting shall be of such design as to allow accurate adjustment and easy removal. Strutting of formwork against the sides of the structures, which is subject to movement or vibration, will not be permitted.
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The inside faces of the forms shall be treated with mould oil or other approved preparation. The treating material shall not have deteriorating effect on concrete as well as formwork. The treating material shall not come into contact with the reinforcement. 12.1 Removal of Formwork The length of time between concreting and the removal of the form is the sole responsibility of the Contractor. However the Engineer will be competent to fix a minimum length of time. For structure foundations minimum time limit specified is 24 hours for removing formwork from the time of placing concrete. Execution of concrete work Before concreting is commenced all form work shall be scrupulously cleaned and wetted and the Contractor shall adopt all necessary measures to ensure that all debris, dirt, wash water and other refuse is removed. The Engineer will then inspect the reinforcement and formwork and concreting shall not be commenced until the Engineer gives permission. Such inspection shall not however relieve the Contractor from any of his responsibilities for the correctness of the work in every respect. 13.1 Casting Programme The Contractors casting programme shall be such that each section of the work can be satisfactorily completed in one operation after permission has been given to proceed. No claim for overtime working for completing a casting programme will be entertained. 13.2 Conveyance of concrete The concrete shall be conveyed from the mixer to its place in the works as rapidly as possible and in such a manner that there shall be no separation or loss of the ingredients. In no circumstances shall more than half an hour lapse between the time when water is added to the mix and the time when the concrete is finally consolidated in position. The use of concrete distributing chutes at an angle of more than 45 degrees from the horizontal will not be permitted. In no case shall concrete be dropped from a height of more than one and half meters. The arrangements to be adopted by the Contractor for conveying and depositing concrete shall be subject to the approval of the Engineer. 13.3 Depositing concrete Before any concrete is put in, the Contractor shall carry out, filling of pockets or trimming the sides where found necessary to suit the level and line of the concrete to be laid as directed by the Engineer at site. Concrete shall be placed in one operation. 13.4 Consolidating Concrete Concrete shall be consolidated by means of sufficient number of mechanical vibrators. The concrete shall be thoroughly vibrated all round the reinforcement and against shutters so that all enclosed air is duly expelled and the concrete surface when stripped be found to be good and free of the formation of air pockets, honey combing or other defects.
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The concrete shall be worked into position where placed and not allowed to flow. For sloping beams, the work of depositing concrete shall start from the lower end and work upwards. The area on which concrete is to be deposited shall be kept free from standing water. Running water if any shall also be brought under control before concreting is commenced. 13.5 Finish of concrete surface: Soon after the formwork is removed the Contractor shall remove all form marks and other imperfections in order to give uniform appearance. The faces of the concrete work shall be sound and solid, free from honey combing. No Patching of any concrete facing will be allowed without the approval of the Engineer. 13.6 Construction Joints Before depositing any concrete resting or abutting on work, previously carried out, the surfaces and ends of the existing work shall be thoroughly hacked to such an extent that no portion of the previous surface remains. Thus roughened surfaces shall be thoroughly cleaned off, brushed and watered immediately before the succeeding operations are commenced. The roughened surface shall be coated with 1:2 cement sand mortar 12 mm thick, immediately before the concrete of the next layer is placed. 13.7 Curing The curing period shall be for a period of 14 days for switchyard structure foundations below ground level. For other civil works the curing period shall be 21 days. Top and side surfaces of the concrete shall be kept moist and be protected from the direct rays of the sun during the period by covering with Jute bags. Curing shall be done as per APSS No 402.8. 14.0 Reinforced Concrete All the steel used for reinforcement shall conform to APSS No 126. All steel reinforcement before the concrete is deposited shall be clean and free from all loose mill scale, dust and loose rust, and coatings such as paints, cement grout, mould oils etc. Cube samples shall be taken and tested in Laboratory and the results shall be furnished.
14.1
Mixes The mix of concrete shall be 1:2:4 using 20mm machine crushed hard granite metal for slab, beams, column footings, columns, lintels, sunshades and portico. The mix for leveling course shall be 1:4:8 using 40mm machine crushed hard granite metal. The thickness of concrete shall be 100 mm.
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The mix for flooring bed shall be 1:6:10 for 100 mm thick with 50% of 20 mm metal and 50% of 40mm machine crushed metal. For other places it shall be as shown in the drawings. 14.2 Cover to Reinforcement The reinforcement shall be covered in all cases as shown in the drawings. It shall be 15mm for slabs and 25mm for beams. Where two bars cross, the outer should have the minimum cover. All reinforcement of columns is to be extended by 930 mm over the top of slab to take up the future expansion. 14.3 Form Bolts All form bolts that are in the concrete shall be withdrawn when the forms are stripped. They shall not be placed within 50mm of any steel reinforcement, so that the holes they leave do not reduce the effective cover on the steel. 14.4 Bending Reinforcement All bends shall be made cold round. Heating of bars for any purpose what so ever will not be allowed. All bends shall have at least four times the diameter of the bars. Where straight rods are used they shall be truly straight. 14.5 Splicing Reinforcement Normally splicing in reinforcement is not permissible. In exceptional cases overlapping in reinforcement is permissible with the approval of Engineer. The spacing and over lapping measurements shall be as per the directions of the Engineer. Welding shall joint no bars. 14.6 Fixing Reinforcement The number, size, form and position of all steel reinforcement bars, stirrups and other parts of reinforcement shall be exact in accordance with the approved drawings, and such parts shall be kept in the correct positions in the forms without displacement during the process of working the concrete into place. The Contractor as directed by the Engineer shall provide Spacebars, supporting stools and distance pieces to maintain the reinforcement in the correct position, without any extra charge to the APEPDCL. All straight bars shall be fixed parallel to each other and to the sides of the forms. Any ties, links or stirrups connecting the bars shall be tied so that the bars are properly braced.
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The inside of the curved parts (stirrups) shall be in actual contact with the bars round which they are intended to fit. 14.7 Binding wire Bars shall be bound together with black annealed steel wire No 16, SWG size conforming to IS : 280 1972 and the binding shall be done tight with proper pliers or automatic binders. (The free ends of the binding wire shall be bent towards inner side of the concrete). 14.8 Scaffolding The Contractor shall provide a method statement detailing the proposed method of providing scaffolding for approval by the Engineer before commencement of work, but such approval shall in no way relieve the Contractor of any of his responsibilities for the sufficiency and efficiency of the work. 14.9 Depositing and Consolidation: No concrete shall be deposited until the formwork and reinforcement has been inspected and approved by the Engineer. Care shall be taken that the steel reinforcement is thoroughly surrounded by the concrete particularly in congested locations and that no voids or cavities are left. Consolidation of the concrete by mechanical vibration shall be to the satisfaction of the Engineer. Under any circumstances there shall not be any impact on the formwork during the process of consolidation. 14.10 Defective work If, on the removal of the shuttering any honey combing or other defective workmanship is found in the face of concrete, the Engineer will decide whether, in his opinion, the strength of the member is affected and whether patching shall be permitted in which case the defective concrete shall be cut out to the extent ordered by the Engineer, and the remaining concrete thoroughly cleaned and made good. If before or during this operation any reinforcement bar is exposed, the cutting out shall continue right round the bar, to form a key. Where reinforcement bars are so exposed, care shall be taken to ensure that the tools used for cutting out the concrete do not damage them. If in the opinion of the Engineer, the defective materials or workmanship he may direct that the whole member shall be removed and a new member affect the strength of the member constructed by the Contractor without any extra charge and without asking for extension of time. If any Patching is discovered which has been carried out without the permission of the Engineer, the whole member affected will be liable for rejection, in which case the member shall be removed and a new member constructed by the Contractor, without charge. 15.0 Leveling of Switchyard After back filling the structure foundations, and after construction of earth pits and copings to the supports, leveling is to be done with the surplus earth suitable for back filling purposes as per specification. If surplus earth is not adequate for leveling, the
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switchyard is to be leveled by supplying red gravel or quarry dust as specified by the Engineer. The switchyard must be 300 mm high over the highest level of the adjacent area. Consolidation is to be done in layers of 300 mm duly wetting and rolling with 2 or 3-ton capacity Roller. Switchyard is to be spread with 20mm size machine crushed, blue granite metal to a thickness of 75 mm, after consolidating the earth mat with roller. Finally the switchyard is to be filled with quarry dust of 25mm thickness. 16.0 Foundations: Cement concrete foundation for Power Transformer plinth should be done as per the drawing no SS 3 or as per any other drawing approved by the Engineer. Foundation for structures (R.S.Joist) should be as per the approved drawings No SS4 Foundation for V.C.B should be as shown in the drawing no SS 5 Station transformers, Potential transformers and Lightning Arresters (Station type) erected on 11KV auxiliary bay structure. AB Switches to be erected on the substation structures. Current Transformers (CTs) to be erected on the VCB structures. 17.0 Cable duct: In the control room, cable duct is to be constructed to a depth of 300 mm and width of 300 mm with one brick wall over a bed concrete, of 100mm thick M100 grade, as per the directions of the Engineer. It shall be plastered neatly with cement mortar of ratio 1:5. The measurements of 300 mm and 300 mm are clear measurements after plastering. The cable trenches are to be covered with pre cast cement concrete blocks, casted with M150 mix of size 400 mm x 400 mm x 50mm thick with two hooks for lifting or MS sheets neatly painted to avoid corrosion. The length of the cable trench depends on the position of fixing of control panels in the control room and it will be normally 6 meters. For taking out the cables from the control room to switchyard 150mm dia G.I.Pipe is to be provided in the control room wall, with a suitable plugging arrangement. In the substation switchyard cables shall be laid in the trench of size 300 mm depth and 300 mm width and back filling shall be done with sand. Control cables to be laid on the sand cushioning of 50mm in the trench. When a cable has to cross a road, it has to pass through R.C.C pipe of 300 mm diameter, 900 mm below the ground level. The length of Hume pipe shall be extended by 500 mm on either side of the road.
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All these arrangements shall be as per the directions and approval of the Engineer. 18.0 Peripheral Fencing: Peripheral fencing to be provided all rounds the substation site, including vacant land. The tentative layout of the substation site is enclosed along with the bid document to have an idea of the quantum of work involved. The fence posts shall be cast in cement concrete as per the specifications mentioned below. Location of Concrete Metal Size Reinforcement Support ratio size 4 Nos 6 Rods and 10 to 12mm Corner 150x150x2400mm 6 Nos stirrups at 450 1:2:4 machine crushed granite c/c with 6 M.S.Rod 4 Nos 6 Rods and 6 10 to 12 mm Intermediate 110x110x2400 Nos stirrups at 450 c/c 1:2:4 machine crushed granite with 6 M.S.Rod 4 Nos 6 Rods and 6 10 to 12 mm Strut 110x110x 2400 mm Nos stirrups at 450 c/c 1:2:4 machine crushed granite with 6 M.S.Rod There shall be a minimum cover of 10mm of cement concrete over reinforcement. The fence posts shall not have any honeycombs. The surface of fence posts shall be finished smooth before erection. The fence posts shall be aligned in excavated pits and concreted with 1:4:8 cement concrete using 40mm granite metal. Corner posts shall be provided with two struts at all corners and at every angle points of more than 10o and at every 30.0 meters distance in straight runs. The distance between intermediate posts is 3.0 meters. Fencing shall be provided as shown in the drawing no SS 6. 16 eyebolts to be used as shown in the drawing for tightening the barbed wire. Precast R.C.C base plate of size 300x300x40 mm to be provided for each strut pole as shown in the drawing. Ten lines of barbed wire to be provided horizontally at the height of 150, 300, 450, 600, 825, 1050, 1275, 1500, 1725, 1900 mm from ground level and vertical stirrups to be provided for every 450 mm length. Barbed wire used shall conform to IS: 278. The wire shall be coated with zinc of grade Zn 98 of IS 209. The line and point wires shall be circular in section and shall be uniformly galvanized. The size of galvanized steel barbed line wire shall have nominal diameter of 2.5 mm and weight of 115 grams per meter length.
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The type of barbed wire shall be of glidden type. The barbs shall have four points and shall be formed by twisting two point wires each two turns tightly around one line wire making altogether four complete turns. The size of point wire shall be 2mm dia. The distance between two barbs shall be 75 + 12 mm. Fencing should be earthed at each terminal point by providing independent electrode system. Minimum of 2m clearances to be maintained between the fencing and the earth grid of the substation. 19.0 M.S. Main Gate: At the entrance of the substation main entry and in line with the peripheral fence a main gate of size 4.5mx1.5m and a wicket gate of size 1.22mx1.5m to be provided. Refer Drawing No SS7. The location, design of gate, size of Brick Masonry pillars and method of fixing the gate shall be as per the approval of the Engineer. The Contractor shall provide a method statement indicating the design of gate, materials proposed to be used and method of fixing for approval by the Engineer before commencing fabrication. After fixing, the gate to be painted with two coats of red oxide paint and two coats of enamel paint. The colour of the paint shall be as directed by the Engineer. On the top of M.S. Sheet, the name of the substation to be painted with Radium paint in bold letters of size not less than 100 mm, in the language approved by the Engineer. 20.0 Specification for the construction of control room: The plan of the Control Room is furnished in the enclosed drawing No SS 1 For above ground level the required drawings will be furnished by APEPDCL. The Contractor has to execute accordingly. Below ground level the Contractor has to design the foundations and obtain approval from the Engineer before commencement of works. The specification for various items of works should conform to the relevant clauses of the APSS and shall conform to Bureau of Indian Standards. The paras 11.0 to 15.0 . Referred earlier are applicable to the control house construction also. 20.1 Type of construction: The building to be constructed over 6Nos. R.C.C Columns and 5Nos. Beams. Roof Slab, Lintels, Portico and sunshades shall be of R.C.C. Super Structure shall be in brick Masonry in cement mortar 1:6 for all walls. Second class well burnt country bricks to be used for walls. The brick shall have a minimum crushing strength of 60 kg per square centimeter. 20.2 Foundation: For Reinforced. Cement Concrete footing a leveling course of 100 mm thick cement concrete 1:4:8 is to be provided with 40 mm HBG metal.
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For walls, 150 mm thick leveling course in cement concrete 1:4:8 using 40 mm HBG metal to be provided. Random Rubble Masonry in CM 1:6 to be constructed over the leveling course cement concrete. R.R.Masonry shall conform to APSS 601 and 615. 20.3 Basement: Basement with R.R.Masonry in C.M (1:6) shall be provided for internal walls. C.R masonry first sort in CM 1:6 shall be constructed for external walls and the exposed faces shall be pointed with cement mortar (1:3). For R.R.Masonry and C.R.Masonry granite stones shall be used. C.R.S. Masonry shall conform to APSS 601, 609 & 611. 20.4 R.C.C Columns and Beams: The details of R.C.C columns and beams to be provided are indicated in the drawings enclosed. (Refer Drawing No SS8) All R.C.C work shall conform to IS : 456. 20.5 Filling foundation and Basement: The work of refilling of foundations and basement is to be done with river sand as per clause 11.2 of the specification. 20.6 Flooring: Flooring to be provided with 1:4:8 cement concrete with granite metal of 50% of 40 mm and 50% of 20mm size to a thickness of 100mm for all the rooms. Anti-termite and antiweed treatment to be provided for flooring. 20.7 Control room, office room and Store room: Flooring to be provided with double polished stones 25mm thick over cement concrete bed. The polished stone shall be fixed over cement mortar bed of 25 to 40 mm thick of proportion 1:8. The pointing material shall be cement sebara putty 1:3 The stone to be used shall be Bethemcharle or Shahabad variety double polished stone. Size of each stone shall not be less than 250x250 mm. The joints shall not exceed 3mm in width. Skirting to be provided with polished stone to 150mm height all round the walls in side the rooms, with 20 mm thick Shahabad / Bethemcharle polished stone. Stones shall be fixed over a bed of CM 1:2. The colour of the stone and quarry shall be as approved by the Engineer. In the front elevation of the control house, name of the sub-station is to be painted as specified by the Engineer. 20.8 W.C. Bath
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Ceramic tiles of size not less than 200mm x 150 mm x 6mm thick of reputed make, uniformly glazed shall be fixed over the cement concrete bed. The tiles shall be fixed by using white cement. The joints shall be less than 1.5 mm width. The colour and make of the tiles shall be as approved by the Engineer. The ceramic tiles shall be commercial type (next to class I). 20.9 Doors and windows All doors except WC/Bath shall be with best quality teak wood door frames of 100x75 mm section and shutter of 30mm thick solid core, machine made phenol formal dehyde bonded prelaminated on both sides and teak wood lipped conforming to IS : 2191 & IS : 202 of approved quality, make and shade including polishing the door frame and lipping with two coats of polish of approved quality, make and shade along with Aluminum fixtures and fittings such as tower bolts, aldrops, mild steel butt hinges as mentioned below: 1. 2. 3. 4. 5. 6. 7. 8. M.S. Oxidised butt hinges 125 mm long Aluminum aldrop 300 mm long Aluminum top tower bolts 300 mm long Aluminum bottom tower bolts 150 mm long 1 No Aluminum door handles 150 mm long Aluminum door stoppers Rubber silencer Hold fasts 3 Nos 1 No 1 No 2 Nos 1 No 1 No 8 Nos
20.10 Door for W.C / Bath P.V.C door (Sintex or equivalent) for toilet of approved shade and quality. The paneling section shall be multi chamber hollow plastic section of 20x200mm with tongue and groove; the shutter frame section shall be extruded plastic section of 59x24 mm in the configuration of A section. The door frame shall be made from extruded PVC section of 60x24 mm size with multi chamber cross section with a wall thickness of 25 mm duly reinforced with steel. The fixtures and fittings shall be as mentioned below. 1. 2. 3. 4. 5. Aluminum butt hinges Aluminum aldrop Aluminum tower bolts Aluminum door handles Hold fasts 125 mm long 3 Nos 300 mm long 1 No 300 mm long 1 No 150 mm long 2 Nos 6 Nos
20.11 Windows Aluminum Alloy sliding windows with fixed glass panels using anodized aluminum extruded sections of finish for frames and mullions made from approved aluminum sections 62x32x1.2 mm at 0.73 kg / RM, providing 4.0 mm thick plain glass fixed to the frame with beeding gasket and glazing chips with all accessories, locking arrangements etc, conforming to APSS No 1609. 20.12 Ventilators Aluminum swing ventilators with fixed glass panels using anodised aluminum extruded sections of mat finish for frames and mullions made from approved aluminum sections
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38x63mm and shutter frame from sections 35x40mm and providing 4.0 mm plain glass fitted to frame with beeding, gasket and glazing chips of size 17x19mm and with all accessories, conforming to APSS No. 1609. 21.0 Bed blocks under lintels: Bed blocks to be provided under the lintels as per the APSS with cement concrete ratio of 1:3:6 using 20mm HBG Metal with necessary form work. 21.1 Lintels: R.C.C 1:2:4 proportions nominal mix using 12mm to 20mm size machine crushed hard granite metal. Machine mixed concrete mix to be used. They shall be finished neatly and cured as per standards. The size of the lintels shall be as per the directions of the Engineer. The rate includes, scaffolding, centering, vibrating, curing, including of cement, steel etc. 21.2 Sun shades: R.C.C 1:2:4 proportion nominal mix to be used. The width of the sun shade from the outer edge of the lintel is 0.61 meters and average thickness of sun shade will be 75mm.Cement plaster with 1:5 mix is to be provided to the exposed faces of the sun shades. Required slopes along with lip at the bottom ends are to be provided while plastering the sunshades. The rate includes scaffolding, centering, vibrating, plastering, curing including cost of cement, steel etc. 22.0 RCC Roof Slab The Engineer will provide the details of reinforcement. To have knowledge about the quantum of work involved, the approximate details of the reinforcement are furnished in the enclosed drawings. The rate is inclusive of cost of steel, binding wire, centering and labour charges. 1:2:4 nominal mix using 12mm to 20mm size machine crushed hard granite metal to be used. R.C.C roof slab shall be plastered immediately after laying with 1:2 cement mix 20mm thick using water proof cement compound at 1 Kg per bag of cement complying to IS:2645 duly forming necessary slopes towards rain water pipes. 22.1 Plastering Plastering to walls and roof ceiling is to be done with cement mortar 1:5 proportion 12mm thick on even surface side and 20mm thick on uneven surface side. 23.0 The rate is inclusive of materials, all leads, lifts and curing complete. Painting The Paints used shall conform to IS : 5-1961. Woodwork: Two coats of synthetic Enamel paint first grade of approved make and colour over one coat of primary (total 3 coats)
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Steel work: Two coats of synthetic Enamel paint of approved make and colour, over one coat of red oxide paint of approved make. Battery Room:Two coats of rubber based acid resisting Enamel paint to the walls and ceiling preferably Asian Panits/Nerolac Paints Outside Walls: Two coats of cement paint snowcem / durocem or other paint of identical or better quality of approved colour and make over a primary coat (total 3 coats). Internal Walls: Two coats of oil bound distemper of approved make and colour, over one coat of cement primer paint. The rate quoted for each item is inclusive of scaffolding, cost and conveyance of paints and sundries, and labour charges, including all leads, lifts etc. The paints used shall conform to relevant IS and samples shall be submitted and got approved by the Engineer. Only ready mixed paints in sealed containers to be used. Approval of specimen paint by the Engineer does not relieve the Contractor of his full and entire liability as to the life and quality of paints. The Contractor shall take into account the conditions of the surfaces to be painted (for Ex: aging of plasters etc). The Contractor is responsible upto the time of final inspection and acceptance. Painted surfaces shall appear absolutely even and free from any trace of brush marks. 24.0 Septic Tank: Septic tank of size 2x0.9x2.3 meters (inner dimensions) is to be constructed. At the bottom of the pit, sand filling is to be done to a height of 150 mm. Over the sand filling 150 mm thick cement concrete 1:3:6 mix to be provided with 20mm granite metal. Brick Masonry with cement mortar 1:6 to be constructed on all 4 side of the tank to a thickness of 230 mm. Baffle walls as required from the inlet pipe level towards floor of the septic tank to be constructed with 115mm thick brick wall in CM 1:6. Roof slab of 100 mm thick in R.C.C 1:2:4 with 12 to 20 mm machine crushed metal, with an opening of 0.6 x 0.6 meters for manhole shall be provided. Two-way reinforcement for roof slab is to be provided with 10mm and 8mm ribbed steel rods at 150mm centre to centre. Septic tanks to be provided with 4.5 meters long 100mm dia A.C. Ventilating pipe with cowl. The outlet from the septic tank should be standard T fitting of glazed earthen wear pipe. The center of the outlet pipe should be 150mm below the center of the inlet. The floor, inner sides, top and up to 600 mm below ground level on the outside walls shall be plastered with 1:3 cement mortar to a thickness of 20mm.
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The floor of the tank should slope at 1 in 30 towards one end to facilitate cleaning of deposits and the manhole should be above this. The tank should be provided with 0.6 m x 0.6m sizes C.I. frame and cover for manhole. The Stone Ware Glazed pipe line with 150mm dia shall be laid from the toilet to the septic tank. The S.W. pipes and special shall conform to IS:651. Laying, jointing and testing shall be carried out in accordance with IS specifications to the satisfaction of Engineer. From the toilet room line connection to flush tank to be provided. 25.0 A.C. Rain Water Pipes: Asbestos Cement Rain Water down take pipes of 100 mm dia to be provided with required specials such as bends, shoes and fixed with clamps on teak wood gutties with screws etc. The pipe joints shall be filled in with cement paste. The rain water pipes shall have beaded shoulders 100 mm distant from the lower ends and fitted so that each length rests on the pipe section below. The upper part of the 100mm long shoulder shall be wrapped in hemp or yarn and coated with linseed oil putty to form a tight sealed joint with the length below. Any surplus putty shall be neatly cleaned off. All rain water pipes shall be fixed 40mm clear of extreme outer face of walls with strong galvanized malleable steel holder bats having 125 mm long ragged tail and circled strap in two pieces with galvanized bolted connections. The rain water pipes shall be fixed in positions shown by the Engineer. The Contractor shall provide proper purpose made swan neck bends, plinth bends, shoes, stopped ends etc wherever required. 26.0 Water supply: The Contractor shall drill and install bore well for source of water. The Contractor shall also establish the suitability of water for drinking purpose by carrying out necessary laboratory tests on water samples from a laboratory approved by the Engineer. Principal Items: Principal items of work to be performed, and materials, equipment, devices and appliances to be furnished and installed hereunder, shall include the following: Investigation for and subsequently drilling a bore well, installing necessary pump, providing and laying of supply pipe line. Providing 1000-liter PVC water storage tank sintex or equivalent approved quality and providing distribution main from this tank to control building. Water supply piping is required to the building and to all earth pits in switchyard. All plumbing fixtures and accessories. 26.1 Specification for drilling and installation of Bore wells
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The work involves investigation for drilling and installation of tube wells as per specifications given below at the substation site. It is emphasized that the tube well will be the sole source of water for the substation and hence a continuous and adequate supply must be ensured. The required total yield is approximately 40 litres per minute. The Contractor shall take suitable precautions to guard against caving in of soil into the borehole. The bore of 150 mm dia shall be drilled into the soil with a rotary rig up to required depth into the water bearing strata, subject to a maximum of 75 m depth in alluvium. In case, boulder formations, not penetrable by the rig in use, are encountered before reaching the desired depth, the hole drilled shall be encased provided strata samples indicate presence of some water bearing formations. Otherwise it shall be abandoned at the discretion of the Engineer. Where caving material is encountered, the casing shall be sunk as fast as the drilling proceeds. After drilling of bore well a casing pipe of PVC to suit the 150 mm dia bore shall be lowered to a depth of 12M. The PVC rigid (HDPE) pipes of 32mm dia and 25mm dia of approved make as per ISI standard shall be provided in the bore well to the required depth including assembly of gunmetal foot valve. The other ends of the HDPE pipes shall be connected to an electric pump of sufficient capacity to lift the water from the bottom of the borehole to the storage tank. A 20 mm dia GI pipe shall be supplied and line laid from the bore well and connected to the PVC water storage tank installed over control building. Two separate 12mm dia GI pipelines from the water tank shall be laid. One connection shall lead to the toilet and the other line shall be laid up to the switchyard. Necessary brass taps 12mm dia of ISI standard shall be supplied and fixed. The scope of the Contractor includes cost of pipes. GI specials (viz. Unions, couplings, bends, tees, nipples GM wheel valves etc) final scheme will be subject to approval of drawing by the Engineer at site. 26.2 Power supply to pump set Power supply feeder for the pump is to be provided in the control building. Contractors scope of supply also includes, supply, laying, termination of power and control cables, suitable starter shall also be provided. 26.3 Piping Work All pipes shall be buried underground. For outdoor pipes the minimum depth under finished surface shall be 0.50 m with minimum of 0.20m of sand cover over the pipe. 27.0 Water closet One number Indian type (Orissa pattern) of size 580mm in white colour, parry ware or equivalent quality as approved by the Engineer to be provided. The pan shall have integral flushing of suitable type. It shall have an inlet horn for connecting flush pipe. The flushing sim and inlet shall be of the self-draining type. It shall have weep hole at the flushing inlet of the pan. The flushing inlet shall be in the
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front. The inside of the bottom of the pan shall have sufficient slope from the front towards the outlet and the surface shall be uniform and smooth to unable easy and quick disposal while flushing. Pan shall be provided with 100 mm P trap with approximately 50mm effective water seal and 50mm dia vent horn. The pan shall conform to IS : 2556. 28.0 Roads The roads shall be 6 meters wide with kerbs on either side The cutting and embarkment to be done for a top width of 10 meters to get the road to be formed to even level and required gradient. 150mm thick metal base to be formed for 5.0 meters width using 63mm granite metal and red gravel. Over this 75mm thick top smooth surface to be formed using 40mm HBG metal and red gravel. Each layer to be well consolidated duly wetting and using 8 to 10 tonne power roller. Road formation shall conform to APSS 1501 and APSS 1506. 29.0 Security Fence Security fence to be provided by the Contractor as per the drawing enclosed with the prior approval of Engineer. [Refer SS9] 29.1 Retaining Wall: Retaining wall round the switchyard to be provided as shown in the drawing (SS9). The retaining wall to be constructed over a bed of CC (1:4;8) mix 150mm thick, using 20mm size granite metal. R.R. Masonry in CM (1:6) shall be constructed below the ground level. The Engineer depending upon the soils will decide the height of R.R. Masonry. Above the ground level C.R Masonry first sort in CM (1:6) to be constructed. The faces of C.R Masonry shall be pointed in CM (1:3). Granite stone to be used for RR Masonry and C.R.. Masonry. 29.2 Security Fencing: drawing enclosed. The Security fencing shall be constructed as per the details in the
29.3
1.22m Wide Gate For security fencing a gate of 1.22mtr wide and 1.5m high to be provided at the location approved by the Engineer. This shall be galvanized tubular construction with well-arranged framework to ensure stiffness and rigidity combined with lightweight. This shall be single leaf with necessary pillars and hinges. The gate shall be provided with suitable locking arrangement and welded to R.S. Joists, fixed at both ends and concreted firmly in the retaining wall.
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30.0
The location, design of gate and method of fixing the gate shall be as per the approval of the Engineer. Electrification of Control House: The Contractor shall provide a drawing for electrification of control house detailing the various points to be provided for the approval of the Engineer. The wiring work is to be done with PVC unsheathed aluminum cable in surface PVC conduit. At least one switchboard in each room is to be provided at the location approved by the Engineer. All switch boards to be provided on suitable size teakwood boxes, covered with white decolam sheet. PVC conduits are to be fixed in the walls and roof slab by suitable arrangement and to be concealed neatly. G.I. Wire No 14 to be left over in conduct pipes to draw wires at a later date. Only reputable makes of fittings, switches fans etc., such as Philips, Compton Greaves, Northwest or their equivalent quality to be used. The Engineer before commencement of work must approve samples of fittings, switches and all other materials being used in the work. Holes made in the walls for fixing fittings and for taking mains are to be closed with cement mortar and neatly finished. Ceiling fans to be fixed with regulators and exhaust fan and its mounting shall be painted with acid resistance paint.
31.0
Substation Steel Structures The Contractor shall assume full responsibility for designing and detailing of the steel structures and for their satisfactory performance. [Refer drawing No SS 2 for guidance] All safety clearances to be maintained as per I.E Rules 1956. Minimum size of structure supports shall be 150x150mm BF beam. All members shall be with M.S.Channel of minimum size 100x50x6.4mm. All M.S. bolts and nuts to be hot dip galvanised. While designing the structures the following points shall be kept in view. a) 33KV Bay width shall be 4.5 meters b) 11KV Auxiliary & Feeder Bay width shall be 4.5 meters c) Minimum height of over head line take off 6.4 meters d) Type of AB switches for 33KV - 800A double break Horizontal type For 11KV LV-800A double break
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e) 33 KV Lightening Arrestors f) 11 KV Lightening Arrestors g) Bus conductor
Horizontal type for 11KV Feeder- 400A single break Horizontal type Bus - Station type Bus - Station type, Feeder-line type 200 Sqmm Panther AAAC/ACSR
Provision to be made for erection of Group Control Breaker on 33 KV side Provision shall be made for erection of HV & LV breakers for the Power Transformers, 33KV & 11KV station type LAs to be erected on the structures in the respective buses. 3Nos. Single Phase P.Ts to be erected in 33 KV bay on the structure, 11KV three phase P.T to be erected on the structure in 11KV Auxiliary bay and 33KV H.G Fuse set to be erected on independent structure. Galvanised step bolts to be provided for the vertical support. Station transformer with AB Switch and HG fuse set to be erected on structure. All 33KV AB switches should be 800A double break horizontal, both at sub-station and also in the line. 11KV AB switches on LV side of PTR should be 800A double break horizontal. 11KV feeder AB switches at sub-station should be 400A single break horizontal. 31.1 Standards Structures steel shall conform to IS: 2062. High tensile structural steel shall conform to IS: 961. All materials for rolled shapes and plates shall be hot rolled structural mild steel. Fabrication of structures shall conform to IS: 802 1978 Part II. Special care to be taken with regard to straightening and punching of holes cutting may be effected by sawing. The surfaces so cut shall be clean, smooth, and free from any distortion. Holes in the members shall either be drilled or punched and shall not be formed by flame cutting process. All deforms left by punching or drilling shall be completely removed. Hot dip galvanizing shall conform to IS: 2629, IS: 2633 and IS: 6745. 31.2 Fasteners and Bolts Bolts used for erection shall preferably be 16mm diameter. In no case bolt diameter shall be less than 12mm and more than 20mm. The length of the bolt shall be such that the threaded portion does not lie in the plane of contact of members. It shall also be ensured that the threaded portion of the bolt protrudes not less than 3mm and not more than 8mm over the nut after it is fully tightened. Holes shall be cylindrical and perpendicular to the structural member. Oval or lobed forms of holes shall not be permitted. The diameter of the hole shall be equal to the diameter of the bolt plus 1.5 mm. 31.3 Spring Washers Spring washers of positive lock type of the following thickness shall be provided for insertion under all nuts. Bolt dia Thickness of spring washer
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12mm 16 mm 20 mm 31.4 Tolerances
2.5 mm 3.5 mm 4.0 mm
The maximum allowable difference in diameter of the holes on the two sides of the channel, Angle or plate shall be 0.8 mm, that is, the allowable taper in a punched hole shall not exceed 0.8mm on diameter. The maximum allowable tolerance cumulative and between consecutive holes shall be within +/- 0.5 mm. Tolerance on overall length of a member shall be with in +/- 1.6 mm. Tolerance on gauge distance shall be within +/- 0.5 mm. 31.5 Inspection One set of structures is to be fabricated for inspection, after approval of the drawings from Engineer and offered for inspection. Balance structures to be fabricated after receipt of approval for the first set. All gauges, templates necessary for conducting tests shall be made available at the time of inspection. 32.0 Foundation Works The details of type of foundations for structures, Power transformer plinth, V.C.Bs and Security fence are enclosed along with bid document. The Contractor shall verify these details and submit the detailed drawings along with the design details for the structures, electro mechanical equipments etc., for the approval by the Engineer. 32.1 General Requirements Safety factor of foundation for uplifting force shall not be less than two. The weight of earth may be assumed to be 1.6 Tonne / m3. The Contractor at site shall verify all the soil data after necessary geo technical investigations before final designs. The tolerance for verticality, Horizontal and bending shall be maintained with the limits as specified in IS standards. The detail drawings shall at least include Detailed dimensions of foundation Details of placing of all reinforcing steel, which shall conform to the latest I.S. Specifications. Details of type, size and length of each reinforcing steel including details of bar bending. 33.0 Installation of Equipment General
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All the equipment and accessories covered under this contract shall be installed in accordance with specified Indian Standard code of practice and the manufacturers instructions. All installations shall be carried out strictly in accordance with the approved drawings. It shall be the responsibility of the Contractor to supply, store, move / transport from storage yard / shed etc., relevant items and accessories to the place of installation and wherever necessary assemble all parts of equipment, strictly in accordance with the specification and approved drawings. The Contractor shall provide consumables etc., required for installation all tools and equipment. It shall be the responsibility of the Contractor to engage specialist / manufacturers Engineers to supervise installation work for plant items such as transformers, switch gear, Battery with charger etc. such services shall be arranged by the Contractor at no extra cost to the Employer. Packing cases and packing materials except for spares shall be cleared from sites at the end of the each day. In order to avoid hazards to personnel moving around the equipment such as switchgear etc., suitable barriers and notices to prevent accidental injury shall cordon off which has been made alive after installation and before commissioning such equipment. Where assemblies are supplied in more than one section, the Contractor necessary mechanical and electrical connections between sections connection between bus bars and wires. The Contractor shall also adjustments / alignments necessary for proper operation of circuit Switches and their operating mechanism. shall make all including the do necessary breakers, AB
Care shall be taken in handling instruments, relays and other delicate devices. Where the instruments, relays are supplied separately, they shall be mounted only after the associated switchgear / control panels are erected and aligned. The blocking materials / mechanism employed for the safe transit of the instruments and relays shall be removed after ensuring that the panels have been completely installed and no further movement of the same would be necessary. Any damage to relays etc shall be reported immediately to the Engineer and all damaged instruments etc., shall be replaced at no extra cost. The Contractor shall submit a method statement detailing the method of installation, testing and commissioning of various equipment and accessories for approval by the Engineer. 33.1 Power Transformer Erection
33.1.1 Packing and Dispatch
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The mode of transport i.e., rail or road has to be chosen depending on the transport facilities available for the route and transformer size and weight, transformers etc. Transformer tank is to be filled with oil or pure inert gas like nitrogen depending on the transport weight limitations. In case the tank is filled with oil, sufficient space is to be left above the oil to take care of the expansion of oil. This space is to be filled with pure dry air or inert gas under atmospheric pressure. In case the tank is filled with inert gas, a positive pressure according to manufacturers standard practice shall be maintained. All external fittings such as Conservator, Buchholtz relay, Dehydrating breather, expulsion vent, radiators etc, which are liable to damage in transit, shall be removed and packed separately. All openings created on the tank by the removal of components are to be blanked with identifiable blanking plates. All openings on the fittings removed are also closed with blanking plates. When any internal parts like tap changers etc., are to be removed for transportation, they are to be dispatched in tanks, filled with oil/inert gas so that they do not absorb moisture. All fragile parts such as temperature indicators, oil level gauges etc., shall be carefully packed to avoid breakage in transit. 33.1.2 Rail Transport Where transformers are transported by rail, the detached parts are to be packed / crated and to be dispatched along with the main body of the unit so that all the parts are received at the destination with the unit. Mobile cranes or railway cranes are to be used for loading the units into the wagons. In the absence of any crane facility, the transformers are to be unloaded from the trailers near the railway track into a platform of adequate height built up of wooden sleepers. Jacks and pull lifts chain pully block of adequate capacity are to be used to slide the transformer over a pair of rails placed on the sleeper platform bridging the trailer width in full. To prevent the trailer from toppling when the transformer is moved to the platform the stage end of the trailer is supported by a sleeper pack. From the platform the transformer is slid onto the wagon taking care to have the rails for the full width of wagon. The rails may be greased for easy movement. The rollers of the transformer are to be removed before leaving the works. While providing a sleeper stage it should slightly be at a higher level to allow for the increase in height of the trailer while the load is released due to springs getting relaxed. 33.1.3 Road Transport Generally road transport is preferred to in the case of smaller units or where rail links are not available or where well developed road systems exist. Multi axel tractor driven low-platform trailers are to be used in case of road transport. The tractors should have adequate hauling capacity and the trailers loading capacity. The road system is to be examined in detail on the following points. Width of the road Bridges and culverts
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Encumbrances enroute Sharp bends Road worthiness Operational constraints of the tractor to be used. Electrical lines and service wires. To clear up any doubts as to the feasibility of the route a rehearsal drive of the tractor trailer unit is to be performed. 33.1.4 Loading and Leashing Transformers are to be loaded into the tractor-trailer preferably using the cranes. Using lugs or shackles provided for the purpose should lift transformers and simultaneous use should be made of all such lugs or shackles in order to avoid any unbalance in lifting. The transformer is to be leashed on all four sides by wire ropes or chain of adequate size and is tightened using turnbuckles with locking facility. Wooden props also may be used. 33.1.5 Movement A pilot vehicle with all tools and tackles jacks, sleepers, chequer plates, crowbars etc and sufficient trained staff should be run in front of the vehicle. Red flags and danger lamps should be exhibited at prominent places to warn the traffic on the route. The branches of avenue trees that are likely to foul the equipment should be cleared while the load is moved. Electric utility power lines to foul should be switched off and lifted temporarily / dismantled while the load is moved. After moving the load for a short distance tightness of the lashings should be checked. In the case of night halt or stoppage of the loaded trailer for a fairly long duration, jacks on all sides thus releasing the load from the tires should support the trailer. Danger lights should be displayed in the front and rear of the vehicle. The brake system on the tractor-trailer has to be operated carefully whenever the vehicle is running with load. While running over any bridge or culvert the vehicle should be run at a low speed. Transportation should be avoided during rains. 33.1.6 Unloading Mobile cranes may be used for unloading the transformers, when ever available. Where no crane facility is available, the transformer is to be unloaded on to a sleeper platform and gradually lowered to plinth level. The sleeper platform level is to be at a slightly higher level to allow for the increase in height of the trailer while the load is released
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due to springs getting relaxed. Winches are to be used for putting the transformer into position. Where it is necessary to use Jacks for lifting or unloading, only the projections provided for the purpose of jacking should be used. The transformer should always be handled in the normal upright position. 33.1.7 Unpacking and Inspection Packages are to be opened carefully so that the tools used for opening do not cause damage to the contents. When the transformer dispatched with gas filled, temperature and pressure shall be checked up and it should be ascertained whether there was any leakage of atmospheric air into the tank. In case of leakage the transformer has to be dried. When the transformer is dispatched filled with oil, a sample of oil shall be taken from the bottom of the tank and tested to IS: 355. Fragile instruments are to be inspected for breakage or other damages. Porcelain portion of bushings should be checked for any crack or chipping. 33.1.8 Installation After thorough inspection the transformer should be erected at its permanent location with radiators, conservator and breather fitted and dry oil filled to the correct level. All the assembly and erection drawings should be available at site at the time of installation. The installation shall conform to IS: 10028 1981 [Reaffirmed 1993] 33.1.9.1 Precautions Suitable precautions to be taken while erecting the transformers during rainy season to avoid moisture absorption by the transformer. All components dispatched separately shall be cleaned inside and outside before being fitted. Fiber cleaning material shall not be used. The presence of loose fibers in suspension in transformer oil can reduce materially its insulating properties. The transformer shall be erected on a level foundation. 33.1.9.2 Site Preparation All tools, tackles and other equipments required for the erection work to be arranged at the site before the work is started. In particular the following items will be required. Lifting equipment such as crane facility or derrick with a chain pulley block, wire rope slings D-Shackles etc.
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Oil purifier 2000lts/hour capacity fitter to be used for purifying oil up to 20,000 lts. Oil testing apparatus conforming to IS: 335 Voltmeter, milli-ammeter, low power factor watt meter AVO meter Set of spanners and screw drivers Set of drum opener, crow bar, pipes, hammer etc. Clean cotton cloth and cotton waste Brushes for painting PVC wires for connecting meters during testing Set of tarpau lines Earth discharge rods. The capacity, sizes etc of each item depend very much on the type and size of transformer. The installation site shall be such that there is easy accessibility for inspecting breather, thermometers, oil level indicators etc with the transformer energized. It should also be possible to have access to the operating mechanisms of on load tap changing equipment etc, if need be through construction of raised platforms. The plinth shall be above the maximum flood or storm water level of the site and of the correct size to accommodate the transformer in such a way that no unauthorized person may step on the plinth. When rollers are fitted and when the transformer is in the final position, the wheels shall be locked to prevent accidental movement of the transformer. 33.1.9.3 Unit Erection Transformer tank containing the core and coil assembly should be first placed in the position. All parts such as gaskets, bushings, radiators, transformer oil etc required should be readily available in good condition. 33.1.9.4 Oil Oil is to be dispatched to site separately in sealed steel / HDPE drums. At the time of filling the drums it is to be ensured that the oil is filtered, clean and dry. Oil used for filling and topping up must comply with IS: 355. The oil sample from the transformer tank before commissioning should meet the following specifications. (i) Electric strength (BDV) KV less than 72.5 KV class 72.5 KV 145 KV class above 145 KV class Water content PPM (Max) Less than 72.5 KV class 72.5 KV 145 KV above 145 KV : : : 40 50 60 25 PPM 20 PPM 10 PPM
(ii)
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(iii) (iv) (v) Precautions:
Interfacial tension at 25o C N/m (min) Resistivity at 90o C Dielectric dissipation factor (tan delta) at 90o C Max
0.03 1x1012 ohm-cm 0.05
a) Keep the oil free from contamination b) Equipment used when handling the oil must be cleaned and washed with transformer oil before use. c) Flexible steel hose is recommended for handling oil, some kinds of synthetic rubber hose are also suitable, but only those known to be satisfactory should be used. Ordinary rubber hose should not be used as oil dissolves the sulphur from the rubber and is there by contaminated. d) Oil must not be emptied near naked lights, as vapour released is inflammable. Sampling: Water and water-saturated oil are both heavier than dry oil and sink to the bottom of any container. Hence samples shall be taken from bottom only. Samples should not be taken unless the oil has been allowed to settle for 24 hours. Dirt from draw off value to be removed. To ensure this a small quantity of oil should be allowed to flow into a separate container before collecting samples for testing. 33.1.9.5 Oil Filling: Before filling the oil in the tank, it should be tested to meet the requirements as laid down under clause 7.4. When filling a transformer with oil it is preferable that the oil be pumped into the bottom of the tank and that a filter press or other reliable oil drying and cleaning device should be interposed between the pump and the tank. 33.1.9.6 Drying of transformer: Before the drying out is started all fittings except coolers and associated accessories shall be fitted. The coolers etc can be conveniently fitted after the successful dryout of windings and insulation. The process of drying out should be carried out carefully and properly without damaging the transformer insulation through over heating etc. The transformer shall not be left unattended during any part of the dry out period. Fire fighting equipment shall be kept near the transformer during the process of drying out. The Contractor shall provide a method statement detailing the proposed method of drying of transformer, he proposes for approval by the Engineer. But such approval shall in no way relieve the Contractor of any of his responsibilities for the sufficiency and efficiency of the work. For the guidance of Engineer : Various methods that can be adopted for drying out a transformer are described below.
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a) By using Filter Machine The most practicable method of drying out is by circulation of hot oil through a streamline filter machine. The vacuum pump of filter machine should have the capacity of creating vacuum as high as possible but not less than 710 mm of mercury. It is preferable to blanket the transformer tank to prevent loss of heat. To start with oil is drawn from the bottom and let into the transformer at the top. After 8 to 12 hours the cycle is reversed i.e., oil is drawn from the top and fed at the bottom. The oil temperature should be of the order of 60oC and in no case it should exceed 70oC. The circulation is continued till the insulation resistance and oil samples test are satisfactory. It will be observed that I.R. values will be low till the moisture come out of insulation and start raising before steadying. b) Hot air circulation: Hot air from external heaters is blown into the transformer after draining the oil, through an opening in the bottom of the tank and is allowed to escape through an opening in the tank top cover. The speed of the air shall not exceed 600m per minute. The temperature of the air raised gradually to 55oC in the first 8 hours, 65oC in the second 8 hours and 75o 80oC in the third 8 hours. The process is continued till the steady values of insulation resistance are obtained. c) Short Circuit Heating: The transformer can be heated up by short-circuiting the low voltage winding and supplying at the high voltage terminal at reduced voltage. All necessary precautions safety to the Power Transformer under draying operation should be taken. The supply voltage should be maintained in such a way that the current in the windings does not exceed 70 percent of normal full load current and the oil temperature about 75oC. In this case the temperature of oil should be measured at the top and bottom of the tank. The temperature of the windings should be in no case exceed 90oC. 33.1.9.7 Circulation of oil in Radiators and Tap Changers: Oil samples are to be taken out and tested. Further circulation is to be carried out till the oil results are satisfactory. 33.1.10 Important fittings & Accessories Gaskets: Gaskets: Whenever blanking plates are removed, a new gasket shall be used.
Bushings: Bushings shall be cleaned thoroughly and checked for any damage.The bushings shall be lifted or using soft manila ropes. Sufficient flexibility in the connecting leads should be provided to avoid mechanical stress on the bushing. The arcing horns if any shall be in proper position. On-load Tap changers: Oil filling and drying out is to be carried out simultaneously along with the transformer. Conservator: Conservator should be assembled with its pipe work, making sure that all gasketed joints are oil tight and the pipe work is clean and free from moisture.
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Oil to be filled to a level indicated by the oil gauge on the conservator to commensurate with the filling oil temperature. Buchholtz Relay: Buchholtz to be tested for correct functioning by injecting air through the test petcock when full of oil. The angle of inclination should be between 3o and 7o. Breathers: Transformer oil should be filled to the correct level in the bottom oil chamber. It is to be ensured that breathing holes at the bottom of the seal is not blocked by dirt etc. the silica gel shall be blue in colour. Expulsion Vent: The temporary cover, which is provided over expulsion vent flange on the tank cover, should be removed, and the expulsion vent pipe fitted with suitable gaskets. Temperature Indicators: The accuracy of all thermal indicators shall be checked by hot oil or water bath. The thermometer pocket should be filled with transformer oil. Completion of Erection work: Final topping of oil is to be done in conservator to commensurate with filling oil temperature and wiring work of alarm / trip contacts, earthing of neutral and transformer tank to be completed. O.L.T.C motor is to be connected with A.C.Supply as per manufacturers instruction manual. Tank surface is retouched with paint wherever required and transformer is made ready for the commissioning tests. 33.1.11 Testing and Commissioning: The following pre-commissioning tests to be carried out i. ii. iii. iv. v. Checking of ratio, polarity and phase relationship. Resistance measurement of winding Insulation resistance Magnetizing current and iron loss Tap changer operation shall be checked for a) Manual operation b) Local electrical operation c) Remote electrical operation d) Parallel operation Beholds relay test by injecting air through the test petcock. Protection for Thermal indicators shall be tested for accuracy at various temperatures and set at required temperatures depending on ambient temperature and loading condition. Oil samples to be checked from top and bottom of tanks, tanks of tap changer and radiator banks.
vi. vii. viii.
General Checks: a) b) c) d) All valves are in correct position All air pockets are cleared. Thermometer pockets are filled with oil Oil is at correct level in the conservator tank etc.
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e) f) g) h)
Earthing connections are done The colour of the silica gel (Blue) and oil in the breather cup at the bottom. Arcing horn gaps on bushings are properly adjusted. Alarm / trip contacts shall be checked for correct function.
If all the above tests / checks are found satisfactory, the transformer is to be connected on both HV and LV sides by using Bimetallic clamps. All protective relays to be set at minimum to the extent possible. Now the transformer can be connected to source on LV side and watched for any abnormality such as vibration of radiator parts, hum etc. if no abnormality is observed switch off the L.V Source and the transformer to be charged from HV side at no load. After 3 to 4 hours, the transformer to be switched off. The Buchholtz relay should be checked for collection of air/gas. Abnormalities noticed should be corrected. All protective relays should be reset to normal values. The transformer can now be recharged and loaded gradually. 33.2 Switchgear, Control / Relays: Switchgear, control and relay panels shall be installed in accordance with specified code or practice and manufacturers instructions. The panels shall be installed on concrete finished surfaces or steel frame. All breakers along with CT are to be erected on concrete foundations. The steel structure shall be as per the manufacturers drawing details. The height of the plinth and structures to be designed to maintain minimum safety ground clearances as per I.E Rules. The operation of AB Switches shall be checked for simultaneous opening and closing of contacts in all the three phases. The arcing horns shall be adjusted in such a way that they close first and open later simultaneously in all the three phases. Operating handle shall be rigidly fixed to the structure at 1.2metres height above the ground level. Handle shall be earthed through No.8. G.I wire closely wound in the spring shape. 33.3 Battery and Battery Charger Installation and testing of Battery and Battery charger shall be done in strict compliance with the manufacturers instructions. 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. Battery shall be set upon racks as soon as possible after receipt utilizing lifting devices. The rocks shall be of approved design by the Engineer. Cells shall not be lifted by the terminals. Contact surfaces of battery terminals and inter cell connectors shall be cleaned, coated with protective grease and assembled. Each connection shall be properly tightened. Each cell shall be tested with hydrometer and results recorded. Freshening charge, if necessary, shall be added.
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The battery shall be fully charged and electrolyte shall be at full level and of specified specific gravity, charge and discharge test of battery is to be done. 33.4 Stringing of Bus bar: 33 KV & 11 KV bus in 33 KV substations shall be formed with 200Sqmm Panther AAAC/ACSR to a tension of 250 KG, comprising of three phases. Aluminum Alloy or Bimetallic clamps and lugs shall be used for all connections between bus and equipment and between equipments. All clamps and lugs shall be of approved quality by the Engineer. All clamps and conductors must be wire brushed through contact grease to remove all oxidation before assembly. Resistance test is to be carried out at each joint, clamp and terminal after installation. The maximum allowable resistance shall be 10 micro ohms per contact interface. A contact interface is defined as the electrical connection between one component and another, e.g. A test from a conductor to a clamp will count as one interface A test from a jumper two a bus bar via a clamp will count as two interfaces. The stringing of bus conductors covers hoisting of insulator strings, post type insulator stacks and other accessories along with tensioning of conductors and clamping. The jumpering to the equipment shall be arranged properly as per the directions of Engineer. Insulators shall be cleaned and examined before hoisting. Insulators with cracks or chips or those having glazing defects exceeding 0.5 Sq cm shall not be used. The sag of bus conductor shall not be more than 2%. Damaged conductor shall not be used. No joints are to be made. The conductor surface shall be clean and smooth without any projections, sharp points, cuts or abrasions etc., and the conductor shall be continuous in the span.
33.5
Control Cables: This section covers laying of cables in cable ducts, cable jointing termination at both ends and testing of the complete cable installation. All cable ducts laid in Switch Yard and Control Room shall be covered with suitable galvanised MS grills welded to frames. Cable identification tags shall be fabricated from aluminum sheet. The details of information to be punched to the tags and method of tying shall be finalized in consultation with the Engineer. Cable Tags shall be attached to both ends of each cable and at every 5 meters apart.
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There shall be no joints in between point-to-point termination of the cable. Sharp bending, twisting and kinking of cables shall be avoided. The bending radius for various types of cables shall not be less than those specified by cable manufacturer. Control cable terminations shall be made using colour codes as per the directions of Engineer. The Contractor shall drill holes suitable for the cables in cable gland plate wherever necessary. Cable glands of suitable size to be provided at all such holes for all armoured Cables double compression cable glands shall be used. Metal sheath and armour of the cable shall be bonded to the earthing system of the station. The contractor for passage of cables shall provide rows of 150mm dia AC pipes in a concrete block at road crossings. LV cables shall be buried at a depth of minimum 750 mm while HV cables shall be buried at a depth of minimum 1000 mm The contractor shall provide cable lugs, and other terminating accessories like jointing ferrules, cable clamps, cable grips, cable compound flux, tapes etc., as necessary and shall include supply of accessories in the quoted rates for cable laying. Wherever lugs are compressed, the bear ends of the connections shall be covered with insulating sleeves so as to prevent accidental contact with ground or with the adjacent terminals. The insulating sleeves shall be fire resistant, and long enough to over pass the conductor insulation and shall be of correct size of the conductor used. Cables are to be laid in cable ducts, trenches, cable trays; ladders and all necessary accessories and fittings are to be provided to complete the installation as per specifications and to the approval of the Engineer. The Contractor shall prepare a detailed layout drawing for cable trenches, cable tray layouts, showing the colour codes to be adopted, detailing the method of cable laying and end termination for approval by the Engineer before commencement of the work. 33.6 Fire Extinguishers: a) 4 Nos. Trolley type 6.8 Kg Co2 fire extinguishers shall be provided with first filling conforming to IS: 2878. Statutory test certificate issued by the Chief Controller of Explosives Department and Cylinder manufacturing test certificate shall be furnished. b) 4Nos. sand buckets painted with portal red and billed with sand should be provided along with the bucket stand. 33.7 Danger Boards Danger boards of approved size shall be provided at places specified by Engineer 33.8 H.G. Fuse Set (33KV):
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H.G.Fuse set to be provided by the Contractor on the independent structures as per the drawing enclosed. Drawing No SS11. 2Nos. 22 KV post type insulators to be provided for each stack of insulator (Total 12Nos.) Tinned Coated Copper flat of 25x6mm to be used for horns Bimetallic connectors to be provided for giving connection to AAAC/ACSR conductor at both ends. Earthing: Requirements The substation earthing system shall be designed in accordance with the following specifications and IEEE 80 regulations and relevant IS Standards where there is conflict the higher standard shall prevail. 35.0 REQUIREMENTS OF THE FINALISED DESIGN. The finalised design will provide the following: a) b) c) d) e) f) g) h) i) The Grid Resistance and Overall Earth Return Impedance values. The earth potential rise (Equipment Potential Rise), for a maximum value of ground current. Specify whether the substation is hot or cold. Show the limits of the hot zone - if applicable. Confirm that at all points, the internal maximum touch and step potentials are below the safe acceptable value. Confirm that at the fence, the maximum touch potentials are below the safe acceptable value. Confirm that the maximum external step potentials are below the safe acceptable value. Where the design makes significant use of vertical rods, the fault current distribution within the grid is required to ensure that the rods can carry their proportion of current without damage. Ensure that there is earth electrode reasonably close to each item of plant which requires connection to it.
34.0
36.0
SOIL RESISTIVITY MEASUREMENTS: Prior to designing the earth grid a soil resistivity test needs to be carried out. This will enable the resistance of any design to be determined. It will also give an early indication as to if the site will be hot, how extensive the design work will be, and whether advantage can be taken from underlying low resistivity soil layers. Soil resistivity and corrosion data shall either accompany the design specification or the specification will require soil resistivity measurements to be undertaken as part of the design process.
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It is important to ensure that site measurements are taken prior to any construction work. The measurement should: be duplicated in different directions to provide an average cover the whole site area plus peripheries determine the likely layering of soil down to a minimum of 20 metres depth. The soil resistivity data should then be used to produce a soil model using a computer modelling tool. For a quick estimation of the Equipment Potential Rise prior to creating a soil model see section 5 below. The design will include the following features: The perimeter of the earth grid will extend for 1m or more outside any metallic fencing. The metallic fencing will be connected to the earth grid in those areas where the perimeter conductor is beyond it. Ideally services (such as water) should have arrangements to avoid possible transfer potentials. For example, metallic services should preferably not be used and if possible they should be plastic type from 2m beyond the substation perimeter. This design is similar to the cold design with the following exceptions: (i) In cases where it is clear that the substation will require an extended earthing system, the grid boundary conductor should be shown installed 1.0Mtr deep using standard M.S. Flat electrode, and normally situated 1.0Mtr outside any metallic fencing. (ii) Convert the outer ring to a mesh by plotting standard tape across the site, in two directions at 900 to each other, each flat being parallel to the outer conductor where practicable. The cross-members should form squares or oblongs, should be spaced a nominal 10 metres apart and laid to a depth of 0.6 metres. They will be bonded to the outer ring and at each crossing point. (iii) Some of the cross members should be laid in rows alongside plant to facilitate the connection of exposed metalwork to the grid. Great care must be taken when planning the grid layout to ensure that critical components such as transformer neutral connection points, switchgear earth bars etc., are provided with direct and duplicated routes to the electrode. (iv) At or near to the connection point of each cross member to the perimeter ring electrode, install one 3m x 150 mm galvanised pipe. Each pipe is to be backfilled with Bentonite or loamy soil (black top soil) with added Gypsum, to a diameter of 300mm. Coke and salt are not to be used as backfill as they are corrosive. (v) Metal fencing should be connected to the grid at each corner and at points long its length not exceeding 50 metres. The permissible limits of step potential and touch potential shall be Maximum Acceptable Step Potential Fault Clearance Times Fault Clearance Times 0.2 seconds 0.35 seconds
0.7 seconds
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On Soil 1050 V 600 V On chippings (150 mm) 1400 V 800 V Maximum Acceptable Touch Potential Fault Clearance Times Fault Clearance Times 0.2 seconds 0.35 seconds On Soil 3200 V 1800 V On chippings (150 mm) 4600 V 2600 V
195 V 250 V 0.7 seconds 535 V 815 V
The short circuit rating of the 33 kV Sub-station is 25 kA for 1 Sec. The earthing system of the substation shall be designed accordingly to ensure equipment safety, personnel safety and should facilitate proper operation of protective system during the earth fault in the system. The Contractor shall measure the soil resistivity of the soil in the substation premises, design the earthing system of the Substation and furnish the earthing layout along with the materials to be used for approval of the Engineer. Sl.No 1. 2. 3. 4. 5. Item Grounding electrodes Earth grid Connection to between electrodes and earth grid Connection between earth grid and equipment (Top connections) Back filling around the electrodes Material to be used 150mm (inner dia) 2.75 meters long CI pipe with a flange at the top. 75x8mm MS Flat 75x8mm MS Flat 50 x 6mm MS Flat Bentonite
The size of trench for burying earth grid shall be 300 mm x 500 mm. The earth mat shall be buried in the ground at a depth of 500mm. The earth grid shall extend over the entire switchyard. All junctions and risers in the earth flat shall be properly welded by providing suitable angle pieces for contact between two flats. Provision shall be made for thermal expansion of steel flats by giving smooth circular bends. Bending shall not cause any fatigue in the material. After welding, the joints and tap off shall be given a coat of Bitumen paint and then covered with Hessian tape to avoid rusting. MS flats shall be touched up with zinc-rich paint where holes are drilled at site for bolting to equipment or structures. The combined earth grid resistance shall be less than 1 Ohm. Back filling of earth grid trench to be done with good earth, free of stones and other harmful mixtures. Back fill shall be placed in layers of 150mm, uniformly spread along the ditch, and tampered by approved means. The earth mat should be laid in the presence of the Engineer only.
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37.0
Work details: a) Transformer Neutral connection earth electrode shall never be used for the equipment earthing. b) A separate earth electrode shall be provided adjacent to the structures supporting lightning arrestors. Earth connection shall be as short and as straight as practicable. For arrestors protecting transformers the earth conductors shall be connected directly to the transformer tank. c) An earthing pad shall be provided under each operating handle of the isolator and operating mechanism of the circuit breakers. Operating handle of the isolator and supporting structures shall be bonded together by a flexible connection and connected to the earthing grid. d) All equipment and switchgear etc., erected shall be earthed as per I.E Rules 1956.
38.0
Illumination of Switchyard: Philips or equivalent quality 125W (Outdoor type) Sodium Vapour lamps shall be provided for yard lighting at locations indicated by the Engineer. The lights shall be fixed on 8.0Mtrs/200 Kg (W.L) PSCC poles with necessary Cantilever arrangement utilising 40mm dia G.I.Pipe. The following are the recommended values of intensity of illumination: Average S.No Particulars illumination level Vertical control panels 300 1. Rear of control panels 150 Control Desks 300 2. Battery room 100 3. Carrier room 300 4. Outdoor switch yard 20 5. Corridors 70 6. Approach roads 20 7. Path ways 20 8. Store room 100 9. D.G.Set room 150
Limiting 19 19 19 16 -
6A capacity MCCB to be provided for each light in an enclosed junction box at the bottom of pole. The lighting system of a particular area, whether outdoor or indoor should be designed in such a way that uniform illumination is achieved. Dark spots should be avoided. The rate is inclusive of all accessories such as G.I.Pipe, clamps, MCCB, Cable etc required for the lights. 39.0 Spreading of H.B.G Metal The work involves spreading of quarry dust to a thickness of 25mm after consolidation of the earth work with a roller and also supply and spreading of 20mm size machine
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crushed blue granite metal to a thickness of 75mm over the above quarry dust in the switchyard. Kerbstones of size 200x200 mm shall be provided in the switchyard to retain the metal all along the periphery of the metal spreading wherever it is required. The kerbstones shall be buried in the ground up to 100 mm deep. The joints between the kerbstones shall be done in CM 1:6 and plastering the kerbstones shall be done in CM 1:2. Before spreading the HBG metal care shall be taken to remove all the vegetation and roots of the plant. The trimming of the earth surface for perfect level ground should be carried out and the surface should be watered and rammed for consolidation with suitable means and the earth surface should be given chemical treatment for anti vegetation growth. Required metal quantity may be stacked at suitable area for easy handling for pre measurement. Higher size metal may be separated and removed from the stacks. The crushed metal dust or quarry dust should not be allowed to be used. The HBG metal shall be brought from the approved quarry as directed by the Engineer in charge and samples of the HBG metal to be used may be shown to the Engineer in charge and prior approval of the Engineer shall be taken before use. Spreading of the metal carried out by dumping at lower heights. 40.0 Earth-grid Design: INTRODUCTION These guidance notes are intended to guide you through the process of designing an effective earth system for a 33/11kV substation installation in accordance with European industry standards. The process is set out below in the form of a flow chart. Accompanying notes in the sections that follow supports the steps of the flow chart.
170
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FIG.1. EARTH DESIGN PROCESS 41.0 CONNECTION OF ABOVE GROUND PLANT AND USE OF METALLIC STRUCTURES. Normally items of plant will be connected to the earth grid via copper or aluminium conductor. However, in many cases it is possible to use the aluminium or steel support structure. If concrete supports are to be specified, it is preferable (to avoid theft) for the above ground bond to be accommodated within a support. This can be achieved by a hollow duct/ channel or incorporating the copper tape within the concrete during production. Steel structures can be used in a similar way to aluminium to provide the connection between the earth grid and equipment on the top and that shunts are required at each
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bolted joint position. Galvanizing (zinc coating) of the steel forms an oxide, which increases in thickness with age and could create a high resistance at steel - steel jointing surfaces. A calculation is required to ensure that the steel has sufficient cross-section area and that the final temperature will not exceed 250C for a bolted joint. Above a temperature of 419C damage will be caused to the protective zinc. BS 7430 provides the following formula to calculate the area required, based on a starting temperature of 30C: Mild steel current carrying rating for 1 second Assume current density = 64 A/mm2 = K amps (R.M.S) per mm2
Minimum cross-section area for 3 seconds duration is : If t 3 = Kg/cm/m 64 k Where k is 64 (see table 8, BS 7430) i.e. the density of mild steel = 7.85x10-6 Kg/mm 42.0 Low Voltage Cables. (i) (ii) Cables used exclusively for in house supplies. The sheaths of these cables must be bonded to the substation grid. Cables used for supplying external loads. L.V. cables for which the neutral/earth connection is within the substation, are not suitable for supplying customers outside if there is any possibility of the Equipment Potential Rise exceeding 430V/650V (as appropriate). For similar reasons, house supplies to a substation should not be provided direct from an adjacent L.V. network.
43.0
COMMUNICATION FACILITIES Because of the high frequencies involved, a different earthing grid design is required. This attempts to maximize the amount of conductor in the immediate vicinity of the structure. For example, at a microwave dish or large aerial, it is normal to have a number of parallel earth down leads near the base of the structure, each of which terminate in an earth rod. This reduces the overall impedance. The mast itself will normally carry most of the fault/lightning current down to the base, even if down leads are fitted. Electrodes, which run out radially, are relatively close together and arranged symmetrically may be used in addition to rods. For further details, specialist advice should be sought. Where (as is usually the case), the communication facility shares the same site as a substation, and then the two earthing systems would normally be well interconnected. Particular attention is required to the bonding/termination of pilot and communication cables and the earthing arrangement for the LV supply. The substation earthing system will be especially important in the event of a lightning strike to the communication tower, as it will help disperse the energy associated with this. The overall design should seek to minimize any potential difference across the earthing system during the strike.
44.0 APPENDIX A - EARTH GRID RESISTANCE GRAPH
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The graph below shows the minimum theoretical resistance of a mesh grid for different soil resistivities and grid area. This can be used as a quick guide as to determine the value of Equipment Potential Rise of the grid. Having established an equivalent soil resistivity from the site measurements the grid resistance can be read off the y-axis for the grid area under consideration along the x-axis. The resistance can then be multiplied by the fault current to give the Equipment Potential rise
Minimum Theoretical Resistance For Various Soil Resistivities Of Earth Grid
10000.00
1000.00
100.00
10k ohm/m
Resistance Grid (ohm/m) Of
10.00
1.00
0.10
25 ohm/m
10000
22500
Area Of Grid ( sqm)

25 50 100 150 300 500 1000 3000 5000 10000
Soil Resistivity (ohm/m)
PRECOMMISSIONING CHECKS AND TESTS

The Contractor shall provide a statement of pre-commissioning checks / tests he proposes to do for various lines and equipment he has erected / proposed to erect atleast one month in advance before commissioning along with the test procedures and formats, in which the test results will be recorded for approval. The Contractor shall be required to conduct tests and checks in accordance with but not limited to those listed below to the satisfaction of the Engineer before commissioning. In particular the Contractor shall conduct the following checks / tests before commissioning.
40000
1600
2500
3600
4900
6400
8100
100
144
196
256
324
400
484
576
676
784
900
16
25
36
49
64
81
0.01 4
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A. 33/11 kV Substations: Before commissioning ensure that: 1. All civil works including yard leveling, security fence, peripheral fence, control house construction, main gate, wicket gate, bore well construction, laying of pipeline etc., are as per the technical specification / technical standards. Yard is clean and drainage is proper. A check of the relevant inspection forms is necessary. Structures are erected as per the approved drawings and all m.s.parts are hot dip galvanised. Earthing is provided as per the approved drawings and earth resistance is with in allowable limits. Control cables are laid and terminated as per the approved drawing / methods. L.V.A.C panel and D.C annunciation panels are erected as per the specification. Battery with charger is erected conforming to specification. Test have been performed as mentioned in para K and L. Yard lighting and control room lighting are provided as per the specification and level of illumination is not less than the minimum required. Fire extinguishers, danger boards and name boards are provided at all required locations. Complete set of drawings, test certificates, instruction manual and complete erection log are all available at site for reference as and when required.
2. 3. 4. 5. 6. 7. 8. 9.
B. Power Transformers The following preliminary tests shall be carried out and test results recorded. 1. Checking of ratio, polarity and phase relationship. Turns ratio meter should be used. In case of OLTC continuity during tap change is to be ensured. 2. Resistance measurement of winding to be done at all tap positions. 3. Insulation resistance 4. Magnetizing current and iron losses 5. Loss angle measurement of transformer winding to be measured. 6. Tap changer: The sequence of operation of the tap changers shall be checked for a) Manual operation b) Local electrical operation c) Remote electrical operation d) Parallel operation 7. Buchottlz Relay operation for alarm and trip are checked by injecting air through the test petcock. 8. Magnetic oil level gauge: The low level alarm of the oil gauge shall be checked. 9. Thermal indicators shall be calibrated and contacts set for WTI and OTI for alarm and trip depending upon ambient temperatures and loading conditions. 10. Fans and Pumps: Check the rotation of fans and pumps wherever they are provided. Protection is to be checked. 11. The wiring from various accessories to marshalling box shall be checked. Insulation of the cables to be checked. 12. Oil samples from top and bottom tanks, tap changer and radiators shall be checked. 13. All valves are in correct position, earthing connections are made properly. Colour of silica gel is blue in the breather, H.G.Fuse is correct gauge and shape, oil is at correct level and all bushings are cleaned properly. The oil in the bottom cup of silica gel
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14. 15. 16. 17.
breather to be ensured. Primary injection tests and secondary injection tests are done on all protection relays. All ground clearances to the bushings conform to I.E. Rules. Tan delta test for EHV bushings also shall be conducted and satisfactory test results are ensured. Earthing of body and PTR neutral are as per standards / specification.
C. Circuit Breakers 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. D. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Check whether All bolts and hard wares are tightened properly. H.V. connections have been made properly. Control cables are laid and connected as per the approved drawings. Breaker body and structure are properly earthed at two places. Local operating mechanism is in perfect working condition. D.C and A.C control supply are available Polarity of D.C terminals is as per the drawing Breaker mechanism is adjusted as per the manufacturers instructions. Space heaters are in service. Measure and record IR Values of control wiring between different phases and between each phase to earth. Contact resistance for interrupters is to be measured and recorded by passing 100 amps current through each pole from a primary injection set. Inter locks and anunciators are to be checked for correct operation. Operate the breaker with electrical command and measure the time of opening and closing by graphic recorder or similar equipment (By operating for 5 times). The value of time should be as stipulated by the manufacturers. Operate the breaker from local control panel, from control room and then by operating relevant relays for its satisfactory operation. If auto reclosing is provided its function also shall be checked. All alarms to be checked Eg. Healthy trip circuit bulbs, DC supply to trip / close circuit to be checked. Gas leakages etc., to be checked. Current Transformers Check whether CT is securely bolted to structure, and installed as per approved drawing. Body and structure are grounded at two places. H.T leads are connected properly Independent cables are laid for each CT terminated and ferruled as per the approved drawings. Bushings are clean and no damages observed by visual examination. Oil is upto the mark and conforms to IS : 335 (oil sample to be tested) There are no oil leaks Measure and record the insulation resistance between control cable and earth. Magnetization curve to be checked. Measure and record the insulation resistance of CT. Neutral of PTR should be connected to a separate earth pit other than station earth and not to be connected to the earth mat. Wherever there are 2 Nos.PTRs existing in the Sub-station, 1 No. Independent
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neutral earth is to be provided for each PTR and a 3rd pit for neutral earthing is to be provided and the above 3 Nos. earth pits are to be interconnected in triangular shape. Measured between IR Temperature Primary Earth Secondary Earth Primary Secondary Secondary resistance of CT as well as its lead resistance to be measured with a wheat stone bridge and values to be recorded. Ratio test to be conducted with a primary injection set and values recorded and Verified with guaranteed technical particulars. Primary Current Secondary Current Calculated ratio Name ratio plate Error Remarks
11. 12
13.
Polarity test to be conducted to confirm the marking on the CTs.
E. Potential Transformers 1. 2. All tests and checks similar to that of CTs from items No 1 to 3 and 5 to 8 are to be conducted. Insulation resistance test to be conducted and results recorded separately on primary and secondary side. a) Primary: Phase R Measured between Phase Y Measured between Phase B Measured between Temperature IR Remarks
IR
IR
b) Secondary: Phase R Y B Polarity Test Ratio Test Resistance Temperature Remarks
Above two tests are included in standard tests also. Hence factory test certificates also to be furnished by the Contractor. F. Protection Relays 1. Manufacturers test procedures approved by the Engineer are to be checked for each relay.
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2. 3. 4.
Different current and time setting of relays are to be checked with relay testing set. Relay characteristics are to be tested. The following secondary injection tests are also to be carried out at site. a) Relay picking current b) Relay dropout current Surge Arresters Check whether Surge arresters are securely bolted to structure Surge arrester body and structure are earthed at two places HV terminal is properly connected LV terminal is properly earthed Outside porcelain is properly cleaned and no defect is noticed on visual inspection. Surge counter if available is properly connected. Insulation resistance is appropriate. Check the insulation between arrestor mounting and structure. Battery and D.C System
G. 1. 2. 3. 4. 5. 6. 7. 8. H.
Before being put into commercial operation ensure that: 1. All cells are in position on wooden stand and insulators 2. All cell connections and end take off connections are made and polarity is clearly marked in each cell. 3. Cells are filled with electrolyte of recommended strength upto the required level. 4. The battery room is well ventilated and exhaust fans provided, no smoking signs etc are installed. 5. Initial charging and discharging cycles were carried out as per manufacturers recommendations. 6. Check polarity of outgoing system and to ensure that the outgoing leads are properly connected. 7. Voltage and specific gravity of each cell is correct. If lower values are obtained, recharging of the battery till correct values are obtained is to be done. 8. 10 hr capacity rating of the battery by discharging process is as per IS : 1652 1981. 9. The main distribution is correctly connected. 10. Insulation resistance of the cable connecting the battery to the main D.C distribution board is satisfactory. 11. Other distribution boards have been tested as per requirements before charging. 12. Ensure that mid point earthing is provided. I. Battery Charger 1. 2. 3. 4. 5. 6. 7. To ensure that erection is complete in all respects and that the panel has been earthed at two places. To check and ensure that panel wiring is done as per approved drawing. To check insulation resistance of the panel wiring. To test the transformer for IR value and voltage ratio. To ensure that under voltage relay has been tested in a standard laboratory. To test the functioning of AVR by applying 3 phase AC voltage through a variac and measuring AC input and DC output voltages. To restore AC supply and check operation of contactor, single phase preventer and
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8. 9. 10. 11.
interlock between contactors. To load the charger with battery and record AC voltage and current and DC voltage and current, for 8 hrs. To check all annunciators. To ensure uninterrupted power supply to DC bus by switching off AC supply one by one to boost and float charger. To check and ensure auto adjustment of charging current by putting the float charger in auto position.
J. Substation Earth The earth resistance is to be measured and the value thus obtained should be compared with the required value. If the actual value is more than the designed value, steps are to be taken to reach the desired value. K. Insulators Ensure that 1. All post and strain insulators are securely bolted to structure. 2. Insulators are clean and there is no damage such as hair line cracks etc. 3. Conductors are properly laid on insulators. This test is to be done by a AGA Thermo vision Camera after the substation is charged. A healthy insulator would show no hot spot. 4. IR values of insulators are to be measured and recorded. L. Isolators Ensure that 1. Individual pole units are securely bolted to structure. 2. Connections are made properly on both sides 3. Structures are earthed at two places 4. Insulators are clean and that there are no damages etc. 5. Rotating bearing and mechanism are lubricated 6. Contacts make properly and simultaneously in all three phases. 7. Insulation resistance to be measured and recorded between poles and between each pole and earth. 8. Contact resistance measurement. A current around 100 amps is to be passed through each contact from a primary injection set and the current as well milli volt drop measured across each contact from which contact resistance is calculated. 9. Operational checks to be made by a) Manual closing and opening b) Local closing and opening, where isolator is pneumatically operated. c) Remote closing and opening d) Semaphore and lamp indications. 10. Earth switch operation if any 11. Interlock checks: a) Inter lock with earth switch, if any b) Inter lock with circuit breaker M. Bus-Bars
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Ensure that all insulators are cleaned and there are defects noticed. 1. All structures are earthed at two places and the connections to the ground mat are made. 2. 3. 4. 5. 6. Torque of each connection shall be Resistance of each joint to be measured All control cables shall be tested Complete sub-station trip tests. Over all alarm test shall be conducted.
TECHNICAL SPECIFICATION FOR H.T (33KV & 11KV) ELECTRONIC TRIVECTOR METERS 1.0 SCOPE:
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This specification covers design, engineering, manufacture, assemble, stage testing, inspection and testing before supply and delivery free at destination of 11KV/110V, 200/1A/ (-/5A) 3 element 4wire CT & PT Operated HT Electronic Trivector Meters of class 0.5 accuracy and 33KV/110V, 200/1A, 3 element 4wire CT & PT Operated HT Electronic Trivector Meters of class 0.2 accuracy capable of performing the functions of metering for tariff purpose in all 4 quadrants energy audit, load survey at various H.T. consumers installations / Feeders . All the meters should have suitable in built network interface hardware for RMR (Remote Meter Reading) compatibility to read data through Dial up modems and also through GSM modems. 1.1 It is not the intent to specify completely herein all the details of the design & construction of material. However the material shall conform in all respects to high standards of engineering, design and workmanship and shall be capable of performing in continuous commercial operation in a manner acceptable to the purchaser, who will interpret the meanings of drawings and specification and shall have the power to reject any work or material which, in his judgment is not in accordance therewith. The offered material shall be complete with all components necessary for their effective and trouble free operation. Such, components shall be deemed to be within the scope of Bidders supply irrespective of whether those are specifically brought out in this specification and/or the commercial order or not. STANDARDS: The equipment shall conform in all respects to the relevant Indian Standard Specification with latest amendments thereto. International & Indian Standard Title Internationally recognized standard CBIP Technical Report Specification for AC Static Electrical IEC 687/1992 Static No.88 (with latest Energy Meters. watt hour meters for amendments) classes 0.2 & 0.5 AC Static Watthour Meters for active IS 14697, 1999 energy Meters of Class 0.5 & 0.2. CBIP Technical Report Specification for Common Meter No.111, May, 1997 Reading Instrument IS-5133/1969 Specification for Boxes for the IEC 0687/1992 Enclosure of electrical accessories Static watt hour meters for (part-II Boxes made of Insulating classes 0.2 & 0.5 material) Equipment conforming to other internationally accepted standards. Which ensure equal or higher quality than the standards mentioned above would also be acceptable. In case the Bidder who wish to offer material conforming to the other standards, salient points of difference between the standards adopted and the specific standards shall be clearly brought out in relevant schedule, Four copies of such standards with authentic English Translations, shall be furnished along with the offer. 3.0 SERVICE CONDITIONS: The equipment to be supplied against this Specification shall be suitable for satisfactory continuous operation under the following tropical conditions. 2.1.1
2.0
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Sl. No. i) ii) iii) iv) v) vi) vii) viii) ix) x) xi)
Location Max. ambient air temperature (deg.C) Max. ambient air temperature in a closed (deg.C) Min. Ambient air temperature (deg.C) Average daily ambient air temperature (deg.C) Max. Relative Humidity (%) Max. altitude above mean sea level (m) Average Annual rainfall (mm) Max. wind pressure (kg/sq.m) Isoceraunic level (days per year) Seismic level (Horizontal accn.) Noise Level
At various Sub-stations in the state of Andhra Pradesh 50 60 7.5 35 100 1000 925 200 50 0.10.g. 45 Db
Moderately hot and humid tropical climate, conducive to rust and fungus growth. The climatic conditions are prone to wide variations in the ambient conditions. Smoke is also present in the atmosphere. Heavy lightning also occurs during June to October 4.0 PRINCIPAL PARAMETERS: The material shall conform to the following specific parameters: SI. No. Item Specification 1. 2. 3. 4. 5. 5.0 5.1 Type of Installation System voltage System frequency No. of phases System of earthing To be installed in VCB panels. 110 V phase to phase (+20%,-30%.) 50 Hz +/-5% Three Solidly grounded
TECHNICAL REQUIREMENTS: MATERIAL USED: The meter shall be made out of high quality materials to ensure higher reliability and long life with self extinguishable type polycarbonate meter casing. It should be compact and of reliable design to make it immune to vibrations and shocks in normal transportation and should be capable of withstanding severest stresses likely to occur in actual service. The latest state of the art technology of surface mounting of components etc., may be used for the purpose. The soldering if any shall be perfect without dry solders. The construction of the meter shall be such as to permit sealing of the meter cover, terminal cover etc. independently to ensure that the internal parts are not accessible for tampering etc. without breaking the seals.
5.2
SUPPLY SYSTEM: The HT Trivector meters should be suitable on HV & EHV system by using necessary CT and PTs of. Primary Voltage 11 kV to 220KV for meter specified Secondary voltage 110V phase to phase Primary current 10A and above Secondary current 1A /5A for meter specified
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The meter shall be suitable for balanced and as well as unbalanced loads at all power factors i.e., Zero lag-Unity-Zero lead. The meter shall be suitable for three phase four wire systems for balanced and as well as unbalanced loads at all power factors i.e., Zero lag-Unity-Zero lead. 5.3 POWER SUPPLY VARIATION: The extreme power supply variation which an operating meter should withstand without damage and without degradation of its meteorological characteristics when it is subsequently operated under its operating conditions: Voltage Frequency PF. range -30% to + 20% +/-5% Zero lag-unity-zero lead
However manufacturer can offer meters which can withstand higher variations 5.4 ACCURACY: A. For 11KV TVR meter: Class of accuracy of meter shall be 0.5. But active energy and reactive measurements should have the class of accuracy 0.5 and 1.0 as per CBIP technical report No. 88 with latest amendments. The accuracy should not drift with time. B. For 33KV TVR meter: Class of accuracy of meter shall be 0.2. But active energy and reactive measurements should have the class of accuracy 0.2 and 0.5 as per CBIP technical report No. 88 with latest amendments. The accuracy should not drift with time 5.5 POWER CONSUMPTION: i) Voltage Circuits: The active and apparent power consumption in each voltage circuit including power supply of the meter at reference voltage reference temperature and reference frequency shall not exceed 1.5 Watts and 8 VA per phase. ii) Current Circuit: The apparent power taken by each current circuit of the meter shall not exceed 1.0 VA/phase at basic current and reference frequency. 5.6 MEASURING PARAMETERS: The meter should be capable of measuring the following electric parameters of polyphase supplies in all the four quadrants at all power factors lagging or leading. 1. LED test/Anomaly indicator of LCD 2. Active energy kWH 3. Reactive energy kVARH/ (lag & lead) 4. Apparent energy kVAH 5. Max. demand with date and time kVA 6. Power factor 7. Elapsed time and rising demand 8. MD reset count 9. Cumulative MD Previous 11Nos. MD values with 10. Display of No. of MD resets date & time and source of reset
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11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
Recording of missing potential & reversal of current with date and time Real time date CT Ratio, PT Ratio TOD register Phase voltage (instantaneous) Phase current (instantaneous) Tamper and fraud details Self diagnostics Frequency Internal multiplying factor of CTs and PTs
NOTE: 1) The parameters kWH, kVARH, kVAH, max. demand and raising demand with elapsed time shall be displayed continuously in cyclic order on the meter to enable the EPDCL/consumer to know the above parameters at any instant. 2) At the start of each sequence of display LED/LCD healthiness anomaly shall be displayed. 3) The meters shall be capable of delivering load survey data for selected days and for selected duration and should be user programmable either through CMRI or from remote metering data terminal PC. 5.6.2 Display Parameter (Auto display): The meter should be capable of displaying the following parameters automatically: Sl. No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 5.6.3 Parameter Active Energy Reactive Energy Apparent Energy Maximum Demand(Occurrence, Date & Time) Rising Demand with elapsed time. M.D Reset Count Last month M.D Date of last month M..D. reset Cumulative M.D Instantaneous Power Factor Line Frequency Self Diagnostic (LCD/ LED segment check & battery check) Real time, date.
Display Parameter (Push Button): The meter should be capable of displaying the following parameters using push button: Sl. No. Parameter 1. Active Energy 2. Reactive Energy
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3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 5.6.4
Apparent Energy Maximum Demand (Occurrence, Date & Time) Elapsed Time & Rise in Demand M.D Reset Count Cumulative M.D Previous 11 Nos. M.D Values with Date & Time and Source of reset Instantaneous Power Factor Line Frequency Real Time & Date Phase Voltages (Instantaneous) Phase Current (Instantaneous) Number of Tamper events. CT Ratio, PT Ratio Self Diagnostics (LCD/ LED segment check & battery check)
Read out Parameters with CMRI/ RMR: The following Read out parameters with CMRI/ RMR should be present in the meter: Sl. No. 1. 2. 3. 4. 5. 6. 7. 8. Parameter Meter Serial Number, Model & Make. All parameters at clause 5.6.3 Energy Registers Billing Registers T.O.D Registers Load Survey Data Temper & Fraud (all event details with date & time) Self diagnostic details (real time calendar, low battery)
5.7
MAXIMUM CURRENT: The maximum current of the meter is 120% Ib at which the meter purports to meet the accuracy requirements. The meter should start registration of energy at 0.1% of basic current (Ib).
5.8
DISPLAY: The meter shall have a minimum 7 digit display of liquid crystal display (LCD) or light emission diode display (LED), with another digit for legend the minimum character height shall be 9 mm. Provision shall be made to read consumption in either whole units of decimal multiples or sub-multiples of one unit. The display shall be digital type with non destructive read out. It shall be possible to display contents of relevant display with another digit displaying legend for identification of display. The meter should have facility of auto display mode where all parameters automatically scroll with in the specified time. The number of parameters and the scrolling period shall be field programmable. The meter should have non volatile memory, so that the registered parameters will not be affected by loss of power. A provision shall be made to read the meter parameters such as MD and consumption etc. through the meter cover without
184
actually opening the meter box cover. The nonvolatile memory should have a minimum retention time of 12 years. 5.9 MAXIMUM DEMAND REGISTRATION: The maximum demand is to be monitored during each demand interval set (30/15 minutes) and the maximum of these in a month shall be stored. Whenever MD is reset the maximum MD value so registered shall be stored along with date and time and source of reset. Under the current integration period, the rising demand should be displayed continuously along with the elapsed time. The registered demand and the number of times the MD is reset shall also be displayed and the information stored. 5.10 MD RESET:
The meter should have provision of maximum demand resetting. a) Manually by operation of a button which is to be covered and sealing provision available for such cover. b) Resetting shall also be possible through hand held common meter reading instrument (CMRI) capable of communicating with the meter. c) Provision for automatic resetting at the end of certain period may be made available and it should be possible to invoke this through CMRI with date and time. For this minimum 30 years calendar shall be programmed by the manufacturer. 5.11 (a)LOAD SURVEY CAPABILITY: The meter should log any six parameters depending upon the EPDCLs requirements which are selectable from KWH, KVRH lag & lead, and max. demand with 30/15min. demand data for last 35 days in its memory and it should be possible to transfer this data on to a base computer station through a DOS based hand held CMRI/ through P&T lines. The base computer shall give complete details of load survey particulars both in numeric data form and in graphic form. Necessary software for invoking the base computer station should be provided. 5.11(b) QUALITY OF SUPPLY: The meter shall provide date & time stamped profiles of each interruptions along with duration. 5.12 TIME OF DAY TARIFF/DEMAND: The meter offered shall contain provisions for multiple tariff metering (time of day metering/demand) and details of the same may be indicated in the tender separately. The meter offered should have a real time clock based on a quartz crystal with a battery totally independent of power supply. The meter shall be capable of being set in to minimum of 8 time zones (optionally more time zones can be offered) in 24 hours cycle to cover morning and evening on and off peak periods separately. TOD register shall be provided for active energy, reactive energy (lag & lead) and demand data as per CBIP technical report No. 88 (with latest amendments). Initially TOD registers are not operated and it should be possible for the Board to invoke them through the use of a CMRI with 2 level pass word protection and necessary software should be loaded by the meter supplier into the Base computer station of the Board for this purpose.
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5.13
REMOTE READ OUT FACILITY/COMMUNICATION CAPABILITY:
(i) The meter shall be provided with a galvanically isolated optical communication port (such as IEC-1107 PACT port, ANSI Port, etc. with open MOD BUS compatibility, so that it can be easily connected to a CMRI for data transfer or subsequently hooked to remote metering device such as modem etc. The optical communication port shall also have sealing provision. Companies may adopt protocol of their choice but should load the software and the protocol software into base computer station of the APEPDCL. It is the responsibility of the meter manufacturer to provide the software and all the facilities required by the APEPDCL to use the DOS based hand held CMRI for reading the meter and generating appropriate reports required by the APEPDCL. The data element size and its over head speed of transmission shall be such that the entire billing data can be transferred within maximum time of 3 minutes. (ii) For remote read out there should be two RS 485 ports convertible to RS 232 port / separately one RS -485 and RS-232 port as per the requirement. (iii)Software: The following software shall be made available by each meter manufacturer whose meters are to interface with hand held meter reading instrument/CMRI. (a) (b) Software to be resident in hand held terminal/CMRI for the purpose of reading and programming the specific make(s) of static meters. Base computer station software for accepting data from hand held terminal/CMRI, processing, generating reports and down loading instructions from the Base computer station to CMRI. Dial up software and protocal software for accepting the data from the meter through P&T lines to the base computer station / central computer station, processing and generating appropriate reports.
(c)
(iii)DATA SECURITY: The meter manufacturers are responsible for maintaining the security of the data extracted from the meters using manufacturer specific algorithms in the software upto down loading to the base computer station. 5.13.1. The meter shall also have the following technical features 1. Voltage and current sources will be available from star-star connected P.T. of the system and current transformer of suitable ratio, respectively. 2. The meter should record and continue to display so long as two potentials are available. The display and recording should have no relevance with reference to the availability of departmental neutral. 3. The meter shall be suitable for lag only tariff. In case of lagging load, KVA H 2 = KWH2 + RKVA H2 and with leading load, KVA H2 = KWH2 . The RKVA H load contribution shall be blocked. 4. The meter shall be site programmable in case of necessity to use these meters in Import/ Export mode and also TOD features. As and when required TOD parameters must be field invocable.
186
5.
Each parameter shall be on display for a minimum period of 6 seconds.
6. Load survey with 30/15 min. integration for KWH, Average Three Phase voltage, R,Y & B currents for 35 days shall be available for the meters. 7. The meter has to record potential missing only when phase voltage is less than 80% of Vn ( nominal voltage) i.e. if the voltage falls below 50.8V for Three Phase 4 Wire meters . 8. MD button and MD display should be labeled preferably in different colours.
9. The phase indicators should flicker only on load but not on no loads which is presently available. 5.14 TERMINAL ARRANGEMENTS: The terminals shall be marked properly on terminal block for giving external connections. A diagram of connections should be provided inside the cover of terminal block. The terminal cover shall be extended such that when it is placed in position it is not possible to approach the connections or connecting wires. The terminals and the screws shall be suitable to carry up to 150% of Imax safely. The terminals shall have a suitable construction with barriers and covers to provide secure and safe connections of Current Transformers and Voltage Transformers leads of stranded copper conductors of 2.5 Sq.mm size. 5.15 TEST TERMINAL BLOCK WITH COVER: A separate TTB is to be provided. Suitable provision shall be made in the test terminal block for disconnecting the meter for testing purposes and for the purposes of testing the meter. The test terminal block shall have provision for isolating the meter from the instrument transformer secondary connections. Proper arrangements for sealing of test terminal blocks cover are to be made. The test terminal block shall also have extended terminal cover such that when it is placed in position it is not possible to approach the connections or connecting wires. The live parts and current terminals shall not be accessible from the rear of TTB to prevent tampering. The TTB shall be of good quality and standard make). 5.16 SEALING OF METER: Proper sealing arrangements should be provided on meter to make it tamper proof and avoid mishandling by unauthorised persons . The manufacturer shall provide minimum two seals for the meter at the factory after calibration and testing. The meter cover shall have provision for placing minimum 2 Nos. additional seals by the purchaser. The terminal block and test terminal block (TTB) with minimum 1 No. each sealing screw. One number separate sealing arrangement to the MD Reset push button. Sealing arrangement for optical port to be used for communication to CMRI should also be provided. The meter should be designed and constructed in such a manner to make it pilfer proof once it is sealed 5.17 5.17 ENVIRONMENTAL ASPECTS: Meter shall be designed and constructed to be capable of withstanding all severe stresses and vibration and dust environments likely to be encountered in actual practice as the meter will be installed outdoor in boxes.
187
If any special precautions etc. are required as the meters are supposed to be installed in outdoor you may please specify them. 5.18 NAME PLATE MARKING:
The name plate shall be clearly marked etched embossed as per relevant Standards. The name plate shall indicate purchasers name purchase order number & date, month and year of manufacture etc. The word APEPDCL JBIC-II must be etched on the nameplate. The name plate shall be provided in such a manner that it is not exposed to the open and is secured against removal. 5.19 IMMUNITY TO ELECTRO MAGNETIC DISTURBANCE: The meter shall be designed in such a way that conducted or radiated electromagnetic disturbance as well as electrostatic discharge do not damage or substantially influence the meter. The test report from any standard lab conducting the test as prescribed in the CBIP technical report No.88 (with latest amendments) and test results submitted. 5.20 GUARANTEED TECHNICAL PARTICULARS: The technical particulars as detailed in the specification shall be guaranteed and a statement of guaranteed technical particulars shall be furnished in format along with the tender. 5.21 TAMPER AND FRAUD PROTECTION:
The meter should have the following features to prevent/detect common ways of tamper and fraud: i) Phase sequence reversal: The meter should work accurately irrespective of phase sequence of the supply. ii) CT shorting/bypassing: The meter must have capability to record shorting/bypassing of one or any phases of the meter with date, time and duration. iii) CT Polarity reversal: The meter should register energy consumption correctly even though the CT polarities are reversed with date and time along with total number of such occurrences for all phases during the above period. iv) Missing Potential : The meter shall be capable of recording occurrences of missing potential phase wise which can happen either owing to a P.T. fuse blowing or due to internal disconnections of a potential lead and its restoration with date and time along with total number of such occurrences during the above period. v) Missing Neutral: The meter shall continue to record accurately even if the neutral of PT supply is accidentally or incidentally disconnected. vi) External magnetic influence: The meter shall not get influenced by any external permanent / electromagnet(s). The continuous Magnetic induction of external origin: The value of magneto motive force to be applied as per the stipulations of CBIP Report No. 88 read with amendments for Static Electronic Energy Meters. vii) Tamper information: Minimum 50 events (occurrences and restoration) with date and time for all tampers individually. The information shall be logged on first in first out basis and total number of tamper events during the period. All these information should be available in simple and easily understandable format.
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5.21.1 The bidder should furnish with detail explanation how their meters are able to detect/protect recording the above tamper and fraud features with sketches phasor diagrams if required. Bids without these details shall be treated as Non-responsive. 5.22 Self diagnostics features: 5.22.1 The meter shall have indications for unsatisfactory/ non functioning of the following: i) Time and Calendar ii) Real Time Clock Battery All Display segments iv) Non volatile memory (NVM) failure indication at BCS v) And any thing else as necessary. 5.22.2 While installing the meter, it should be possible to check the correctness of Current Transformer, Potential Transformer connections to the meter and their polarity from the functioning of the meter for different voltage injections. For this purpose suitable software for field diagnosis of the meter connections with the help of meter and meter reading instruments should be supplied. The details of the self-diagnostic features shall be furnished by the Bidder. 5.23 FLEXIBLE SHIELDED CABLES: 5.23.1. Interface between meter and CMRI: Meter optical sensor terminating into RS 232 C, 9 Pin D-type male connector with a flexible shielded cable of length 1500 mm + / - 10mm with electrical circuit as illustrated a Appendix. This cable shall be supplied along with every Meter. The two ends of the cable shall be stress relieved. 5.23.2. SALIENT FEATURES: The meter shall have the following additional salient features: i) It should be possible to check the healthiness of phase voltages by displaying all the voltages on the meter display. ii) The meter shall have provision to be read through communication port in the absence of power through an external source. An inductive coupling arrangement shall be provided so that it should not be possible to damage the circuitry of the meter by applying excess voltage directly in the meter. The meter should power up using an external battery pack only in absence of power supply to the meter to enable taking of meter readings through display and communication port.
iii)
iii) The meter should work accurately irrespective of phase sequence of the mains supply. iv) The meter should remain powered up and functional even when either of any two phases or any one phase along with neutral is available to the meter. v) The meter should continue to record accurately as per prevailing electrical conditions even if the neutral of potential supply gets disconnected.
vi) a) The meter shall record active energy in forward direction even if one or more CTs are reversed. The current vector direction shall always be considered as positive (import) for the computation of 3 phase active energy which shall be added in the main active energy (import) register.
b) The meter shall record apparent energy in forward direction even if one or more CTs are reversed. c) The maximum demand shall be computed from the main active and apparent energy registers. 6.0 6.1 TESTS: TYPE TESTS: As per the specification, the metes shall be supplied for JBIC Ph-II works. The test certificates not more than two years old on the date of awarding of work from the recognized accredited national test laboratory as per the relevant standards shall be submitted along with the meters. After supplying of meters the random inspection will be conducted in the presence of bidder and the same will be sent for testing at 3rd party Government laboratory for all the type tests as per IS 13779/1999 at your cost. If any meter fails in the above tests the entire lot will be rejected. 6.1.1 6.1.2 Tests for Trivector Meters : As per CBIP Technical Report No. 88.( with latest amendments) IEC-687. Tests for boxes: As per IS 5133 (Part II) 1969 and in addition the box material will be tested for withstanding temperatures of boiling water for 5 minutes continuously for non distortion or softening of the material. The successful bidder shall submit the test reports for box within two weeks of clear purchase order. 6.2 ACCEPTANCE AND ROUTINE TESTS: All acceptance tests as stipulated in the relevant standards shall be carried out by the supplier in presence of employers representative. All routine tests as in the relevant standards shall be carried out and routine test certificates shall be submitted to each consignee while dispatching the material. The employer reserves the right to insist for witnessing the acceptance/routine testing. 6.2.1 6.2.2 Tests for Trivector Meters: As per CBIP Technical Report No.88 (with latest amendments) The following shall constitute acceptance test for box: i) ii) 6.2.3 Physical verification of dimensions of the box. Compatibility of the box for housing the meter, TTB where applicable and ensuring ease of connecting and reading the meter.
Tests during manufacture: The Bidder shall furnish details of tests carried out during the process of manufacture and end inspection by the bidder to ensure the desired quality of the equipment to be supplied. ADDITIONAL TESTS: The purchaser reserves the right of having at suppliers expenses any other tests(s) of reasonable nature carried out at Bidders premises, at site, or in any other place in addition
6.3 6.3.1
190
to the aforesaid type, acceptance and routine tests, to satisfy himself that the material comply with the specifications. 6.3.2 In case of failure in any type test, the supplier is required to modify the design of the material and the material shall be type tested again for the modified design, without any extra cost to the purchaser. No delivery extension shall be given for this additional testing. TEST REPORTS / TEST CERTIFICATES: Record of routine test reports shall be maintained by the Bidder at his works for periodic inspection by the purchasers representative. Test certificates of tests conducted during manufacture shall be maintained by the Bidder. These shall be produced for verification as and when desired by the purchaser. TEST FACILITIES: The tests shall be carried out as per relevant Standards and test certificates shall be furnished for approval. The Bidder shall indicate the details of the equipment available with him for carrying out the various tests as per relevant Standards. The bidder shall indicate the sources of all materials. NOTE: The Meters used for conducting tests shall be calibrated periodically at reputed Government accredited Test Laboratories and test certificates shall be available at works for verification by employer representative. 7.0 7.1 INSPECTION: The purchasers representative shall, at all times, be entitled to have access to the works and at all places of manufacture where equipment is offered, and manufactured and the representative shall have full facilities for unrestricted inspection of the bidders works, raw materials and process of manufacture and conducting necessary tests as detailed herein. The Bidder shall keep the purchaser informed in advance of the time of starting and of the progress of manufacture of the offered equipment in its various stages so that arrangements can be made for inspection. The supplier shall give 15 days advance intimation to enable the purchaser to depute his representative for witnessing acceptance and routine tests. No material shall be dispatched from its point of manufacture before it has been satisfactorily inspected and tested, unless the inspection is waived off, by the purchaser in writing. The acceptance of any quantity of material shall in no way relieve the Bidder of any of his responsibilities for meeting all requirements of the specification, and shall not prevent subsequent rejection if such material is later found to be defective. NOTE FOR FOREIGN BIDDERS: The bidder shall indicate the name(s) of reputed inspection agencies and the inspection charges clearly for each lot. The inspection charges shall be borne by the supplier.
6.4 6.4.1 6.4.2 6.5
7.2
7.3 7.4
7.5
7.6
191
However the purchaser reserves the right to appoint at its cost any inspection agency to carry out the inspection. 8.0 QUALITY ASSURANCE PLAN: The bidder shall invariably furnish the following information along with his bid, failing which his bid shall be liable for rejection. Information shall be separately given for individual type of material offered. The structure of organization. The duties and responsibilities assigned to staff ensuring quality of work.
i) ii)
iii) The system of purchasing, taking delivery and verification of materials. iv) The system for ensuring quality of workmanship. v) The quality assurance arrangements shall conform to be relevant requirements of ISO 9001 or ISO 9002 as appropriate. vi) Statement giving list of important raw materials names of sub-suppliers for the raw materials, list of standards according to which the raw materials are tested. List of test normally carried out on raw materials in presence of Bidders representative, copies of test certificates. vii) Information and copies of test certificates as in (vi) above in respect of bought out accessories. viii) List of manufacturing facilities available. ix) Level of automation achieved and list of areas where manual procession exists. x) List of areas in manufacturing process, where stage inspections are normally carried out for quality control and details of such tests and inspections.
xi) Lists of testing equipment available with the bidder for final testing of equipment specified and test plant limitation. If any, vis-a-vis the type, special acceptance and routine tests specified in the relevant standards. These limitations shall be very clearly brought out in schedule of deviations from specified test requirements. The successful Contractor shall within 30 days of placement of order, submit following information to the employer. i. ii. iii. List of raw materials as well as bought out accessories and the names of sub suppliers selected from those furnished along with offers. Type test certificates of the raw materials and bought out accessories if required by the employer.. Quality assurance plan (QAP) with hold points for employers inspection. The quality assurance plan and purchasers hold points shall be discussed between the employer and Contractor before the QAP is finalized.
The Contractor shall submit the routine test certificates of bought out accessories and central excise asses for raw material at the time of routine testing if required by the purchaser and ensure that the quality assurance requirements of specification are followed by the sub-contractor. The quality assurance programme shall give a description of the quality system and quality plans with the following details.
192
A)
Quality System: The structure of the organisation. The duties and responsibilities assigned to staff ensuring quality of work. The system for purchasing, taking delivery and verification of materials. The system for ensuring quality workmanship. The system for control of documentation. The system for the retention of records. The arrangement for the contractors internal auditing. A list of administration and work procedures required to achieve and verify contracts quality requirements. These procedures shall be made readily available to the purchaser for inspection on request. Quality Plans: An outline of the proposed work and programme sequence. The structure of the contractors organisation for the contract. The duties and responsibilities assigned to staff ensuring quality of work. Hold and Notification points. Submission of Engineering documents required by the Specification. The inspection of materials and components on receipt. Reference to the contractors work procedures appropriate to each activity. Inspection during fabrication/Construction. Final inspection and test. DOCUMENTATION: All drawings shall conform to International Standards Organisation (ISO) A series of drawings sheet/India Standards Specifications IS :656. All drawings shall be in ink and suitable for micro filming. All dimensions and data shall be in S.I. Units. LIST OF DRAWINGS AND DOCUMENTS: The bidder shall furnish the followings along with bid: i) ii) iii) Two sets of drawings showing clearly the general arrangements, fitting details, electrical connections etc. Technical leaflets (users manual giving operating instructions.) Dimensional drawings of the box for each quoted item.
B)
9.0 9.1
9.2
9.3
The manufacturing of the equipment shall be strictly in accordance with the approved drawings and no deviation shall be permitted without the written approval of the purchaser. All manufacturing and fabrication work in connection with the equipment prior to the approval of the drawing shall be at the suppliers risk. 9.4 Approval of drawings/work by purchaser shall not relieve the supplier of his responsibility and liability for ensuring correctness and correct interpretation of the drawings for meeting the requirements of the latest revision of application standards, rules and codes of practices. The equipment shall conform in all respects to high standards of engineering, design, workmanship and latest revisions of relevant standards at the time of ordering and purchaser shall have the power to reject any work or materials which, in his judgment is not in full accordance therewith.
193
9.5
The successful Bidder shall, within 2 weeks of placement of order, submit three sets of final versions of all the drawings as stipulated in the purchase order for purchasers approval. The purchaser shall communicate his comments/approval on the drawings to the supplier within two weeks. The supplier shall, if necessary, modify the drawings and resubmit three copies of the modified drawings for their approval. The successful bidder shall furnish a sample of box duly mounting the meter, TTB where applicable within two weeks of clear purchase order along with type tests certificates as per Clause 6.1.3. Supplies shall commence only after approval of these. Eight sets of operating manuals/technical leaflets shall be supplied to each consignee for the first instance of supply. One set of routine test certificates shall accompany each dispatch consignment. The acceptance test certificates in case pre-dispatch inspection is routine, test certificates in cases where inspection is waived shall be got approved by the purchaser. CDs containing protocol Software and RMR enabling software in 2 sheets shall be furnished. PACKING & FORWARDING: The equipment shall be packed in crates suitable for vertical/horizontal transport as the case may be and suitable to withstand handling during transport and outdoor storage during transit. The supplier shall be responsible for any damage to the equipment during transit, due to improper and inadequate packing. The easily damageable material shall be carefully packed and marked with the appropriate caution symbol. Wherever necessary, proper arrangement for lifting, such as lifting hooks etc., shall be provided. Any material found short inside the packing cases shall be supplied immediately by supplier without any extra cost. Each consignment shall be accompanied with a detailed packing list containing the following information. a) Name of the consignee. b) Details of consignment. c) Destination. d) Total weight of consignment. e) Handling and packing instructions. f) Bill of Material indicating contents of each package. The supplier shall ensure that the packing list and bill of materials, are approved by the employer before dispatch. The packing shall be done as per the manufacturers standard practice. However, he should ensure the packing is such that, the material should not get damaged during transit by Rail/Road. The marking on each package shall be as per the relevant Standards and shall also contain APEPDCL-JBIC-II., PO reference , Name of the supplier, make, meter type and meter serial No. QUANTITY AND DELIVERY REQUIREMENTS:
9.6
9.7. 9.7.1 9.7.2 9.7.3. 10.0 10.1.
10.2
10.3 10.4
10.5
11.0
194
The quantity and delivery requirements are indicated in Section- IV. 12.0 SUPERVISION SERVICES: NIL The purchaser will arrange for unloading of the consignments. 12.1 MANDATORY SPARES & TOOLS: The bidder shall give the list of spares required for the equipment along with price list for them & shall keep a reasonable stock of the same during the warranty period. The bidder shall indicate the sources of spares like battery packs, interfacing cables in India and also mention the service agencies. 13.0 SAMPLE: After supply of meters 2Nos. sample meters of HT Static TVR meters for 11KV of class 0.5 accuracy and 2Nos. sample meters of HT Static TVR meters for 33KV of class 0.2 accuracy shall be selected at random in the presence of bidder. This sample may be subjected to various tests as per CBIP Technical Report No. 88 (with latest amendments) IEC 687 / IS wherever applicable & tamper and fraud protection tests. The samples shall comply with the specification. In the event of the testing of the sample meter as above would at the cost of the bidder. 14.0 TECHNICAL DEVIATIONS: Any deviation in Technical Specification as indicated in Section-V shall be specifically and clearly indicated in the enclosed Technical deviation format as per Section VII. GUARANTEE:
15.0
15.1. The material should be guaranteed for satisfactory operation for a period of 5 years from the date of receipt of material at destination stores by the consignee in good condition. During the guarantee period if the meter while in its normal operation is found defective, it shall be replaced by the supplier with a new meter free of cost with in 15 days. If the meter is not replaced within 30 days of intimation the supplier should note that the guarantee period will be extended to that extent by the number of days delayed beyond 30 days. If the tenderer does not replace within 180 days the cost of the meter(s) will be recovered from the existing bills/ future bills/ Bank Guarantees available APEPDCL. For the purpose of ensuring 5 years guarantee meter may be sealed at manufacturers premises and despatch in sealed condition after inspection by the APEPDCL representative. 15.2 GUARANTEED TECHNICAL PARTICULARS The Bidder shall furnish the guaranteed Technical Particulars as per enclosed Annexure-I-A for HT ELECTRONIC TRIVECTOR METERS used in meters, Annexure I B for BOX used for meter and submit the same with the Tender. 15.3 GENERAL:
a) Principle of operation of the meter, outlining the methods and stages of computation of various parameters starting from input voltage and current signals including the sampling rate if applicable shall be furnished by the bidder.
195
b) The bidder shall indicate the method adopted to transform the voltage and current to the desired low values with explanation on devices used such as CT, VT or Potential divider as to how they can be considered superior in maintaining ratio and phase angle for variation of influence quantities during its service period. c) The bidder shall furnish details of memory used in the meter. d) Details of testing facilities: The manufacturer laboratory must be well equipped for testing of the meters. They must have computerized standard power source and standard equipment calibrated not later than a year (or as per standard practice). The details of testing facilities available for conducting (a) The routine tests and (b) Acceptance tests shall be furnished in a statement. Bids without these details will be treated as Non responsive.
APPENDIX DIAGRAM SHOWING THE 9 PIN CONNECTOR 9 PIN MALE CONNECTOR
500 mm
1 500 mm
RS 232C 9 PIN D TYPE MALE CONNECTOR
*5 *9 *4 *8 *3 *7 *2 *6 *1
PIN FUNCTION LISTING:

PIN 01 02 03 04 05 06 07 08 09
SIGNAL NAME NC ( Not Connected) Transmit Data TXD Receive Data RXD NC Signal Ground (SG) NC NC NC Power supply ( +4.75 V to +12.5 V) ACRONYMS
Reference Abbreviations IEC ISO ISS CBIP CT PT Deg. C Max Accn. db MD TOD Min. CMRI
Name and Address International Electro Technical Commission Bureau Central de la Commission Electro Technique International, Rue de verembe Geneva, Switzerland. International Organization for Standardization, Danish Board of Standardization Aurehoegyej 12, DK 2900, Heel prup, DENMARK. Indian Standard Bureau of Indian Standards Nanak Bhavan, 9, Bhadur Shah Zafar Marg, NEW DELHI 110002, INDIA. Central Board of Irrigation and Power, Malcha Marg, Chankyapuri, NEW DELHI 110021, INDIA. Current Transformer Potential Transformer Degrees centigrade Maximum Acceleration Decibels Maximum Demand Time off day Minimum Common Meter Reading Instrument
For the purpose of ensuring 5 years guarantee meter may be sealed at manufacturers premises and despatch in sealed condition after inspection by the APEPDCL representative. ANNEXURE I A
GUARANTEED TECHNICAL PARTICULARS FORHT ELECTRONIC TRIVECTOR METERS
Sl. No. 1. 2. 3. 4. 5
Characteristics Markers name and country Type of meter/model Standards to which the meter conform Accuracy class Power consumption for phase i) Voltage circuit
197
6 7 8 9 10 11 12 13 14 15
16.
17. 18. 19. 20.
21.
ii) Current circuit Parameters measured P.F. Range Overload capacity Variation of voltage at which meter functions normally Minimum starting current Dynamic range MD reset provisions Display of cumulative MD Display of MD resets along with date and time No. of digits of display; and height of character Particulars of readout a) Continuous display b) Manually on display c) Auto display i) Parameters ii) Scrolling period iii) Display of period between two Cycles d) With MRI a) Meter terminal block having sealable extended terminal corner b) Test terminal block (TTB) with sealable extended cover c) Connection diagram inside the terminal cover d) Maximum safe current the terminals and screws shall carry Non volatile memory retention time in absence of power Details capacity (KB) Details of ratings/capacities a) Current ratings b) Integration period a) Remote readout facility provision b)Communication protocol used c) Sealing provision for optical port d) Baud rate of data transmission e) Required software to be resident in CMRI and BCS f) Data security Change in errors ( accuracy) due to variation in a) Voltage variation
ii i) + 20% to + 10% ii) + 10% to - 10% iii) -10% to -20% iv) - 20% to - 30%
b) Frequency variation 22
i) 50+10% Hz ii) 50+ / -5% Hz iii) 50-10% Hz
c) Temperature Basic current

i) <5% Ib ii) 5%Ib to 120% iii) > 120% Ib
PF ( zero lagging, unity, zero lead)
198
23
24 25
Details of tamper and fraud provisions a) On display b) With meter reading instrument and data transfer Detailed explanation how the tamper detection made is furnished or not Import / Export features Whether the meter is four quadrant meter Sealing of the meter ( Nos. of seals) Meter cover Terminal block cover MD reset push button Communication port Test terminal block Others, if any No. of TOD registers Whether meter carries any certification mark Self diagnostics features ( Provide details) Principle of operation ( Provide details) Guarantee for satisfactory operation of meter
26
27 28 29 30 31
199
QUALITY ASSURANCE: 1.0 QUALITY ASSURANCE PROGRAME
To ensure that the equipment are in accordance with the specifications the contractor shall adopt suitable quality assurance programme to control such activities at all points, as necessary such programme shall be out lined by the contractor and shall be finally accepted by owner/authorized representative after discussions before the award of contract. The QA programme shall be generally in line with ISO-9000/IS-14000. A quality assurance programme of the contractor shall generally cover the following. i) ii) iii) iv) v) vi) vii) viii) ix) x) xi) xii) xiii) xiv) xv) xvi) His organization structure for the management and implementation of the proposed quality assurance programme Quality system manual. Design control System Documentation control system Qualification data for bidders key personnel The procedure for purchase of material, parts, components and selection of sub vendors service including vendors analysis, source inspection, incoming raw material inspection, verification of materials purchased etc. System for shop manufacturing control including process controls, fabrication and assembly controls Control of non-conforming items and systems for corrective actions. Inspection and test procedure Control of calibration and testing of measuring and testing equipment. System for indication and appraisal of inspection status. System for quality audit System for authorities release of manufactured product to owner. System for maintenance of records System for handling storage and delivery All the plant standard/written down practices followed by the manufacturer/contractor against the manufacturing activities in their works will be submitted in electronic media preferably in at least one set of compact discs.
2.0 2.1
GENERAL REQUIREMENS QUALITY ASSURANCE
All materials, components and equipment covered under the specification shall be procedure manufactured and tested at all the stages, as per a comprehensive quality programme. An indicative programme of inspection/tests to be carried out by the contractor for some of the major items is given in this specification. This is however, not intended to form a comprehensive programme as it is the contractors responsibility to draw up and implement such programme duly approved by the Owner. The detailed quality plans for the manufacturing activities should be drawn up by the bidder and will be submitted to Owner for approval. Schedule for finalization of such quality plans will be finalized before award. 2.2 Manufacturing quality plan shall detail out for all the components and equipments, various tests, inspection, to be carried out as per the requirements to this specification and standards mentioned therein and quality practices and procedures followed by contractors Quality Control Organization, the relevant reference documents and standards acceptance norms, inspection documents
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raised etc. during all stages of material procurement manufacture, assembly and final testing/performance testing. 2.3 The Bidder shall also furnish copies of the reference documents/Plant Standard/Acceptance norms/Test and inspection procedure etc. as referred in Quality Plan along with Quality Plans .the Quality Plans and reference documents/standards etc. will be subject to Owners approval and will form a part of the contract in these approved Quality Plan, Owner shall identify customer hold points (CHP) which shall be carried out in presence of the Owners Project Manager and beyond which work shall not proceed without written consent of Owners Project Manager/Authorized representative in writing. All deviation to this specifications approved quality plans and applicable standard must be documented and referred to Owner along with technical justification for approval and disposition. No material shall be dispatched from the manufactures works before the same is accepted subsequent to pre-dispatch final inspection including verification of records of all previous tests/inspections by Owners Project manager/authorized representative, and duly authorized for dispatch issuance of MDCC. All materials used and supplied shall be accompanied by valid and approved materials certificates and tests and inspection reports. These certificates and reports shall indicate the heat numbers or other such acceptance identical numbers of the material. The material certified shall also have the identification details stamped on it. All materials used for equipment manufacture including casting and forging etc. shall be of tested quality as per relevant codes standard. Details of results of the tests conducted to determine the mechanical properties chemical analysis and details of heat treatment procedure recommended and actually followed shall be recorded on certificates and time temperature chart. Tests shall be carried out as per applicable material standards and/or agreed details All welding and brazing shall be carried out as per procedure drawn and qualified in accordance with requirements of ASME. Section IX/BS-4870 or other international equivalent standard acceptable to the Owner. All welding/brazing procedure shall be submitted to the Owner authorized representative for approval prior to carrying out the welding/brazing. All brazers, welders and welding operations employed on any part of the contract either in Contracts/his Sub-contractors works or at site elsewhere shall be qualified as per ASME Section IX or BS 4871 or other equivalent international Standards acceptable to the Owner. Test results of qualification tests and specimen testing shall be furnished to the Owner for approval. However where required by the Owner, tests shall be conducted in presence of Owner/Authorized representative.
2.4
2.5
2.6
2.7
2.8 2.9
2.10
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2.11 2.12 2.13
All the heat treatment results shall be recorded on time temperature charts and verified with recommended regimes. Results of all non-destructive testing shall be record on certificate. All the sub-vendors proposed by the Contractor for procurement of major bought out item including castings, forgings, semi-finished and finished components/equipment, list of which shall be drawn up by the Contractor and finalized with the Owner shall be subject to owner approval. The contractor proposal shall include vendors facilities established at the respective works, the process capability process stabilization, QC Systems followed experience list, etc along with his own technical evaluation and shall be submitted to approval shall not relieve the contractor from any obligation duty or responsibility under the contract. For components/equipment procured by the Contractors for the purpose of the Contract, after obtaining the written approval of the Owner, the Contractors purchase specifications and enquiries shall call for quality plans to be submitted by the suppliers along with their proposals. The quality plans called for from the vendors shall set out, during the various stages of manufacture, the quality practices and procedures followed by the vendors quality control organization, the relevant reference documents/standards used acceptance level, inspection of documentation raised etc. Such quality plans of the successful vendors shall be finalized with the owner and such approved Quality Plans shall form a part of the purchase order/contracts between the contractor and the vendor, within three weeks of the release of the purchase order/contract for such bought out items. Components, a copy of the same without price details but together with the detailed purchase specifications, quality plans and delivery conditions shall be furnished to the Owner by the Contractor. The purchase specifications for the major bought out items, list of which shall be drawn up by the Contractor and finalized with the Owner shall be furnished to the Owner for comments and subsequent approval before orders are placed. Owner reserves the right to carry out quality audit and quality surveillance of the systems and procedures of the Contractors or their sub-vendors quality management and control activities. The contractor shall provide all necessary assistance to enable the Owner carry out such audit and surveillance. The Contractors shall carry out an inspection and testing programme during manufacture in his works and that of his sub-contractors and at site to ensure the mechanical accuracy of components compliance with drawings, conformance to functional and performance requirements, identity and acceptability of all materials parts and equipment. He shall carry out all tests/inspections required to establish that the items/equipments conform to requirements of the specifications and the relevant codes/standards specified in the specifications, in addition to carrying out tests as per the approved Quality Plan.
2.14
2.15
2.16
2.17
2.18
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2.19
Quality audit/surveillance/approval of the results of the tests and inspection will not, however, prejudice the right of the Owner to reject the equipment if it does not comply with the specification when installed or does not comply with the specification in service and the above shall in no way limit the liabilities and responsibilities of the Contractor in ensuring complete conformance of the materials/equipment supplied to relevant specification, standard data sheet, drawings etc. For all spares and replacement items, the quality requirements as agreed for the main equipment supply shall be applicable. Repair/rectification procedures to be adopted to make the job acceptable shall be subject to the approval of the Owner/authorized representative.
2.20 2.21 3.0
QUALITY ASSURANCE DOCUMENTS : 3.1 The Contractor shall be required to submit two sets of compact discs of the following Quality Assurance documents within three weeks after dispatch of the equipment. i) The inspection plan with verification, inspection plan check points, verification sketches, if used and methods used to verify that the inspection and testing points in the inspection plan were performed satisfactorily. ii) Factory tests results for testing required as per applicable codes and standard referred in the specification. iii) Inspection reports duly signed by QA personnel of the Owner and Contractor for the agreed inspection hold points. During the course of inspection, the following will also be recorded: a) When some important repair work is involved to make the job acceptable and b) The repair work remains part of the accepted product quality
iv) All the accepted deviations shall be included with complete technical details. v) The contractor shall transfer all the guarantees/warranties of the equipment purchased by him to the employer, which are supplied as a part of the contractor for executing the works.
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SECTION - 5 Technical Specification

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SECTION 5 TECHNICAL SPECIFICATIONS TECHNICAL SPECIFICATIONS FOR ERECTION OF 33/11KV SUB-STATIONS WITH CONNECTED 33KV & 11KV LINES

Section-5 : Technical Specification

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4.2.4 4.3 4.3.1 4.3.2

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4.4.4 4.5 4.5.1

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4.5.8 4.5.9 5.0 5.1 5.1.1

CONTINUOUS MAXIMUM RATING AND OVERLOADS:

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III. IV. 5.7

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RADIATORS MOUNTED DIRECTLY TO THE TANK/BANKED :

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Dielectric type tests. Temperature rise test. Short circuit.

6.3 6.3.1 6.3.2

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6.5.3 6.5.4 6.6

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6.9 7.0 7.1

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Sl. No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

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12. 13. 14.

15. 16. 17. 18. 19.

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vii) viii) ix)

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