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ASSAM POWER DISTRIBUTION COMPANY LTD.

BID DOCUMENT FOR R&M OF 33/11kV Bijni Sub-Division ON TURNKEY MODE UNDER BONGAIGAON ELECTRICAL CIRCLE, APDCL (LAZ)

SCHEME: ASSAM BIKASH YOJANA- 2010-2011


NIT No.CGM (PP&D)/ APDCL/ABY-2010-11/R&M/Bijni S S /10

SECTION -1
NOTICE INVITING TENDER

ASSAM POWER DISTRIBUTION CO. LTD


PROJECT PLANNING & DESIGN

NIT No.CGM (PP&D)/ APDCL/ABY-2010-11/R&M/Bijni S S/10 Sealed Tenders are invited from experienced & financially sound Electrical Contractor(s) (individual or joint venture)/Firm(s) having valid electrical contractor license up to 33kV issued by the competent authority of the Govt. of Assam for R&M of 33/11kV Bijni substation under Bongaigaon Electrical Circle, APDCL (LAZ) on Turnkey mode. Cost of Tender Paper: Rs.3000/-(Rupees three thousand) only in the form of A/C Payee Demand Draft/Bankers Cheque (non-refundable) duly pledged in favour of ASSAM POWER DISTRIBUTION COMPANY LIMITED. Tender papers can be purchased in all working days up to 4 PM w.e.f. 25.07.2011 to 02.08.2011 from the office of the Chief General Manager (PP&D), APDCL, Bijulee TH Bhawan, Paltan bazar 6 Floor, Guwahati-1 Details may be seen in the website www.apdcl.gov.in

Chief General Manager (PP&D), th APDCL, 6 floor, Bijulee Bhawan. Guwahati-1 Memo No. CGM(PP&D)/APDCL/ABY-2010-11/R&M of Bijni SS/5 Dt. 20.07.2011 Copy to: 1. PS to the Chairman cum Managing Director, APDCL, Bijulee Bhawan for kind appraisal of the CMD. 2. The CGM (D), APDCL(LAZ), Bijulee Bhawan, Guwahati-1 for favour of kind information. 3. The General Manager, Guwahati Zone, APDCL(LAZ), Guwahati for information. 4. The DGM, Bongaigaon Electrical Circle, APDCL (LAZ), for information & necessary action. 5. The PRO, ASEB, Bijiulee Bhawan, Paltan Bazar, Guwahati for publication of the above tender in one issue of The Sentinel and Dainik Janambhumi. 6. The OSD to MD, APDCL, Bijiulee Bhawan, Paltan bazaar, Guwahati for publication in the official website.

Chief General Manager (PP&D), th APDCL, 6 floor, Bijulee Bhawan. Guwahati-1

ASSAM POWER DISTRIBUTION CO. LTD


PROJECT PLANNING & DESIGN

NOTICE INVITING TENDER NIT No.CGM (PP&D)/ APDCL/ABY-2010-11/R&M/Bijni S S/10

Sealed Tenders are invited from experienced & financially sound Electrical Contractor(s) (individual or joint venture)/Firm(s) having valid electrical contractor license up to 33kV issued by the competent authority of the Govt. of Assam for R&M of 33/11kV Bijni substation under Bongaigaon Electrical Circle, APDCL(LAZ) on Turnkey mode. Source of Fund: Assam Bikash Yojana 2010-11 Eligibility Criteria: 1. Average Annual turnover of the bidder for the last three financial years for the work should be as mentioned below and duly certified by registered Chartered Accountant with Registration No. 2. Past and present performance of the bidder in ASEB or in any of its successor companies will be taken into account to decide the eligibility as per clause 4(b) of sec-2. 3. The bidders must have adequate experience in doing similar electrical construction work and to be substantiated through certificate issued by an Engineer not below the rank of DGM/SE along with supporting copies of the work executed under any reputed utility / department. Lack of experience of the bidders will render the bid liable for rejection. The certificate should form a part of the techno-commercial bid.(as per clause no 4 of Sec-2) 4. The bidder must not be involved in any litigation with ASEB/ or any successor company of ASEB. The bidder should submit a declaration to that effect. 5. Earnest money should be as mentioned below. However Earnest money deposit (EMD) will be 50% for SC, ST & OBC bidder subject to submission of caste certificate along with the TechnoCommercial bid of the tender.
Package Work description Average annual turnover (Rs in lakh) EMD amount (Rs. In lakh)

Period of completion In days 285 (two hundred eighty five) days from the date of issue of work order

ABY 201011 /Bijni/01

R&M of 33/11 kV Bijni, substation under Bongaigaon Electrical Circle, APDCL(LAZ)

30.0

1.20

Bid validity: 180 days from the date of submission of Bid. Cost of Tender Paper: Rs.3000/-(Rupees three thousand) only in the form of A/C Payee Demand Draft/Bankers Cheque (non-refundable) duly pledged in favour of ASSAM POWER DISTRIBUTION COMPANY LIMITED. Tender papers can be purchased on all working days up to 4 PM w.e.f. 25.07.11 TH to 02.08.11 from the office of the Chief General Manager (PP&D), APDCL, Bijulee Bhawan, 6 Floor, Guwahati-1. Alternatively, the Bid Document can be downloaded from the website: www.apdcl.gov.in for tender submission purpose. The bid can be downloaded upto 4 pm of 02.08.11. The Bidders using
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downloaded document will attach with their Bids(Techno-commercial) an A/C Payee Demand Draft/Bankers Cheque (non-refundable) of Rs.3000/-(Rupees three thousand only) duly pledged in favour of Assam Power Distribution Company Limited, Guwahati-1as a cost of tender paper. Bidders will ensure that the complete document in full is downloaded and used. Any bid without the payment of Rs. 3000.00 as above will be rejected outright ; the date of purchase of said A/C Payee Demand Draft/ Bankers Cheque should be within the date of issue of Tender paper. Date of submission of Tenders: Up to 13-00 Hrs. of 17.08.11 Date of opening of Bid: Techno-commercial bids will be opened on 17.08.11 at 13-30 Hrs. and the price bid on a date to be notified later on. Terms & Conditions: 1. The work should be carried out as per latest REC specification and construction standard. 2. In case of a joint venture firm, the relevant deed in support of joint venture, an agreement duly registered or certified by Notary must be submitted along with the bid. In absence of such documents, the tender from a joint venture firm shall be rejected.( for joint venture requirement refer Sl 5 of Sec-2) 3. The Techno-Commercial& Price bids must be submitted in two separate sealed cover superscripting the following on both the covers a) Name of bidder with full address b) Techno-Commercial bid with earnest money for envelope containing Technocommercial Bid and Price bid for envelope containing the price bid. c) NIT reference number. 4. Rates should be quoted both in figures and words legibly and no overwriting will be accepted. 5. Earnest money as stipulated should be submitted with the Techno-Commercial bid in the form of Bank Guarantee (BG) of Nationalized Bank/ Bank Call Deposit/NSC/KVP /Term Deposit pledged in favour of ASSAM POWER DISTRIBUTION COMPANY LIMITED, Guwahati-1 valid upto Apr 2012. Any tender without earnest money will be rejected outright. 6. Quoted rate should be firm and inclusive of all taxes and duties. 7. Quoted rate must be valid for a minimum of 180 days. 8. There will be pre-bid discussion with the intending tenderer to be held on 11.08.11 at 1500 Hrs in the office of the undersigned regarding terms and conditions and scope of work. 9. The tender should be submitted in the office of the Chief General Manager (PP&D), APDCL, th Bijulee Bhawan, 6 floor, Paltanbazar, Guwahati-1 and will be opened on the scheduled date & time in presence of the intending tenderers. 10. The Company reserves the right to accept or reject any tender in part or in full or spilt the work or cancel/withdraw the Notice inviting tender without assigning any reason thereof whatsoever and in such case, no tenderer/ intending tenderer shall have any claim arising out of such action.

Chief General Manager (PP&D), th APDCL, 6 floor, Bijulee Bhawan. Paltan bazar,Guwahati-1

SECTION 2
TENDER INVITING PROPOSAL

ASSAM POWER DISTRIBUTION CO. LTD


PROJECT, PLANNING & DESIGN

TENDER INVITING PROPOSALS WITH TERMS & CONDITIONS FOR

R&M of 33KV Bijni substation under Bongaigaon Electrical Circle, APDCL (LAZ) on TURN KEY
MODE as per details below.

1.

Intent of the Tender Enquiry

The intent of the Tender Enquiry is to invite proposals from the prospective and relevantly experienced and financially sound contractor(s) (individual or joint venture)/firms to carry out the work of R&M of 33KV Bijni substation under Bongaigaon Electrical Circle, APDCL (LAZ) ON TURNKEY MODE. 2. Scope of Work

The various activities under the scope of work shall among other related aspects cover the following. i. Procurement and supply of all materials required for the work. ii. Site unloading, storage and handling of all materials supplied including watch and ward for safe custody. iii. Site fabrication work as per requirement. iv. Submission of implementation schedule from the date of award of contract for: Route survey for laying new lines wherever required Erection, testing and commissioning of all materials/equipment supplied/system installed. v. Project management and site organization. vi. Obtaining clearance from statutory Agencies, Government Departments, Village Panchayats etc. wherever necessary vii. Submission of specification/Test Certificate/Drawings etc. of all materials supplied. viii. A list of various items normally involved in proposed type of work is provided in this document. This, however, is not to be considered as limiting but only typical. Vendors scope will include all other items and materials as may be required to effectively complete the work. Above all, the scope of work of the vendor/contractor will include all items and facilities as may be necessary to complete the electrification work on turnkey basis and as binding requirement. 3. i. Basic specification of the various equipment/ works to be supplied /carried out. All equipment supplied shall conform to the requirement of relevant ISS (BIS) as approved by ASEB/Company and that of REC specification and construction standards. ii. All materials supplied shall be erected, protected as per approved standard practice for proposed type of electrical work so as to supply electricity to the consumers most effectively and in an intrinsically safe manner. iii. All equipment supplied and installed shall provide easy and effective: Maintainability Reliability Availability Long life All equipment supplied and installed shall be provided stable and adequate weather protection, system earthing etc. LA should be earthed separately. iv. All items, which may require frequent opening up/ dismantling for maintenance, shall be adequately sealed against any tampering/ theft etc. v. Generally supply and erection of materials and system shall meet the requirement of construction standard being followed in the electrification work.
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4.

Basic qualifying requirement: The prospective bidder must fulfill the following pre-bid qualifying requirement a. The bidder must have valid electrical Contractors and Supervisors License (HT) issued by the Licensing Authority of Govt. Of Assam. b. The bidder must have successfully erected and commissioned at least 1 no. of 33/11kV substation during last 10years as on the date of bid opening and which must be in satisfactory operation for at least 1 (one) year as on the date of bid opening. c. The bidder shall furnish details of the work / works along with its value already in hand either of APDCL, or in any other successor companies of ASEB along with date of completion as per Letter of Award and actual date of completion duly certified by the competent authority as per format enclosed as Annexure-IA. This shall be treated as one of the major qualifying criteria for technical evaluation of the bid. d. bidder shall furnish details of the work / works along with its value already in hand either of APDCL, or in any other successor companies of ASEB . e. Average annual turnover of the bidder for best of three financial years out of five/ last three consecutive financial years should be as per NIT and the annual turnover should be certified by a registered Chartered Accountant. f. The bidder shall furnish latest VAT registration and clearance certificate, WCT, CST Registration certificate, Service tax registration, Employee Provident fund and valid Labour License. g. The bidder shall furnish copy of their Pan Card. The card must be in the name of the firm if the bidder is a firm. If it is a joint venture copy of Pan Card of both the partner must be submitted. h. Joint venture agreement should be a registered one or certified by Notary. i. Power of attorney should be a registered one. j. Formal authority Registered/Notorised for signing the tender or other documents on behalf of the firm / individual must be submitted along with the bid. In case of registered company Boards resolution of the company for authorized signatory Joint Venture Requirement The Bid and, in case of successful Bid, the form of agreement shall be signed so as to be legally binding both the partners. One of the partners shall be authorized to be as the lead partner and this authorization shall be evidenced by submitting a Power of Attorney signed by legally authorized signatories of the partners. Also the lead partner must have valid electrical Contractors and Supervisors License (HT) issued by the Licensing Authority of Govt. Of Assam The lead partner shall be authorized to incur liabilities, receive payments and receive instructions for and on behalf of any or all partners of the joint venture and the entire execution of the contract. All the partners of the joint venture shall be jointly and severally liable for the execution of the contract in accordance with the contract terms and a relevant statement to this effect shall be included in the authorization mentioned under (ii) above as well as in the bid form and the form of agreement (in case of successful bidder). A copy of the agreement entered into by the joint venture partners shall be submitted with the bid. The figure of average annual turnovers for the joint venture partners shall be added together to determine the bidders compliance with the minimum average turnover requirement for the package. However, the lead partner must meet at least 40% and other partner must meet the at least 25% of the minimum average annual turnover criteria given in the Tender.

5. i. ii.

iii.

iv.

v. vi.

6.

Other requirements: The Bidder i) Should be acquainted himself with relevant conditions of the local geography and socio economic setup of the different location of the State and being capable accordingly to mobilize, organize and expedite the activities.
8

ii)

Should have adequate working personnel comprising of Electrical/ Mechanical engineers, electrical supervisor, skilled and unskilled labour to be deputed to the proposed assignment. iii) Should be conversant with the code/ standards applicable to proposed type of work. ISS, REC guidelines

7.

Submission of bid The bidder shall submit the bid/bids in sealed envelope/envelopes as follows: a. Techno-commercial bid Techno-commercial bid should be submitted in a sealed envelope, Superscribing Technocommercial bid with EMD with name of bidder, full address and NIT reference, package no. and under this will be included and defined vendors scope of work, responsibilities, guarantees, specification of equipment, commercial terms and conditions, vendors company credentials, experience of similar assignments, registration details, etc. as per requirement. Tender proforma for techno-commercial Bid is enclosed as Annexure-I. b. Earnest Money Deposit (EMD): The Tender must be accompanied with earnest money as mentioned in the NIT against the work to be deposited in the form of Bank Guarantee (BG) of Nationalized Bank/ Bank Call Deposit/NSC/KVP /Term Deposit pledged in favour of ASSAM POWER DISTRIBUTION COMPANY LIMITED. Guwahati-1. The EMD should be submitted along with TechnoCommercial bid. The earnest money will be released to the unsuccessful bidders on finalization of the tenders. The EMD to the successful bidder will be released on submission of Security Deposit at the time of execution of the agreement as per clause 10.3 c. i) ii) iii) iv) v) vi) vii) viii) ix) x) Submission of documents with technical bids. Detail list of makes and materials offered with catalogues, technical specification etc. Certificates and testimonials in support of credentials of the bidders organization. Details past experience along with present works in hand with awarded amount and progress report. Brief write-up on methodology to carry out the assignment, if awarded. Details of manpower to be engaged for the assignments. Any other information, the vendor may feel facilitative in evaluating the bid. Copies of bidder and supervisors license, etc. Certificate from Registered Charted Accountant in support of Annual turn over Solvency certificate from Bank Certificate in support of performance of the bidder

d. Price Bid Price bid should be submitted in a sealed envelope superscribing Price Bid with name of bidder, NIT reference No. Under this will include rates of supply and erection of different items for electrification. The tender proforma for price Bid is enclosed as Annexure-II e. Submission of bid Both the envelope should be placed in a bigger envelope duly sealed superscribing name of bidder, NIT reference and addressed to CGM(PP&D), APDCL, Bijulee Bhawan, Paltanbazar, Guwahati. Note:-: a. If there is discrepancy between the unit price and the total price that is obtained by multiplying the unit price and quantity, the unit price shall prevail and total price should be corrected. If there is a discrepancy between the words and figures, the amount in word should prevail. If the bidder does not accept the correction of the errors as above, his bid will be rejected and the amount of bid guarantee/security will be forfeited. b. No separate declaration offering discount on price will be allowed. Offered price in the price schedule will be final.

8. (A) Estimation of material requirement: The total quantity of materials required is indicated in the BOQ B) Quantity Variation: There may be increase or decrease in quantity of individual item subject to the condition that the corresponding change in total contract value does not increase or decrease by more than 15% keeping the unit rate of individual material and labour unchanged. 9. Award of work: i) The evaluation of bids will be carried out, first of techno-commercial bid and thereafter opening the price bid of only those who qualify and meet the technical requirement. ii) iii) iv) Company reserves the right not to order/ award the job to the price-wise lowest party if the party during evaluation is found technically non responsive. Work should be started within fifteen (15) days from the date of issue of the work order, failing which order will be cancelled without further correspondence. The Sub-station equipments installed shall be under custody of the contractor till the date of commissioning and charging. The properties will be taken over by APDCL,LAZ after satisfactory commissioning and charging.

9. 10.

Period of completion: 285 (Two Hundred eighty five) days from the date of issue of work order . Implementation schedule: Comprehensive implementation schedule of work for R&M of 33KV Bijni substation under Bongaigaon Electrical Circle, APDCL (LAZ) EXECUTION PERIOD 10 days 20 days 90 days 90 days 60 days Description 15 days Sl no.

1 2 3 4 5

Signing of Agreement Survey works Manufacture & supply of materials Erection of equipments Testing & commissioning

11. Termination of work order: Company reserves the right to terminate the work order at any stage in accordance with the Companys General Condition of Supply and Erection in force.

12. 12.1

Terms of Payment: During the currency of the contract, maximum of 2(two) nos. of progressive payment on the actual work done can be made against the claims preferred by the contractor subject to 80% of the claimed amount. 20% will be retained as security deposit which will be released along with final bill on satisfactory completion including commissioning. All payment shall be made from the office of the CGM(F&A), APDCL on the bill submitted to the concerned CGM(D) after due verification by the concerned SDE and duly passed by the Sr. Manager concerned and countersigned by the DGM concerned and on submission of work
10

progress report( as per format which will be enclosed at the time of awarding work order ). Bills whether progressive or final shall be entertained only after completion of both supply and erection of works of specified items. 12.2 Security deposit and agreement: The successful bidders shall have to deposit security money in the form of Bank Guarantee issued by any Nationalized Bank/Scheduled Bank in Companys standard proforma on nonjudicial stamp of appropriate value for an amount equal to 2.5% of the contract value at the time of execution of agreement. The security deposit is liable to be forfeited in case of non-execution of contract/ work order. The security deposit will be released on successful commissioning and testing of the materials ordered and after depositing performance B/G as per clause 14(d). 13 Project Management and site Organizations: In Consideration of the tight schedule of the project, the successful bidder(s) /Contractor(s) shall exercise systematic closely controlled project management system with the aid of commonly used soft tools. Following are the major activities/deliverables to be organized /generated for submission to the Board. (I) Liaison/Construction offices will be established in each Circle of APDCL,LAZ. (II) Work Progress Report: Progress monitoring by the contractor as per implementation schedule and approved milestones. Fortnightly progress report will be submitted to the concern Deputy General Manager, Senior Manager & Sub-Divisional Engineers. The progress report will highlight the points like, work completion vis--vis planned, plan for next working period, delay analysis vis--vis committed schedule with reasons and remedies, etc. (III) Site Organization. The vendor at each working site shall establish the following. Store house Site fabrication facilities Construction supervision office All offices shall be adequately furnished and staffed so as to take all site decisions independently without frequent references to head Works/offices. 14 Guarantees and Penalties (a) Liquidated Damages (LD) The proposed work is on top priority of Government of Assam and therefore has to be completed within stipulated/agreed schedule. Any delay beyond that will attract penalty as per Companys General condition of supply and erection. (b) Equipment and system installed shall be guaranteed individually for integrated operations for a period of 18 (Eighteen) months from date of commissioning of a system. In case of detection of any defect in individual equipment or system as a whole, the same shall be replaced by the vendor free of cost within 15 days of intimation by the Companys representative. (c) Warranty from the manufacturer shall be produced along with manufacturers test certificate for all equipment/ materials covered under Manufacturers warranty. (d) A performance Bank Guarantee from a Nationalized Bank/Scheduled Bank in Boards standard proforma on Non judicial stamp paper of appropriate value with a validity of 18 (eighteen) months @ 10% of total value of work executed shall have to be furnished by the Contractor before final payment.

11

15

Approvals/Clearances: 1. APDCL, concerned DGM shall approve all site and documents prepared by the contractor for construction of the Line. 2. GTP and drawings of all equipment/ materials shall be approved by CGM (PP&D), APDCL. 3. The contractor shall obtain all statutory approvals and clearances from the statutory authorities before charging the system at his/her own cost. Environmental Considerations: While carrying out the assignment, no damage to environment /forests will be caused by the contractor. If so done, the contractor will have to compensate the same to the satisfaction of the concerned Authority.

16.

17. i.

Submission of documents. With bids. i) Detail list of makes and materials offered with catalogues, technical specification etc. ii) Certificates and testimonials in support of credentials of the bidders organization. iii) Details past experience along with present works in hand with awarded amount and progress report. iv) Brief writ-up on methodology to carry out the assignment, if awarded. v) Details of manpower to be engaged for the assignments. vi) Any other information, the vendor may feel facilitative in evaluating the bid. vii) Copies of contractor and supervisors license, etc. viii) Certificate from Registered Charted Accountant in support of Annual turn over ix) Solvency certificate from Bank x) Earnest money deposit along with Techno- Commercial bid xi) Certificate in support of performance of the bidder During project execution i) All documents for approval shall be submitted in 6 copies. ii) All final documents to be submitted to statutory organizations will be furnished as per requirement of the authority. Funding of the project. The proposed work is funded by the G.O.A. under Assam Bikash Yojana 2010-11 Disclaimer: While the Company will make every endeavor to extend necessary facilitation in expediting the work, the contractor shall be responsible to organize and arrange all necessary inputs right from mobilization activities up to completion of the project. Company will not entertain any failure / delay on such accounts. Also, Company will not be responsible for any compensation, replenishment, damage, theft etc. as may be caused due to negligent working, insufficient coordination with Government / non Government / Local Authority by the contractor and/ or his personnel deputed for work. The contractor shall take necessary insurance coverage under LIC/GIC. etc. for his working personnel and the goods in store as well as in transit. The contractor will be deemed to have made him acquainted with the local working conditions at site(s) and fully provide for into the bid submitted.

b)

18.

19.

20.

Terms and conditions, which are not specified, herein above will be governed by Companys General Conditions of supply and erection in force.

12

Annexure - I Tender Proforma part I (Techno-commercial Bid) NIT No.CGM (PP&D)/ APDCL/ABY-2010-11/R&M/Bijni S S/10 1. 2. Name and full address of the Bidder. Particulars of payment made for Purchase of tender document in the shape of . Amount of earnest money paid in the shape of Whether Sales Tax clearance certificate submitted VAT Registration. No/ Service Tax Regd No. Acceptance of guarantee clause of Materials /equipment and system Installed individually and for integrated Operation. Acceptance of penalty clause Acceptance of terms of payment : :

: : : Yes / No

3. 4.

5. 6.

7. 8.

: :

9.

Certificate/ documents regarding adequate Experience of doing similar job Details of work presently in hand with amount (Awarded by APDCL and other successor Companies of ASEB)- a separate sheet if Required may be enclosed. Details of manpower and T&Ps including Vehicles available with the firm to be Enclosed separately. List of documents enclosed . a) . b) . c) .

10.

11.

12.

Signature with full name and designation of bidder or his/her authorised representative with seal

13

SECTION 3
BILL OF MATERIALS
&

PRICE BIDDING SCHEDULE

14

Bill of Quantity (BOQ) for Electrical work only


Name of work:

R&M of 33KV Bijni sub station under Bongaigaon Electrical Circle, APDCL(LAZ) Scheme: Assam Bikash Yojana 2010-11 NIT No.CGM (PP&D)/ APDCL/ABY-2010-11/R&M/Bijni S S/10
Items Unit Qty 50 72 18 18 18 150 3 1 2 3 3 1 2 1 1 1 1 1 18 4 4 1 180 120 220 2 2 4 4 130 130 70 48 1 1 150 1 200 1 1 1 2 6

Sl no 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 37 38 39 40 41 42 43 44

GI Channel for 11kV gantry and 33kV bus (100x50x6)mm Disc Insulator (70 kN), B&S Hardware fittings for Disc Insulator Tension clamp for wolf 33 kV Pin Insulator with GI Pin AAA Wolf conductor for 33 kV Switch Yard & jumpering works 33 kV VCB with mounting structure and marshalling box 33 kV Relay & Control Panel for Feeder 33 kV Relay & Control Panel for Transformer 33 kV, 10kA Lightning Arrestor station type with mounting structure 33 kV Isolator, 400A with earth blade complete with mounting structure 33kV Current transformer outdoor type(CT Ratio 200-100/5-5A) with terminal connector and all accessories, mounting structure & Marshalling box 33kV Current transformer outdoor type(CT Ratio 200-100/5-5-5A) with terminal connector and all accessories, mounting structure & Marshalling box 33 kV Potential transformer outdoor type with terminal connector along with terminal connector and all accessories, mounting structure & Marshalling box Battery Bank of 110V, 100AH, 55 cells Maintenance free value regulated lead acid 110V DC 100AH, Battery Charger suitable for charging of 110 V DC 100AH Battery bank AC Distribution Board 110V, DC Distribution Board including connected cables with terminations. 11 kV Pin Insulator with GI Pin 11kV GOAB 11kV LA 11 KV DO fuse set LT XLPE cable, 3-core, 120 Sq. mm. 11 KV XLPE cable, 3-core, 300 Sq. mm. 11 KV XLPE cable, 3-core, 240 Sq. mm. 11 KV Cable Kit for XLPE, 3-core, 300 Sq. mm.(outdoor) 11 KV Cable Kit for XLPE, 3-core, 300 Sq. mm.(indoor) 11 KV Cable Kit for XLPE, 3-core, 240 Sq. mm.(outdoor) 11 KV Cable Kit for XLPE, 3-core, 240 Sq. mm.(indoor) Supply and laying of Cu. Control Cable, 7-core, 2.5 sq. mm. and terminating arrangements completely wired with equipments as per direction. Supply and laying of Cu. Control Cable, 4-core, 2.5 sq. mm. and terminating arrangements completely wired with equipments as per direction. GI nuts and bolts with GI washer Aluminium lug assorted Materials for earthing system with MS flats 50x8mm GI, electrodes etc Station transformer 11/.43kV, 100kVA Switchyard gravelling with broken stone (50 mm)size Materials as required for foundation for LA, isolator VCB, CT PT bus etc including supply of all foundation materials & Labour Construction of Cable Trenches including supply of all materials and labour as per specification and drawing Materials as required for Switch yard lighting Control Room furniture( 1 table, 4 chairs, 1 almirah, 1 rack.) Installation of deep tube well with all piping, 1 HP submersible pump, 500 litre overhead storage tank etc as per Specification with all materials and labour. Fire extinguisher CI earth pipe

Mtr No set No No Mtr set No No Set set set set set set No No No Set No set Set mtr Mtr Mtr No No No No Mtr Mtr Kg No LS no Sq mtr LS Mtr No LS No No No

15

Annexure-II
The schedule of itemwise rates of various works against Assam Bikash Yojana 2010-11 for R&M of Bijni Substation under Bongaigaon Electrical Circle, APDCL(LAZ) )
Supply of materials Unit price of item, inclusive of E.D., F&I up to work site (Rs)
5

NB. Bidder should fill up all columns properly. If any column of taxes/ octroi and duties is left blank or written as NA, the applicable taxes against that item shall be added in bid evaluation
Erection of materials Unit erection/ installati on charges (Rs)

S.N o.

Brief Item Description

Unit

Qty

Total amount (Rs)

Total Sales Tax (Rs)

Other levies eg. Octroi/E ntry Tax (Rs)


8 = (6 X Rate)

Total cost of the Item (Rs)

Total Erection cost (Rs)

Work contract Tax (Rs)

Servic e Tax (Rs)

Total cost of erection (Rs)

Grand Total

6=(4x5)

7= (6 X Rate)

9=(6+7+8 )

10

11= (4X10)

12= (11 X Rate)

13= (11 X Rate)

14 = 11+12+13

15 = 9 + 14

2 3 4

Supply & erection of GI Channel (100x50x6)mm for 33kV bus as per drawing & direction. Supply, fitting of 70 kN, B&S Disc insulator for 33 kV bus with H/W fitting & tension clamp for wolf, ( 1 set comprises of 4 Disc insulator fitted in series with necessary H/W fitting & tension clamp) Supply & erection of 33kV pin insulator with GI pin Supply and stringing of AAAC Wolf conductor for 33kV & 11kV bus and jumpering with PG clamp as per direction Supply, erection, testing and commissioning of 33 KV VCB Outdoor type along with terminal box, marshalling box, steel mounting structure( to be painted with two coats of Red Oxide Primer and two coats of Ant-Corrosive Aluminum Paint) and all accessories as per TS and approved drawing. Foundation as required for installation of new 33 kV VCB (including cost of all materials) as per TS and approved drawing. Supply, erection, testing and commissioning of 33 kV C&R Panel for feeder and all accessories as per TS. Supply, erection, testing and commissioning of 33 kV C&R Panel for transformer and all accessories as per TS. Supply, erection, testing and commissioning of 33 kV, LA with mounting structure( to be painted with two coats of Red Oxide Primer and two coats of AntCorrosive Aluminum Paint) and all accessories as per TS and approved drawing.

Mtr

50

set set Mtr

18 18 150

set

No

7 8

No No

1 2

Set

16

10

Foundation as required for installation of 33 kV, LA (including cost of all materials) as per TS and approved drawing. Supply, erection, testing and commissioning of 33 kV Isolator, 400 A Double Break with earth blade with mounting structure( to be painted with two coats of Red Oxide Primer and two coats of AntCorrosive Aluminum Paint) and all accessories as per TS and approved drawing. Foundation as required for installation of 33 kV Isolator with earth blade (including cost of all materials) as per TS and approved drawing. Supply, erection, testing and commissioning of CT 200-100/5-5A with Marshalling box, mounting structure( to be painted with two coats of Red Oxide Primer and two coats of Ant-Corrosive Aluminum Paint) and all accessories as per TS and approved drawing. Foundation as required for installation of CT 200100/5-5A (including cost of all materials) as per TS and approved drawing. Supply, erection, testing and commissioning of CT 200-100/5-5-5A with marshalling box, mounting structure( to be painted with two coats of Red Oxide Primer and two coats of Ant-Corrosive Aluminum Paint) and all accessories as per TS and approved drawing. Foundation as required for installation of CT 200100/5-5-5A (including cost of all materials) as per TS and approved drawing Supply, erection, testing and commissioning of 33 kV(33/3)/(110/3) V Potential Transformer Outdoor type along with terminal box, marshalling box, mounting structure ( to be painted with two coats of Red Oxide Primer and two coats of AntCorrosive Aluminum Paint) as per TS and approved drawing. Foundation as required for installation of 33 kV(33/3)/(110/3) V Potential Transformer (including cost of all materials) as per TS and approved drawing Supply, installation testing and commissioning of Battery Bank of 110V, 150AH, 55 cells Maintenance free Supply, installation testing and commissioning of 110V DC 150AH, Battery Charger suitable for charging of 110 V DC 150AH Battery bank

no

11

set

12

no

13

set

14

no

15

set

16

no

17

set

18

No

19

set

20

no

17

21 22 23 24 25 26 27

Supply, installation testing and commissioning of AC Distribution Board Supply, installation testing and commissioning of 110V, DC Distribution Board including connected cables with terminations. Supply and erection 11 kV Pin Insulator with GI Pin for 11kV Gantry Supply and installation 11 kV GOAB switch in 11kV outgoing feeders Supply and erection of 11 kV, LA with necessary earthing arrangement Supply and laying of LT XLPE 3core 120 sqmm Supply and laying of 11 kV, XLPE cable, three core 300 mm2 with necessary lugs, clamps, nuts & bolts etc. Supply and laying of 11 kV, XLPE cable, three core 240 mm2 with necessary lugs, clamps, nuts & bolts etc. Supply & fitting of XLPE HT heat shrinkable type, three core outdoor cable termination kit including all accessories suitable for jointing 11 KV three core 300 mm2 XLPE cable with necessary lugs, clamps, nuts & bolts etc. Supply & fitting of XLPE HT heat shrinkable type, three core indoor cable termination kit including all accessories suitable for jointing 11 kV three core 300 mm2 XLPE cable with necessary lugs, clamps, nuts & bolts etc Supply & fitting of XLPE HT heat shrinkable type, three core outdoor cable termination kit including all accessories suitable for jointing 11 kV three core 240 mm2 XLPE cable with necessary lugs, clamps, nuts & bolts etc. Supply & fitting of XLPE HT heat shrinkable type, three core indoor cable termination kit including all accessories suitable for jointing 11 kV three core 240 mm2 XLPE cable with necessary lugs, clamps, nuts & bolts etc Supply and laying of Cu. Control Cable, 7-core, 2.5 sq. mm. and terminating arrangements completely wired with equipments as per direction. Supply and laying of Cu. Control Cable, 4-core, 2.5 sq. mm. and terminating arrangements completely wired with equipments as per direction. Installation of earthing system with MS flats 50x10mm(for earthing mat) with GI flat 25x6mm(for earthing conductor)and GI pipe 50mm dia. of length 3000mm( for earth electrodes) as per direction Construction of Cable Trenches Size:1260x650 mm including supply of all materials and labour as per specification and drawing,

No No set set set mtr Mtr

1 1 18 4 4 180 120

28

Mtr

220

29

No

30

no

31

No

32

No

33

mtr

130

34

mtr

130

35

LS

36

Mtr

100

18

37

38

39

40 41 42

Construction of Cable Trenches Size:(950x400) mm including supply of all materials and labour as per specification and drawing Supply & installation of Switch yard lighting with pressure die cast aluminium integral flood light with 400 Watt MH tubular lamp total 10 numbers to be fixed in switchyard structure including fitting & fixing with required size of cable to be connected with ACDB as per direction Installation of deep tube well with all piping of 4 dia PVC supreme for boring and with required dia PVC pipe for delivery to toilet etc as directed, 1/2 HP submersible pump boring of upto 30 mtrs, 500 litre overhead Sintex make storage tank to be fitted on the roof slab of control room building and installation of ladder with MS angle 50x50x6 mm and 16 mm dia MS plain bar as steps from ground to Control room roof slab etc as per Specification with all materials and labour. Fire extinguisher: Carbon Dioxide type fire extinguishers (capacity 3 kg) as per specification Switchyard gravelling of 0.225 mtr(thickness) by broken stone of 50mm size inclusive of labour and material Temporary arrangement for evacuation of power at 11 KV side by 1 set of GOAB and 1 set of DO fuse unit for each feeder Supply and installation & commissioning of 11/0.4kV, 100kVA Distribution transformer on PSC pole with necessary cables(LT XLPE cable 3-core 120 sq.mm) as per direction with necessary earthing with CI Earth pipe and other accessories Supply of good quality control room furniture ( 1 table, 4 chairs, 1 almirah, 1 rack.)

Mtr

100

Job

Job

No. Sq. Mtr. Job

2 150 1

43

No Job

1 1

44

Signature of the bidder Date Name Address

19

SECTION -4
GENERAL REQUIREMENTS

20

GENERAL REQUIREMENTS

1.0 1.1

1.2

1.3

The bidder shall comply with the following general requirements along with other specifications. QUALITY ASSURANCE PLAN The bidder shall invariably furnish the following information along with his offer failing which the offer shall be liable for rejection. Information shall be separately given for individual type of equipment offered. i) The structure of organization ii) The duties and responsibilities assigned to staff ensuring quality of work 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 confirm to the relevant requirement of ISO 9001 on ISO 9002 as applicable. vi) Statement giving list of important raw materials, names of sub-supplies for the raw materials, list of standards according to which the raw material are tested, list of tests normally carried out on raw material in the presence of suppliers representative, copies of test certificates. vii) Information and copies of test certificates as on (i) above in respect of bought out items viii) List of manufacturing facilities available ix) Level of automation achieved and list of areas where manual processing exists. x) List of areas in manufacturing process, where stage inspections are normally carried out for quality control and details of such test and inspection. xi) List of testing equipment available with the bidder for final testing of equipment specified and test plant limitation, if any vis--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 the specified test requirement. The contractor shall within 30 days of placement of order, submit the following information to the purchaser. i) List of the raw material as well as bought out accessories and the names of sub-suppliers selected from those furnished along with the offer. ii) Type test certificated of the raw material and bought out accessories if required by the purchaser. iii) Quality Assurance Plant (QAP) with hold points for purchasers inspection. QAP and purchasers hold points shall be discussed between the purchaser 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. i) Quality System The structure of the organization. The duties and responsibilities assigned to staff ensuring quality of work. The system of purchasing, taking delivery of verification of materials The system of ensuring of quality workmanship. The system of control of documentation. The system of retention of records. The arrangement of contractor internal auditing. A list of administrator and work procedures required to achieve contractors quality requirements. These procedures shall be made readily available to the purchaser for inspection on request. ii) Quality Plans An outline of the proposed work and program sequence. The structure of contractors organizations for the contract. The duties and responsibilities ensuring quality of work. Hold and notification points. Submission of engineering documents required by this specification. The inspection of the materials and components on request. Reference to contractors work procedures appropriate to each activity. Inspection during fabrication /construction. Final inspection and test.

2.0 2.1

Inspection The Owner's representative or third party nominee shall at all times be entitled to have access to the works and all places of manufacture, where insulator, and its component parts shall be manufactured and the representatives shall have full facilities for unrestricted inspection of the Contractor's and sub-Contractor's works, raw materials, manufacture of the material and for conducting necessary test as detailed herein. The material for final inspection shall be offered by the Contractor only under packed condition as detailed in the specification. The Owner shall select samples at random from the packed lot for carrying out acceptance tests. Insulators

2.2

21

2.3 2.4

2.5

shall normally be offered for inspection in lots not exceeding 5000 nos. the lot should be homogeneous and should contain insulators manufactured in the span of not more than 3-4 consecutive weeks. The Contractor shall keep the Owner informed in advance of the time of starting and the progress of manufacture of material in their various stages so that arrangements could be made for inspection. No material shall be dispatched from its point of manufacture before it has been satisfactorily inspected and tested unless the inspection is waived off by the Owner in writing. In the latter case also the material shall be dispatched only after satisfactory testing for all tests specified herein have been completed. The acceptance of any quantity of material shall be no way relieve the Contractor of his responsibility for meeting all the requirements of the specification and shall not prevent subsequent rejection, if such material are later found to be defective. Additional Tests The Owner reserves the right of having at his own expense any other test(s) of reasonable nature carried out at Contractor's premises, at site, or in any other place in addition to the type, acceptance and routine tests specified in these bidding documents against any equipments to satisfy himself that the material comply with the Specifications. The Owner also reserves the right to conduct all the tests mentioned in this specification at his own expense on the samples drawn from the site at Contractor's premises or at any other test center. In case of evidence of noncompliance, it shall be binding on the part of the Contractor to prove the compliance of the items to the technical specifications by repeat tests or correction of deficiencies, or replacement of defective items, all without any extra cost to the Owner. Test Reports Copies of type test reports shall be furnished in at least six (6) copies along with one original. One copy shall be returned duly certified by the Owner only after which the commercial production of the concerned materials shall start. Copies of acceptance test reports shall be furnished in at least six (6) copies. One copy shall be returned duly certified by the Owner, only after which the material shall be despatched. Record of routine test reports shall be maintained by the Contractor at his works for periodic inspection by the Owner's representative. Test certificates of test during manufacture shall be maintained by the Contractor. These shall be produced for verification as and when desired by the Owner. List of Drawings and Documents: The bidder shall furnish the following along with bid. Two sets of drawings showing clearly the general arrangements, fitting details, electrical connections etc. Technical leaflets (users manual) giving operating instructions. Three copies of dimensional drawings of the box for each quoted item. 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 supplier's risk. 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 specification. 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. The successful Bidder shall within 2 weeks of notification of award of contract submit three sets of final versions of all the drawings as stipulated in the purchase order for purchaser's 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 supplier shall within two weeks. Submit 30 prints and two good quality report copies of the approved drawings for purchaser's use. 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 or routine test certificates in cases where inspection is' waived shall be got approved by the purchasers. Any Item specification if not available in this document Contractor shall supply and execute the items meeting the relevant IS specification with the approval of the purchaser.

3.0 3.1

3.2

4.0 4.1 4.2 4.3 4.4

5.0 5.1

i) ii) iii)

5.2

5.3

5.4 5.4.1 5.4.2

6.0

22

SECTION 5 FORMS OF BID

23

PROFORMA OF BANK GUARANTEE FOR BID GUARANTEE/SECURITY

(To be stamped in accordance with Stamp Act) The non-Judicial stamp paper should be in the name of issuing bank Ref.. To The Chief General Manager (PP&D) Assam Power Distribution Company Ltd. Bijulee Bhawan, Paltanbazar Guwahati-1 Dear Sirs/ Madam, In accordance with invitation to bid under your Bid No. M/s. having its Registered/ Head Office at ..( hereinafter called the Bidder) wish to participate in the said Bid or and you, as a special favour have agreed to accept an irrevocable and unconditional Bank Guarantee for an amount of .. valid upto. On behalf of Bidder in lieu of the Bid deposit required to be made by the bidder, as a condition precedent for participation in the Said Bid. We, the . Bank at have our Head Office at..( local address) guarantee and undertake to pay immediately on demand by Assam Power Distribution Company Limited, the Amount of ..( in words & figures) without any reservation, protest, demur and recourse. Any such demand made by said Owner shall be conclusive and binding on us irrespective of any dispute or difference raised by the Bidder. The Guarantee shall be irrevocable and shall remain valid up to and including . @....................... if any further extension of this guarantee is required, the same shall be extended to such required period ( not exceeding one year) on receiving instruction from M/s . on whose behalf this guarantee is issued. In witness whereof the Bank, through its authorized office, has set its hand and stamp on this day of .. 20 at WITNESS (Signature) .. (Name) . ( Official Address) . ( Signature) (Name) (Official Address) Bank Guarantee No.. Date.

@ This date shall be thirty (30) days after the last date for which the bid is valid.

24

PROFORMA OF BANK GUARANTEE FOR CONTRACT PERFORMANCE (To be stamped in accordance with Stamp Act) Ref.. To The Chief General Manager (PP&D) Assam Power Distribution Company Ltd. Bijulee Bhawan, Paltanbazar Guwahati-1 Dear Sirs/ Madam, In consideration of Assam Power Distribution Company Ltd., (herein after referred to as the Owner which expression shall unless repugnant to the context or meaning thereof include its successors, administrators and assigns) having awarded to M/s ..with registered/ Head office at .( hereinafter referred to as Contractor which expression shall unless repugnant to the context or meaning thereof include its successors, administrators, executors and assigns), a Contract by issued of Owners Letter of Award No dated.. and the same having been acknowledged by the contractor, resulting in a contract bearing No.. dated contractor having agreed to provide a Contract Performance Guarantee for the faithful performance of the entire Contract equivalent to being(%) (Percent *) of the said value Contract to the Owner. We.. (Name & Address) having its Head Office at ( hereinafter referred to as the Bank , which expression shall, unless repugnant to the context or meaning thereof, include its successors, administrators, executors and assigns) do hereby guarantee and undertake to pay the owner, on demand any all monies payable by the contractor to be extent of . As aforesaid at any time up to ..**( day/month/year) without any demur, reservation , contest , recourse or protest and / or without any reference to this contractor. Any such demand made by the owner on the bank shall be conclusive and binding notwithstanding any difference between the Owner the Contractor or any dispute pending before any Court, Tribunal, Arbitrator or any other authority . The bank undertakes not to revoke this guarantee during its currency without previous consent of the owner and further agrees that the guarantee herein contained shall continue to be enforceable till the owner discharges this guarantee. The Owner shall have the fullest liberty without affecting in any way the liability of the Bank under the guarantee, from time to time to extend the time for performance or the contract by the contractor. The owner shall have the fullest liberty, without affecting this guarantee, to postpone from time to time the exercise of any power vested in them or of any right which they might have against the contractor, and to exercise the same at any time in any matter, and either to enforce or to for bear to enforce any covenants, contained or implied, in the contract between the owner and the contractor or any other course or remedy or security available to the owner. The Bank shall not be released to its obligations under these presents by any exercise by the owner of its liberty with reference to the matters aforesaid or any of them or by reason of any other act of omission or commission on the part of the owner or any other indulgences shown by the owner or by any other matter or thing whatsoever which under law would , but for this provision have the effect of relieving the Bank. The bank also agrees that the owner at its option shall be entitled to enforce this guarantee against the Bank as a principal debtor, in the first instance without proceeding against the contractor and not withstanding any security or other guarantee the owner may have in relation to the Contractors liabilities. Notwithstanding anything contained herein above our liability under this guarantee is restricted to . And it shall remain in force up to an including .. and shall be extended from time to time for such period( not exceeding 1 year) as may be desired M/s.on whose behalf this guarantee has been given. Bank Guarantee No.. Date.

25

Dated this. Day of .. 20 at

WITNESS . (Signature) (Name) .. (Official address)

(Signature) .. (Name) .. (Official address)

Attorney as per power Of Attorney No.. Date..

Notes * This sum shall be 10%(Ten) of the Contract price. ** The date will be 90(Ninety) days after the end of the Warranty Period as specified in the contract. 1. The stamp paper of appropriate value shall be purchased in the name of issuing bank.

26

PROFORMA OF EXTENSION OF BANK GUARANTEE Ref.. To The Chief General Manager (PP&D) Assam Power Distribution Company Ltd. Bijulee Bhawan, Paltanbazar Guwahati-1 Dear Sirs/ Madam, Sub: Extension of Bank Guarantee No.. for Rs. Favouring yourselves , expiring on . On account of M/S.. in respect of contract no. dated .. ( hereinafter called original Bank Guarantee). Date.

At the request of M/s we bank, branch office at .. and having its Head Office at . Do hereby extend our liability under the above mentioned Bank Guarantee No datedfor a further period of ( Years/ Months) from.. to expire on.. expect as provided above, all other terms and conditions of the original Bank Guarantee No. dated . Shall remain unaltered and binding. Please treat this as an integral part of the original Bank Guarantee to which it would be attached.

Yours faithfully For Manager/ Agent/Accountant .. Power of attorney No Dated SEAL OF BANK Note: The non-judicial stamp paper of appropriate value shall be purchased in the name of the Bank who has issued the Bank Guarantee.

27

PROFORMA OF BANK GUARANTEE FOR ADVANCEPAYMENT ( To be stamped in accordance with Stamp Act ) Ref.. Date. To The Chief General Manager (PP&D) Assam Power Distribution Company Ltd. Bijulee Bhawan, Paltanbazar Guwahati-1 Dear Sirs/ Madam, In consideration of Assam Power Distribution Company Ltd.(hereinafter referred to as the Owner, which expressions shall unless repugnant to the context or meaning thereof include its successors, administrators and assigns) having awarded to M/s hereinafter referred to as the Contractor which expression shall unless repugnant to the context or meaning thereof , include its successors, administrators, executors and assigns), a Contract by issue of Owners letter of Award No Datedand the same having been acknowledged by the contractors, resulting in a Contract bearing no. Dated. Valued (at( in words and figures). For .Contract (space of work).. (hereinafter called the Contract) and the Owner having agreed to make an advance payment to the Contractor for performance of the above contract amounting (in words and figures) as an advance against Bank Guarantee to be furnished by the Contractor. We..( Name of the Bank) having its Head Office at ( hereinafter referred to as the Bank, which expression shall, unless repugnant to the context or meaning thereof , include its successors, administrators, executors and assigns) do hereby guarantee and undertake to pay the owner , immediately on demand any or, all monies payable by the contractor to the extent of ..as aforesaid at any time upto.. (a.) without any demur, reservation, contest, recourse or protest and/or without any reference to the contractor. Any such demand made by the Owner on the Bank shall be conclusive and binding notwithstanding any difference between the Owner and the Contractor or any dispute pending before any Court, Tribunal, Arbitrator or any other authority. We agree that the guarantee herein contained shall be irrevocable and shall continue to be enforceable till the owner discharge this guarantee. The Owner shall have the fullest liberty without affecting in any way the liability of the Bank under this guarantee, from time to time to vary the advance or to extent the time for performance of the contract by the Contractor. The Owners shall have the fullest liberty without affecting this guarantee, to postpone from time to time the exercise of any power vested in them or of any right which they might have against the Contractor and to exercise the same at any time in any manner, and either to enforce any covenants, contained or implied, in the contact between the Owner and the Contractor or any other course or remedy or security available to the Owner. The Bank shall not be released of its obligations under this presents by any exercise by the owner of its liberty with reference to the matter aforesaid of any of them or by reason of any other act or forbearance or other acts of omission or commission on the part of the owner or any other indulgence shown by the owner or by any other matter or thing whatsoever which under law would be for this provision have the effect of relieving the Bank. The Bank also agrees that the Owner at its option shall be entitled to enforce this guarantee against the Bank as a principal debtor, in the first instance without proceeding against the contractor and not withstanding any security or other guarantee that the owner may have in relation to the contractors liabilities. Notwithstanding anything hereinabove our liability under this guarantee is limited to and it shall remain in force upto an including .( @ and shall be extended from time to time for such period ( not exceeding 1 year as may be desired by M/s...dated this . Day of .. 20. At.. WITNESS.. (Signature) . (Name) ... (Designation) (Official Address) (With Bank Stamp) Attorney as per Power of attorney No . Dated. Strike whichever is not applicable ... (Signature) (Name) Bank guarantee No

@ The date will be 90(ninety) days after the date of completion of the Contract. 28

PROFORMA OF AGREEMENT (To be executed on non-Judicial stamp paper)


This Agreement made this .. day of two thousand. Between Assam Power Distribution Company Ltd. having its head office at Bijulee Bhawan, Paltanbazar, Guwahati-1 ( hereinafter referred to as Owner or APDCL, which expression shall include its administrators, successors and assign on one part and (hereinafter referred to as the Contractors X ( Name of the contracting Co.) which expression shall include its administrators, successors, executors and permitted assigns) on the other part. WHEREAS APDCL desirous of .. in . Circle associated with APDCL at .(District) invited Bids for.. . (Briefly describe scope of works) for the first state of the project as per its Bid Specification No AND WHEREAS.X . Had participated in the above referred Bidding vide their proposal No. dated. And awarded the Contract to.. X.. on terms and conditions documents referred to therein which have been acknowledged by.X..resulting into a Contract NOW THEREFORE THIS DEED WITNESS AS UNDER:1.0 Article 1.1 Award of Contract APDCL awarded the contract to..X for the work of on the terms and conditions contained in its letter of Award No.. . Dated and the documents referred to therein. The award has taken effect from aforesaid letter of award. The terms and expression used in this agreement shall have the same meaning as are assigned to them in the Contract Documents referred to in this succeeding Article. 2.0 Documentation 2.1 The contract shall be performed strictly as per the terms and condition stipulated herein and in the following documents attached herewith( hereinafter referred to as Contract Documents.) i) Section 1-11 of the Bidding Document. ii) Proposal Sheets, Data Sheets, Drawing work schedule submitted by X. APDCLs Letter of Award No.. dated.duly acknowledged by X. Quality Plans for manufacturing and field activities entitled as Quality Plan. All the aforesaid Contract Documents shall form an integral part of this agreement , in so far as the same or any part conform to the bidding documents and what has been specifically agreed to by the Owner in its letter of Award. Any matter inconsistent therewith, contrary or repugnant thereto or any deviations taken by the Contractor in its Proposal but not agreed to specially by the Owner in its Letter of Award shall be deemed to have been withdrawn b y the Contractor. For the sake of brevity, this agreement along with its aforesaid Contract Documents shall be referred to as the Agreement. 3.0 Conditions & Covenants 3.1 The scope of Contract, Consideration, Terms of Payment, Price Adjustments, Taxes wherever applicable, Insurance, Liquidated Damage, Performance Guarantees and all other terms and conditions are contained in APDCLs Letter of Award No........... dated read in conjunction with other aforesaid contract documents. The contract shall be duly performed by the Contract Documents, but which are needed for successful, efficient, safe and reliable operation of the equipment unless otherwise specifically excluded in the specification under exclusion or Letter of Award. 3.2 The scope of work shall also include supply and installation of all such items which are not specifically mentioned in the contract Documents, but which are needed for successful, efficient, safe and reliable operation of the equipment unless otherwise specifically excluded in the specifications under exclusions or Letter of Award. 3.3 Time Schedule 3.3.1 Time is the essence of the Contract and schedules shall be strictly adhered to X shall perform the work in accordance with the agreed schedules. 3.4 Quality Plans 3.4.1 The Contractor is responsible for the proper execution of the Quality Plans mentioned in Section 4.8 of GTC. The work beyond the customers hold points will progress only with the owners consent. The Owner will also undertake quality surveillance and quality audit of the Contractors /Sub-contractors works, systems and procedures and quality control activities. The Contractor further agrees that any change in the Quality Plan will be made only with the Owners approval. The contractor shall also perform all quality control activities, inspection and tests agreed with the Owner to demonstrate full compliance with the contract requirements. 3.4.2 The contractor also agrees to provide the Owner with the necessary facilities for carrying out inspection, quality audit and quality surveillance of contractors and its Subcontractors Quality Assurance Systems and Manufacturing Activities. These shall include but not limited to the following: Relevant plant standards, drawing and procedures; Detailed Quality Assurance System manuals for manufacturing activities. Storage procedures and instructions weld, NDT, heat treatment prior to commencement of manufacture; Complete set of log sheets (blank) mentioned in the Quality Plans. It is expressly agreed to by the contractor that the quality test and inspection by the owner shall not in any way relief the contractor of its responsibilities for quality standards and performance guarantee and their other obligations under the Agreement.

29

3.4.4 X agrees to submit quality Assurance Documents to APDCL for review and record after completion and within 3 weeks of dispatch of material. The package will include the following : Factory test result, inspection report for testing required by this contract or applicable codes and standards. Two copies of inspection reports duly signed by Quality Assurance personnel of both APDCL and X for the agreed customer hold points. Report of the rectification works where and if applicable. 3.5 It is expressly agreed to by the Contractor that notwithstanding the fact that the Contract is termed as Supply-cum-Erection Contract or indicates the break-up of the Contract consideration, for convenience of operation and for payment of sale tax on supply portion, it is in fact one composite Contract on single source responsibility basis and the Contractor is bound to perform the total Contract in its entirely and non-performance of any part or portion of the Contract shall be deemed to be breach of the entire Contract. 3.6 The Contractor guarantees that the equipment package under the Contract shall meet the ratings and performance parameters as stipulated in the technical specifications (Section 10) and in the event of any deficiencies found in the requisite performance figures, the Owner may at its option reject the equipment package or alternatively accept it on the terms and conditions and subject to levy of the liquidated damages in terms of Contract documents. The amount of liquidated damages so leviable shall be in accordance with the contract document and without any limitation. 3.7 It is further agreed by the contractor that the contract performance guarantee shall in no way be constructed to limit or restrict the owners equipment right to recover the damages/compensation due to shortfall in the equipment performance figures as stated in Para 3.6 above or under any other clause of the agreement. The amount of damages/compensation shall be recoverable either by way of deduction from the contract price, contract performance guarantee and or otherwise. The contract performance guarantee furnished by the contractor is irrevocable and unconditional and the owner shall have the power to invoke it notwithstanding any dispute or difference between the owner and the contractor pending before any court tribunal, arbitrator or any other authority. 3.8 This Agreement constitutes full and complete understanding between the parties and terms of the payment. It shall supersede all prior correspondence terms and conditions contained in the Agreement. Any modification of the agreement shall be effected only by a written instrument signed by the authorized representative of both the parties. 4.0 SETTLEMENT OF DISPUTES 4.1 It is specifically agreed between parties that all the differences or disputes arising out of the agreement or touching the subject matter of the agreement shall be decided by process of settlement and Arbitration as specified in clause 41 of the General Condition of the Contract and provision of the Indian Arbitration Act, 1996 shall apply. Guwahati Courts alone shall have exclusive jurisdiction over the same. 4.2 NOTICE OF DEFAULT Notice of default given by either party to the other under agreement shall be in writing and shall be deemed to have been duly and properly served upon the parties hereto if delivered against acknowledgement or by telex or by registered mail with acknowledgements due addressed to the signatories at the addresses mentioned at Guwahati. IN WITNESS WHEROF, the parties through their duly authorized representatives have executed these presents (execution where of has been approved by the competent authorities of both the parties) on the day, month and year first above mentioned at Guwahati . WITNESS: 1. .. 2. 3. .. 4. .. (Owners signature) ( Printed Name) (Designation)( Companys Stamp) (Contractors Signature)(Companys Name) (Designation)(Companys Stamp)

Applicable in case of single award is placed on one party on Supply-cum- Erection basis. In two separate awards are placed on single party/two different parties this clause is to be modified suitably while signing the contract agreement to be signed separately for two awards to incorporate cross fall breach clause.

30

FORM OF POWER OF ATTORNEY FOR JOINT VENTURE (On Non-judicial Stamp Paper of Appropriate value to be Purchased in the Name of Joint Venture) KNOW ALL MEN BY THESE PRESENTS THAT WE, the Partners whose details are given hereunder................................................................. have formed a Joint Venture under the laws of..and having our Registered Office(s)/Head Office(s) at .....(herein after called the 'Joint Venture' which expression shall unless repugnant to the context or meaning thereof, include its successors, administrators and assigns) acting thorough M/S .. being the Partner in-charge do hereby' constitute, nominate and appoint M/S ..a Company incorporated under the laws of arid having its Registered/Head Office at..as our duly 'constituted lawful Attorney (hereinafter called "Attorney" or" Authorized Representative" or "Partner In-charge") to exercise all or any of the powers for and on be.ha1f of, the Joint Venture in regard* to ---------------------(Name of the Package) (Specification No.------------------------) of Assam Power Distribution Company Ltd. Bijulee Bhawan, Paltan Bazar, GUWAHATI (hereinafter called the "Owner"). and the bids for which' have been invited by the Owner, to undertake the following acts: To submit proposal and participate in the aforesaid Bid Specification of the Owner on behalf of the Joint Venture. ii) To negotiate with the Owner 'the terms and' conditions for award of the Contract pursuant to the aforesaid Bid and to sign the Contract with the Owner for and on behalf of the "Joint Venture'. iii) To do any other act or submit any document rated to the above. iv) To receive, accept and execute .the Contract for and on behalf of the "Joint Venture". It is clearly understood that the Partner In-charge (Lead Partner) shall ensure performance of the Contract(s) and if one or more Partner fail to perform their respective portion of the Contract(s), the same shall be deemed to be a default by all the Partners. It is expressly understood that this Power of Attorney shall remain valid binding and irrevocable till completion of the Defect Liability Period in terms of the Contract. The Joint Venture hereby agrees and undertakes to ratify and confirm all the above whatsoever the said Attorney/ Authorized Representative/Partner In-charge quotes in the bid, negotiates and signs the Contract with the Owner and/or proposes to act on behalf of the joint Venture by virtue of this Power of Attorney and the same shall bind the Joint Venture as if done by itself. * Strike which is not applicable. i)

IN WITNESS THEREOF the Partners Constituting the Joint Venture as aforesaid have executed these presents on this .. day of ....... under the Common Seal(s) of their Companies.

for and on behalf of the Partners of Joint Ventures The Common Seal of the above Partners of the Joint Venture: The Common Seal has been affixed there unto in the presence of : WITNESS 1. Signature _________________________ Name___________________________ Designation_______________________ Occupation ________________________ Signature _________________________ Name___________________________ Designation_______________________ Occupation ________________________

2.

31

FORM OF JOINT VENTURE AGREEMENT (ON NON-JUDICIAL STAMP PAPER OF APPROPRIATE VALUE TO BE PURCHASED IN THE NAME OF JOINT VENTURE) PROFORMA OF JOINT VENTURE AGREEMENT BETWEEN ______________________ ______________________________ AND ____________________________________________ FOR BID SPECIFICATION No_______________________________OF ASSAM POWER DISTRIBUTION COMPANY LTD. THIS Joint Venture agreement executed on this _____day of ______________Two thousand eight and between M/S _________________________________________________ a Company incorporated under the laws of _______________________________ and having its registered office at __________________________________ _____________________________ (herein after called the Lead Partner which expression shall include its successors, executors and permitted assigns) and M/S _______________________________________________ a Company incorporated under the laws of _______________________________ and having its registered office at ________________________________________________________________ (herein after called the Partner which expression shall include its successors, executors and permitted assigns) for purpose of making a bid and entering into a contract* (in case of award) for Construction of _______________________________(name of the package) against the specifications No._____________________ of APDCL BIJULEE BHAWAN, PALTAN BAZAR, GUWAHATI 781001, an Electricity Distribution Company registered under Indian Electricity Act, 2003 having its registered office at Bijulee Bhawan, Paltan Bazar, Guwahati 781001 (herein after called the Owner) WHEREAS the Owner invited bids as per the above mentioned Specification for the design manufacture, supply and erection, testing and commissioning of Equipment/Materials stipulated in the bidding documents under subject Package* For_________________ (Package Name) (Specification No.:_____________________) AND WHEREAS Annexure A (Qualification Requirement of the Bidder). Section-4, forming part of the bidding documents, stipulates that a Joint Venture of two or more qualified firms as partners, meeting the requirement of Annexure-A, Section 4 as applicable may bid, provided the .Joint Venture fulfills all other requirements of AnnexureA, Section 4 and in such a case, the BID shall be signed by all the partners so as to legally bind all the Partners of the .Joint Venture, who will be jointly and severally liable to perform the Contract and all obligations hereunder . * Strike which is not applicable. The above clause further states that the Joint Venture agreement shall be attached to the bid and the contract performance guarantee will be as per the format enclosed with the bidding document without any restriction or liability for either party. AND 'WHEREAS the bid has been submitted to the Owner vide proposal No ................................. dated ........................................................... by Lead Partner based on the Joint Venture agreement between all the Partners under these presents and the bid in accordance with the requirements of Annexure-A (Qualification Requirements of the Bidders), Section -4 has been signed by all the partners.

NOW THIS INDENTURE WITNESSETH AS UNDER: In consideration of the above premises and agreements all the Partners to this ,Joint Venture do hereby now agree as follows: 1. In consideration of the award of the Contract by the Owner to the Joint Venture partners, we, the Partners to the Joint Venture agreement do hereby agree that M/S__________________ shall act as Lead Partner and further declare and confirm that we shall jointly and severally be bound unto the Owner for the successful performance of the Contract and shall be fully responsible for the design, manufacture, supply, and successful performance of the equipment in accordance with the Contract. In case of any breach of the said Contract by the Lead Partner or other Partner(s) of the Joint Venture agreement, the Partner(s) do hereby agree to be fully responsible for the successful performance of the Contract and to carry out all the obligations and responsibilities under the Contract in accordance with the requirements of the Contract. Further, if the Owner suffers any loss or damage on account of any breach in the Contract or any shortfall in the performance of the equipment in meeting the performance guaranteed as per the specification in terms of the Contract, tile Partner(s) of these presents undertake to promptly make good such loss or damages caused to the Owner, on its demand without any demur. It shall not be necessary or obligatory for the Owner to proceed 32

2.

3.

4.

5.

6. 7.

8.

against Lead Partner to these presents before proceeding against or dealing with the other Partner(s) The financial liability of the Partners of this Joint Venture agreement to the Owner, with respect to any of the claims arising out of the performance of non-performance of the obligations set forth in the said Joint Venture agreement, read in conjunction with the relevant conditions of the Contract shall, however, not be limited in any way so as to restrict or limit the liabilities of any of the Partners of the Joint Venture agreement. It is expressly understood and agreed between the Partners to this Joint Venture agreement that the responsibilities and obligations of each of the Partners shall be as delineated in Appendix-I (*To be incorporated suitably by the Partners) to this agreement. It is further agreed by the Partners that the above sharing of responsibilities and obligations shall not in any way be a limitation of joint and several responsibilities of the Partners under this Contract. This Joint Venture agreement shall be construed and interpreted in accordance with the laws of India and the courts of Delhi shall have the exclusive jurisdiction in all matters arising there under. In case of an award of a Contract, We the Partners to the Joint Venture agreement do hereby agree that we shall be jointly and severally responsible for furnishing a contract performance security from a bank in favour of the Owner in the forms acceptable to purchaser for value of 10% of the Contract Price in the currency/currencies of the Contract. It is further agreed that the Joint Venture agreement shall be irrevocable and shall form an integral part of the Contract, and shall continue to be enforceable till the Owner discharges the same. It shall be effective from the date first mentioned above for all purposes and intents.

IN WITNESS WHEREOF, the Partners to the Joint Venture agreement have through their authorised representatives executed these presents and affixed Common Seals of their companies, on the day, month and year first mentioned above. IN WITNESS WHEREOF, the Partners to the Joint Venture agreement have through their authorized representatives executed these presents and affixed Common Seals of their companies, on the day, month and year first mentioned above. 1. Common Seal of_________________ Partner has been affixed in my/our presence pursuant to the Board of Director's (Signature of authorized resolution dated________________ representative) Name Signature Designation Name Designation 2. For Lead

Common Seal of the Company

Common Seal of_________________ Other Partner has been affixed in my/our presence pursuant to the Board of Director's (Signature of authorized resolution dated_______________ representative) Name Signature Designation Name Designation

For

Common Seal of the Company

WITNESSES 1. Name . (Signature)

(Official address) 2. Name (Official address) 33 . (Signature)

SECTION 6 TECHNICAL SPECIFICATION

34

6.0

GENERAL TECHNICAL SPECIFICATIONS

1.0 Part A General:


1.1. It is not the intent to specify herein complete details of design and construction of the plant/equipment/material. The plant offered shall conform to the relevant standards and shall be of high quality, sturdy, robust and of good design and workmanship complete in all respects and capable to perform continuous and satisfactory operations in the actual service conditions at site and shall have sufficiently long life in service. The dimensional drawings attached with the technical Specification in Volume II are generally of illustrative nature. In actual practice, not withstanding any anomalies, discrepancies, omissions, incompleteness, etc. in these specifications and attached drawings, the design and constructional aspects, including materials and dimensions, will be subject to good engineering practice in conformity with the required quality of the product and to such tolerances, allowances and requirements for clearances etc. as are necessary by virtue of various stipulation in that respect in the relevant Indian Standards, IEC standards, I.E. Rules and other statutory provisions.

1.2. The plant/equipment/material offered shall be complete with all parts necessary for their effective and trouble free operation. Such parts will be deemed to be within the scope irrespective of whether they are specifically indicated in the Bid documents or not.

2.0 Quality Assurance Programme: 2.1. Bidder must establish that a proper quality assurance program is being followed by them for manufacture of plant/equipment. Quality Assurance Program must have a structure as detailed in following paragraphs. 2.2. Quality assurance and failure prevention starts with careful study and scrutiny of our technical specifications and requirements. Bidder/manufacturer shall carefully study all the technical parameters and other particulars and the Bidder/manufacturer shall categorically give his confirmation that these requirements shall be met in a satisfactory manner. 2.3. Bidder/manufacturer shall furnish the checks exercised in design calculations. The salient features of design shall be made available to the Employer. 2.4. Bidder/manufacturer shall indicate the various sources of the items being procured. Type of checks, quantum of checks and acceptance norms shall be intimated and random test and check results should be made available for inspection whenever so desired. 2.5. The Bidders shall invariably furnish following information. 1. Statement giving list of important raw materials, names if sub-Bidder/manufacturers for the raw material, list of standards according to which the raw material is purchased and copies of test certificates thereof. Information and copies of test certificates as in (i) above in respect of bought out items. List of machines and manufacturing facilities available Levels of automation achieved and list of areas where manual processing exists List of areas in manufacturing process, where stage inspections are normally carried out for quality control and details of such tests and inspections List of testing equipment available with the Bidder for final testing of materials specified and test plant limitation, if any, vis-a-vis 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 equipments

2. 3. 4. 5. 6.

3.0 Pre Dispatch Inspection: 3.1. The Employers representative may carry out stage inspection of the plant/equipment during manufacturing/ assembling stage. The Employer shall have absolute right to reject the raw material/ component/ sub assemblies or complete equipment not found to be conforming to the specification or being of poor quality/ workmanship. The stage inspection will particularly include tests specified for any particular plant or

35

equipment in the technical specification, general routine tests and physical measurements to be conducted during manufacturing stages as per manufacturers standard practice. 3.2. The Bidder/manufacturer shall give fifteen (15) days advance notice to enable the Employer to arrange for inspection. Inspection and testing shall be conducted at the place of manufacture. Inspection and testing of any material under this specification by the Employer shall not relieve the Bidder/manufacturer of his obligation to supply the plant/equipment in accordance with the specification and shall not prevent subsequent rejection if it is found to be defective. 3.3. The Bidder/manufacturer shall afford the Employers representative all reasonable facilities, without charge, to satisfy him that the plant/ equipment is being manufactured in accordance with the specifications. The Bidders/manufacturer must have adequate set of instruments for conducting tests as per ISS specification. Instruments shall be duly calibrated and calibration certificate should not be older than one year on the date of inspection. Calibration shall be done by NABL accredited laboratories. A comprehensive list of testing equipment/ instruments indicating make, Sr.No., type, class of accuracy, calibrating agency, calibration date etc. should be furnished, as and when desired. Calibrated instruments shall be duly sealed by calibrating agency to avoid any tampering with calibration and the details thereof shall be clearly mentioned in the calibration certificate(s). 4.0 Defect Liability: 4.1. The defect liability period of plants/ equipments shall be as indicated in GCC of the bid document

36

3.2
1.0

SPECIAL TECHNICAL SPECIFICATIONS FOR NEW SUBSTATION CIVIL WORKS & SWITCHGEAR GENERAL

The intent of specification covers the following: Design, engineering, and construction of all civil works at sub-station. All civil works shall also satisfy the general technical requirements specified in other Section of this Specification and as detailed below. They shall be designed to the required service conditions/loads as specified elsewhere in this Specification or implied as per National/International Standards. All civil works shall be carried out as per applicable Indian Laws, Standards and Codes. All materials shall be of best quality conforming to relevant Indian Standards and Codes. The Contractor shall furnish all design, drawings, labour, tools, equipment, materials, temporary works, constructional plant and machinery, fuel supply, transportation and all other incidental items not shown or specified but as may be required for complete performance of the Works in accordance with approved drawings, specifications and direction of Employer. The work shall be carried out according to the design/drawings to be developed by the Contractor and approved by the owner based on Tender Drawings Supplied to the Contractor. by the Owner. For all buildings, structures, foundations, etc., necessary layout and details shall be developed by the Contractor keeping in view the functional requirement of the substation facilities and providing enough space and access for operation, use and maintenance based on the input provided by the Owner. Certain minimum requirements are indicated in this specification for guidance purposes only. However, the Contractor shall quote according to the complete requirements. 1.2 GEO-TECHNICAL INVESTIGATION 1.3 The Contractor shall perform a detailed soil investigation to arrive at sufficiently accurate, general as well as specific information about the soil profile and the necessary soil parameters of the Site in order that the foundation of the various structures can be designed and constructed safely and rationally. A report to the effect will be submitted by the contractor for Owner's specific approval giving details regarding data proposed to be utilized for civil structures design. 2.0 SCOPE OF WORK This specification covers all the work required for detailed soil investigation and preparation of a detailed report. The work shall include mobilization of necessary equipment, providing necessary engineering supervision and technical personnel, skilled and unskilled labour, etc., as required to carry out field investigation as well as, laboratory investigation, analysis and interpretation of data and results, preparation of detailed Geo-Technical report including specific recommendations for the type of foundations and the allowable safe bearing capacity for different sizes of foundations at different founding strata for the various structures of the substation. The Contractor shall make his own arrangement for locating the co-ordinates and various test positions in field as per the information supplied to him and also for determining the reduced level of these locations with respect to the benchmark indicated by the Owner. All the work shall be carried out as per latest edition of the corresponding Indian Standard Codes. 2.1 Bore Holes Drilling of bore holes of 150 mm dia, in accordance with the provisions of IS: 1982 at the rate of minimum two number of bore holes per bay to 15 m depth or to refusal which ever occur earlier. (By refusal it shall mean that a standard penetration blow count (N) of 100 is recorded for 30 cm penetration). However, in case deep pile foundations are envisaged the depths have to be regulated as per codel provisions. In cases where rock is encountered, coring in one borehole per bay shall be carried out to 3 M in bedrock and continuous core recovery is achieved. Performing Standard Penetration Tests at approximately 1.5 m interval in the borehole starting from 1.5 m below ground level onwards and at every change of stratum. The disturbed samples from the standard penetrometer shall also be collected for necessary tests. Collecting undistributed samples of 100/75 mm diameter 450 mm long from the boreholes at intervals of 2.5 m and every change of stratum starting from 1.0 m below ground level onwards in clayey strata. The depth of Water Table shall be recorded in each borehole. All samples, both disturbed and undisturbed, shall be identified properly with the borehole number and depth from which they have been taken. The sample shall be sealed at both ends of the sampling tubes with wax immediately after the sampling and 37

shall be packed properly and transported to the Contractor's laboratory without any damage or loss. The logging of the boreholes shall be compiled immediately after the boring is completed and a copy of the bolero shall be handed over to the Engineer-in - Charge, 2.2 Dynamic Cone Penetration Test Dynamic cone penetration tests of two numbers shall be carried out with the circulation of bentonite slurry at specified locations and a continuous record of penetration resistance (NG) upto 15.00 meter from natural ground level or the refusal shall be maintained by the Contractor IS: 4968 (Part-2) shall be followed for carrying out the test and reporting results. The location for tests shall be as directed by the Owner. On completion of the test, the results shall be presented as a continuous record as the numbers of blows required for every 300 mm penetration of the cone into the soil. 2.3 Trial Pits Trial pits shall be carried at specified one locations of per bay as directed by the Owner. The trial pits shall be 2m x 2m in size extending to 4 m depths, or as specified by the Owner. Undisturbed samples shall be taken from the trial pits as per the direction of the Owner. 2.4 Electrical Receptivity Test This test shall be conducted to determine the Electrical receptivity of soil required for designing safe grounding system for the entire station area. The specifications for the equipments and other accessories required for performing electrical receptivity test, the test procedure, and reporting of field observations shall confirm to IS: 3043. The test shall be conducted using Wagner's four electrode method as specified in IS: 1892, AppendixB2. Unless otherwise specified at each test location, the test shall be conduced along two perpendicular lines parallel to the co-ordinate axis. On each line a minimum of 8 to 10 readings shall be taken by changing the spacing of the electrodes from an initial small value of 0.5 m upto a distance of 10.0 m.

2.5 Plate Load Test Plate load test shall be conducted to determine the bearing capacity, modulus of sub-grade reaction and load/settlement characteristics of soil at shallow depths by loading a plane and level steel plate kept at the desired depth and measuring the settlement under different loads, until a desired settlement takes place or failure occurs. The specification for the equipment and accessories required for conducting the test, the test procedure, field observations and reporting of results shall conform to IS: 1888. Modulus of sub-grade reaction shall be conducted as per IS: 9214. The location and depth of the test shall be as given below: 1) One at Control Building location at the proposed foundation depth below finished ground level for bearing capacity. 2) One test at Transformer foundation location at proposed foundation depth below FGL.

Undisturbed tube samples shall be collected at 1.0 m and 2.5 m depths from natural ground level for carrying out laboratory tests. The size of the pit in plate load test shall not be less than five times the plate size and shall be taken upto the specified depth. All provisions regarding excavation and visual examination of pit shall apply here. Unless otherwise specified the reaction method of loading shall be adopted. Settlement shall be recorded from dial gauges placed at four diametrically opposite ends of the test plate. The load shall be increased in stages. Under each loading stage, record of time Vs. Settlement shall be kept as specified in IS: 1888. Backfilling of the pit shall be carried out as per the directions of the Owner. Unless otherwise specified the excavated soil shall be used for this purpose. In cases of gravel-boulder or rocky strata, respective relevant codes shall be followed for tests. 2.6 Water Sample Representative samples of ground water shall be taken when ground water is first encountered before the addition of water to aid drilling of boreholes. The samples shall be of sufficient quantity for chemical analysis to be carried out and shall be stored in airtight containers.

38

2.7 Back Filling Bore Holes On completion of each hole, the Contractor shall backfill all boreholes as directed by the Owner. The backfill material can be the excavated material. 2.8 laboratory Test The laboratory tests shall be carried out progressively during the field work after sufficient number of samples have reached the laboratory in order that the test results of the initial boreholes can be made use of in planning the later stages of the field investigation and quantum of laboratory tests. All samples brought from field, whether disturbed or undisturbed shall be extracted/prepared and examined by competent technical personnel, and the test shall be carried out as per the procedures laid out in the relevant I.S.Codes. The following laboratory tests shall be carried out: i. Visual and Engineering Classification. ii. Liquid limit, plastic limit and shrinkage limit for C soils. iii. Natural moisture content, bulk density and specific gravity. iv. Grain size distribution. v. Swell pressure and free swell index determination. vi. California bearing ratio. vii. Consolidated un-drained test with pore pressure measurement. i) Chemical tests on soil and water to determine the carbonates, sulphates, nitrates, chlorides, Ph value, and organic matter and any other chemicals harms to the concrete foundation. ii) Rock quality designation (ROD), RMR in case of rock is encountered.

2.9 Test Results and Reports 1. The Contractor shall submit the detailed report in two (2) copies wherein information regarding the geological detail of the site, summarized observations and test data, bore logs, and conclusions and recommendations on the type of foundations with supporting calculations for the recommendations. Initially the report shall be submitted by the Contractor in draft form and after the draft report is approved, the final report in four (4) copies shall be submitted. The test data shall bear the signatures of the Investigation Agency, Vendor and also site representative of POWERGRID. 2. The report showing the locations of the exploration work i.e., bore holes, dynamic cone penetration tests, trial pits. Plate load test, etc. a) A plan showing the locations of the exploration work i.e., bore holes, dynamic cone penetration tests, trial pits. Plate load test, etc. b) Bore Logs: Bore logs of each bore holes clearly identifying the stratification and the type of soil stratum with depth. The values of Standard Penetration Test (SPT) at the depths where the tests were conducted on the samples collected at various depths shall be clearly shown against that particular stratum. Test results of field and laboratory tests shall be summarized strata wise as well in combined tabular form. All relevant graphs, charts tables, diagrams and photographs, if any, shall be submitted along with report. Sample illustrative reference calculations for settlement, bearing capacity, pile capacity shall be enclosed. 3.0 Recommendations The report should contain specific recommendations for the type of foundation for the various structures envisaged at site. The Contractor shall acquaint himself about the type of structures and their functions from the Owner. The observations and recommendations shall include but .not limited to the following: a) Geological formation of the area, past observations or historical data, if available, for the area and for the structures in the nearby area, fluctuations of water table, etc. slope stability characteristics and landslide history of the area shall be specifically highlighted. Remedial measures to be adopted shall also be given. b) Recommended type of foundations for various structures. If piles are recommended the type, size and capacity of pile and groups of piles shall be given after comparing different types and sizes of piles and pile groups. c) Allowable bearing pressure on the soil at various depths for different sizes of the foundations based on shear strength and settlement characteristics of soil with supporting calculations. Minimum factor of safety for calculating net safe bearing capacity shall be taken as 3.0 (three). Recommendation of liquifaction characteristics of soil shall be provided. d) Recommendations regarding slope of excavations and dewatering schemes, if required. Required protection measures for slope stability for cut and fill slopes of switchyard and approach road with stone pitching/retaining walls shall be clearly spelt out. Calculation 39

f)

shall also be provided for stability adequacy. Comments on the Chemical nature of soil and ground water with due regard to deleterious effect of the same on concrete and steel and recommendations for protective measures. If expensive soil is met with, recommendation on removal or retainment of the same under the structure, road, drains, etc., shall be given. In the later case detailed specification of any special treatment required including specification or materials to be used, construction method, equipments to be deployed, etc., shall be furnished. Illustrative diagram of a symbolic foundation showing details shall be furnished. g)Recommendations for additional investigations beyond the scope of the present work, if considered such investigation as necessary. e) SITE PREPARATION

4.0

The Contractor shall be responsible for proper leveling of switchyard site as per layout and levels of switchyard finalized during detailed engineering stage. The Contractor at his own cost shall make the layout and levels of all structure, etc., from the general grids of the plot and benchmarks set by the Contractor and approved by the Owner. The Contractor shall give all help in instruments, materials and personal to the Owner for checking the detailed layout and shall be solely responsible for the correctness of the layout and levels. Site leveling shall be in the scope of the contractor. Bidder may decide the level of the sites. However, the level shall be such that it is 300 mm higher than the highest flood level (HFL) of the site.

5.0

SCOPE OF WORKS This clause covers the design and execution of the work for site preparation, such as clearing of the site, the supply and compaction of fill material, slope protection by stone pitching/retaining walls depending on the site location/ condition, excavation and compaction of backfill for foundation, road construction, drainage, trenches and final topping by stone (broken hard stone).

5.1

General

1) The Contractor shall develop the site area to meet the requirement of the intended purpose. The site preparation shall conform to the requirements of relevant sections of this specification or as per stipulations of standard specifications. Necessary protection of slope of switchyard area and approach road shall also be carried out by contractor. 2) If fill material is required, the fill material shall be suitable for the above requirement. The fill shall be such a material and the site so designed as to prevent the erosion by wind and water of material from its final compacted position or the in-site position of undisturbed soil. 3) When embankments are to be constructed on slopes of 15% or greater, benches or steps with horizontal and vertical faces shall be cut in the original slope prior to placement of embankment material. Vertical faces shall measure not more than 1 m in height. 4) Embankments adjacent to abutments, culverts, retaining walls and similar structures shall be constructed by compacting the material in successive uniform horizontal layers not exceeding 15 cm in thickness. (Of loose material before compaction). Each layer shall be compacted as required by means of mechanical tampers approved by the Owner. Rocks larger than 10 cm in any direction shall not be placed in embankment adjacent to structures. 5) Earth embankments of roadways and site areas adjacent to buildings shall be placed in successive uniform horizontal layers not exceeding 20 cm in thickness in loose stage measurement and compacted to the full width specified. The upper surface of the .embankment shall be shaped so as to provide complete drainage of surface water at all times. 6) The pitching shall be designed and provided for slope protection as per approved drawings. The stone used shall be sound, hard, durable and fairly regular in shape. Stones subjected to marked deterioration by water or weather shall not be used. Suitable measures shall be provided to prevent erosion by seepage of water. Largest stone procurable shall be used as approved by owner for the work. Random rubble masonry (1:6) retaining walls shall be provided wherever required as per site condition.

40

5.2

Compaction 1. The density to which fill materials shall be compacted shall be as per relevant IS and as per direction of Owner. All compacted sand filling shall be confined as far as practicable. Backfilled earth shall be compacted to minimum 95% of the Standard Proctor's density at OMC. The sub-grade for the roads and embankment filling shall be compacted to 70% relative density (minimum). 2. At all times unfinished construction shall have adequate drainage. Upon completion of the road's surface course, adjacent shoulders shall be given a final shaping, true alignment and grade. 3. Each layer of earth embankment when compacted shall be as close to optimum moisture content as practicable. Embankment material, which does not contain sufficient moisture to obtain proper compaction, shall be wetted. If the material contains any excess moisture then it shall be allowed to dry before rolling. The rolling shall begin at the edges overlapping half the width of the roller each time and progress to the center of the road or towards the building as applicable. Rolling will also be required on rock fills. No compaction shall be carried out in rainy weather.

5.3

Requirement for fill material under foundation The thickness of fill material under the foundations shall be such that the maximum pressure from the footing, transferred through the fill material and distributed onto the original undisturbed soil will not exceed the allowable soil bearing pressure of the original undisturbed soil. For expansive soils the fill materials and other protections, etc., to be used under the foundation is to be got approved by the Owner.

6.0 6.1

ANTI-WEED TREATMENT AND STONE SPREADING Scope of Works The Contractor shall furnish all labour, equipment and materials required for complete performance of the work in accordance with the drawings specification and direction of the Owner. Stone spreading shall be done in the areas of the switchyard wherever equipments and or structures are to be provided under present scope of work. The stone spreading in future areas shall also be provided in case potential without stone layer is not well within safer limits.

7.0

GENERAL REQUIREMENT

7.1 The material required for site surfacing/stone filling shall be free from all types of organic materials and shall be
of standard quality, and as approved by the Owner. The material to be used for stone filling/site surfacing shall be uncrushed/ crushed/broken stone of 20 mm nominal size (upgraded single size) conforming to Table 2 of IS:383-1970. Hardness, Flakiness shall be as required for wearing courses are given below: a) Sieve Analysis Limits (Gradation) (IS: 383 - Table 2) Sieve Size % passing by weight 40mm 100 20 mm 85 - 100 10 mm 0-20 4.75 mm 0-5 b) Hardness Abrasion value (IS: 2386 Part-IV) - not more than 40% Impact value (IS: 2386 Part-IV) - not more than 30% and frequency shall be one test per 500 cum with a minimum of one test per source, c) Flakiness Index One test shall be conducted per 500 cum of aggregate as per IS: 2386 Part-I and maximum value is 25%,

7.2 After all the structures/equipments are erected and anti-weed treatment is complete, the surface of the
switchyard area shall be maintained, rolled/ compacted to the lines and grades as decided by Engineer-inCharge. Deweeding including removal of roots shall be done before rolling is commenced, Engineer-in-Charge shall decide final formation level so as to ensure that the site appears uniform devoid of undulations, The final formation level shall however be very close to the formation level indicated in the drawing using half ton roller 41

with suitable water sprinkling arrangement to form a smooth and compact surface.

7.3 A base layer of uncrushed/crushed/broken stone of 20 mm nominal size (ungraded single size) shall be spread
and rolled/compacted by using half ton roller with 4 to 5 passes and water sprinkling to form a minimum 50 mm layer on the finished ground level of the specified switchyard area excluding roads, drains, cable trench and tower and equipment foundations as indicated in the drawing.

7.4 Over the base layer of site surfacing material, a final surface course of minimum 50 mm thickness of 20 mm
nominal size (single size ungraded) broken stone as specified above shall be spread and compacted by light roller using half tones steel roller (width 30" and 24" diameter) with water sprinkling as directed by he Engineerin-Charge. The water shall be sprinkled in such a way that bulking does not take place.

7.5 In areas that are considered by the Engineer-in-Charge to be too congested with foundations and structures for
proper rolling of the site surfacing material by normal rolling equipments, the material shall be compacted by hand, if necessary. Due care shall be exercised so as not to damage any foundation structures or equipment during rolling compaction.

7.6 Before taking up stone filling, anti-weed treatment shall be applied in the switchyard area wherever gravel filling
is to be done, and the area shall be thoroughly de-weeded including removal of roots. The recommendation of local agriculture or horticulture department shall be sought wherever feasible while choosing the type of chemical to be used. Nevertheless the effectiveness of the chemical shall be demonstrated by the Contractor in a test area of 10M x 10M (approx.) and monitored over a period of two to three weeks by the Engineer-inCharge. The final approval shall be given by Engineer-in-Charge and final approval given based on the results.

7.7

The anti-weed chemical shall be procured from reputed manufacturers. The dosage and application of chemical shall be strictly followed as per manufacturer's recommendation. The contractor shall be required to maintain the area free of weeds for a period of 1 year from the date of st application of 1 dose of anti-weed chemicals.

8.0
1.

SITE DRAINAGE Adequate site drainage system shall be provided by the Contractor. The Contractor shall obtain rainfall data and design the storm water drainage system, (culverts, ditches, drains, etc.) to accommodate run off due to the most intense rainfall that is likely to occur over the catchment area in one hour period on an average of once in tem years. The surface of the site shall be sloped to prevent the ponding of water. The maximum velocity for pipe drains and open drains shall be limited to 2.4m/sec and 1.8m/sec respectively. However, minimum non-slitting velocity of 0.6 m/sec shall be ensured. Longitudinal bed slope not milder than 1 in 1000 shall be provided. For design of RCC pipes for drains and culverts, 18:456 and 18:783 shall be followed. The Contractor shall ensure that water drains are away from the site area and shall prevent damage to adjacent property by this water. Adequate protection shall be given to site surfaces, roads, ditches, culverts, etc., to prevent erosion of material by water. The drainage system shall be adequate without the use of cable/pipe trenches. (Pipe drains shall be provided in areas of switchyard where movement of crane will be necessary in operating phase of the substation). Open surface drains shall be provided with the Cement Concrete 1:2:4 of minimum thickness of 100 mm or more as per design condition. Pipe drains shall be connected through manholes at an interval of max. 30m. Effluents shall be suitably treated by the Contractor to meet all the prevalent statutory requirements and local pollution control norms and treated effluents shall be conveyed to the storm water drainage system at a suitable location for its final disposal. Invert of the drainage system shall be decided in such a way that the water can easily be discharged above the High Flood Level (HFL) outside substation boundary at suitable location upto a maximum 50M beyond boundary wall ot substation or actual whichever occurs earlier and approved by Owner. Pumps for drainage of water (it required) shall be provided by Contractor. All internal site drainage system, including the final connection/disposal to owner acceptance points shall be pat of Supplier's scope including all required civil work, mechanical and electrical systems. The Contractor shall connect his drain(s) at one or more points to outfall points as feasible at site. The drainage scheme and associated drawings shall be got approved.

2.

3. 4.

5. 6. 7.

8.

9.

10.

42

9.0
1.

ROADS AND CULVERTS The main approach road including modification of existing road to meet the site conditions, roads for access to equipment and building within substation are in the scope of bidder. Layout of the roads shall be based on General detail and Arrangement drawing for the substation. All substation roads be constructed so as to permit transportation of all heavy equipment. The roads shall have min.3.75 black topping. Moorum shoulder shall be provided on either side of the road. The width of the shoulder shall be as per approved drawing depending upon the site conditions. Road construction shall be as per IRC standards. Adequate provision shall be made for road drainage. Protection of cut and embankment slopes of roads as per slope stability requirement shall be made. All the culverts and its allied structure (required for road/rail, drain trench crossings, etc.) shall be designed for Class-AA loading as per IRC standards code and should be checked for loading. All roads shall be designed for Class-'E' of traffic as per IRC-37 Guidelines for the design of flexible pavements.

2.

3. 4.

5.

6.

10.0

TRANSFORMER FOUNDATION

The Contractor shall provide a road system integrated with the transformer foundation to enable installation and the replacement of any failed unit by the spare unit located at the site. This system shall enable the removal of any failed unit from its foundation to the nearest road. If trench/drain crossings are required the suitable R.C.C. culverts shall be provided in accordance with I.R.C. Code & relevant IS.

11.0 11.1 11.2

FIRE PROTECTION WALLS General

Fire protection walls shall be provided in accordance with Tariff Advisory Committee (TAC) recommendations. Application Criteria A firewall shall be erected between the transformer to protect each one from the effects of fire on another as per TAC guidelines. Also, if the free distance between the transformer and auxiliary services transformer is less.

11.3

Fire resistance

The firewall shall have a minimum fire resistance of 3 hours. The partitions, which are made to reduce the noise level, shall have the same fire resistance where the partitions are also used as firewalls. The walls of the building, which are used as firewalls, shall also have a minimum fire resistance of 3 hours. The firewall shall be designed in order to protect against the effect of radiant heat and flying debris from an adjacent fire.

11.4

Mechanical resistance The firewall shall have the mechanical resistance to withstand local atmospheric conditions. If this wall shall serve as a support for equipment such as insulators, etc., its mechanical rigidity must be increased. Connecting the walls by steel or other structures, which may produce a reversing torque if overheated, shall be avoided. Dimensions The firewall shall extend at least 2 m on each side of the transformer and at least 1 m above the conservator tank or safety vent. These dimensions might be reduced in special cases, and if T AC permits so, where there is lack of space. A minimum of 2 meter clearance shall be provided between the equipments e.g., transformer and fire walls. The building walls, which act as firewalls, shall extend at least 1 m above the roof in order to protect it.

11.5

11.6 Materials
The firewall may be made of reinforced concrete (M-20 grade), as per the system requirements. Materials used must conform to the standards of the National Fire Prevention Association and T AC norms. 43

12.0
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

CABLE AND PIPE TRENCHES The cable trenches and precast removable RCC cover (with lifting arrangement) The cable trench wall shall be designed for the following loads. Dead load of 155 Kg/m length of cable support + 75 Kg on one tier at the end. 2 Triangular earth pressure + uniform surcharge pressure of 2 T/m . 2 Cable trench covers shall be designed for self-weight of top slab + UDL of 2000 Kg/ m + concentrated load of 200 Kg at centre of span on each panel. Cable trench crossing the road/rails shall be designed for class AA. Loading of IRC/relevant IS Code and should be checked for transformer loading. Trenches shall be drained. Necessary sumps be constructed and sump pumps if necessary shall be supplied. Cable trenches shall not be used as storm water drains. The top of trenches shall be kept at least 100 mm above the finished ground level. The top of cable trench shall be such that the surface rainwater does not enter the trench. All metal parts inside the trench shall be connected to the earthing system. Cables from trench to equipments shall run in hard conduit pipes. Trench wall shall not foul with the foundation. Suitable clear gap shall be provided. The trench bed shall have a slope of 1/500 along the run and 1/250 perpendicular to the run. All the construction joints of cable trenches i.e., between base slab to base slab and the junction of vertical wall to base slab as well as from vertical wall to wall and all the expansion joints shall be provided with approved quality PVC water stops of approx. 230 x 5 mm size for those sections where the ground water table is expected to rise above the junction of base slab and vertical wall of cable trenches. Cable trenches shall be blocked at the ends if required with brick masonry in cement sand mortar 1:6 and plaster with 12 mm thick 1:6 cement sand mortar. Cable trenches shall be provided with suitable hangers to support the running cables.

14. 15.

13.0 FOUNDATION I RCC CONSTRUCTION 13.1 General


1. Work covered under this Clause of the Specification comprises the design and construction of foundations and other RCC constructions for switchyard structures, equipment supports, trenches, drains, jacking pad, control cubicles, bus supports, transformer, marshalling kiosks, auxiliary equipments and systems, buildings, tanks, boundary wall or for any other equipment or service and any other foundation required to complete the work. This clause is as well applicable to the other ECC constructions. 2. Concrete shall conform to the requirements mentioned in IS: 456 and all the tests shall be conducted as per relevant Indian Standard Codes as mentioned in Standard field quality plan appended with the specification. A minimum grade of M20 concrete (1:5:3 mix) shall be used for all structural/load bearing members as per latest IS 456. 3. If the site is sloppy, the foundation height will be adjusted to maintain the exact level of the top of structures to compensate such slopes. 4. The switchyard foundation's plinths and building plinths shall be minimum 300 mm and 500 mm above finished ground level respectively. 5. Minimum 75 mm thick lean concrete (1:4:8) shall be provided below all underground structures, foundations, trenches, etc., to provide a base for construction. 6. Concrete made with Portland slag cement shall be carefully cured and special importance shall be given during the placing of concrete and removal of shuttering. 7. The design and detailing of foundations shall be done based on the approved soil data and sub-soil conditions as well as for all possible critical loads and the combinations thereof. The Spread footings foundation or pile foundation as may be required based on soil/sub-soil conditions and superimposed loads shall be provided. 8. If pile foundations are adopted, the same shall be case-in-situ driven/bored or precast or under-reamed type as per relevant parts of IS Code 2911. Only RCC piles shall be provided. Suitability of the adopted pile 44

foundations shall be justified by way of full design calculations. Detailed design calculations shall be submitted by the bidder showing complete details of piles/pile groups proposed to be used. Necessary initial load test shall also be carried out by the 'bidder at their cost to establish the piles design capacity. Only after the design capacity of piles has been established, the Contractor shall take up the job of piling. Routine tests fro the piles shall also be conducted. All the work (design & testing) shall be planned in such a way that these shall not cause any delay in project completion.

13.2 Design
All foundation shall be of reinforced cement concrete. The design and construction of RCC structures shall be carried out as per IS: 456 and minimum grade of concrete shall be M-20. Higher grade of concrete than specified above may be used at the discretion of Contractor without any additional financial implication to the Owner. Limit state method of design shall be adopted unless specified otherwise in the specification. For detailing of reinforcement IS: 2502 and SP: 34 shall be followed. Cold twisted deformed bars (Fe=415 N/mm2) conforming to IS: 1786 shall be used as reinforcement. However, in specific areas, mild steel (Grade-I) conforming to IS: 432 can also be used. Two layers of reinforcement (on inner and outer face) shall be provided for wall and slab sections having thickness of 150 mm and above. Clear cover to reinforcement towards the earth face shall be minimum 40 mm. RCC water retaining structures like storage tanks, etc., shall be designed as uncracked section in accordance with IS: 3370 (Part I to IV) by working stress method. However, water channels shall be designed as cracked section with limited steel stresses as per IS: 3370 (Part I to IV) by working stress method. The procedure used for the design of the foundations shall be the most critical loading combination of the steel structure and or equipment and or superstructure and other conditions, which produces the maximum stresses in the foundation or the foundation component and as per the relevant IS Codes of foundation design. Detailed design calculations shall be submitted by the bidder showing complete details of piles/pile groups proposed to be used. Design shall consider any sub-soil water pressure that may be encountered following relevant standard strictly. Necessary protection to the foundation work, if required shall be provided to take care of any special requirements for aggressive alkaline soil, black cotton soil or any other type of soil which is detrimental/harmful to the concrete foundations. RCC columns shall be provided with rigid connection at the base. All sub-structures shall be checked for sliding and overturning stability during both construction and operating conditions for various combinations of loads. Factors of safety for these cases shall be taken as mentioned in relevant IS Codes or as stipulated elsewhere in the Specifications. For checking against overturning, weight of soil vertically above footing shall be taken and inverted frustum of pyramid of earth on the foundation should not be considered. E Earth pressure for all underground structures shall be calculated using coefficient of earth pressure at rest, coefficient of active or passive earth pressure (whichever is applicable). However, for the design of substructures of any underground enclosures, earth pressure at rest shall be considered. ln addition to earth pressure and ground water pressure etc., a surcharge load of 2T/Sq.m shall also be considered for the design of all underground structures including channels, sumps, tanks, trenches, substructure of any underground hollow enclosure, etc., for the vehicular traffic in the vicinity of the structure. Following conditions shall be considered for the design of water tank in pumps house, channels, sumps, trenches and other underground structures: a) Full water pressure from inside and no earth pressure and ground water pressure and surcharge pressure from outside (application only to structures, which are liable to be filled up with water or any other liquid). b) Full earth pressure, surcharge pressure and ground water pressure from outside and no water pressure from inside.

45

c) Design shall also be checked against buoyancy due to the ground water during construction and maintenance stages. Minimum factor of safety of 1.5 against buoyancy shall be ensured ignoring the superimposed loadings. The foundations shall be proportioned so that the estimated total and differential movements of the foundations are not greater than the movements that the structure or equipment is designed to accommodate. The foundations of transformer and circuit breaker shall be of block type foundation. Minimum reinforcement shall be governed by IS: 2974 and IS: 456. The tower and equipment foundations shall be checked for a factor of safety of 2.2 for normal condition and 1.65 for short circuit condition against sliding, overturning and pullout. The same factors shall be used as partial safety factor overloads in limit st1te design also. 13.3 Admixtures & Additives Only approved admixtures shall be used in the concrete for the Works. When more than one admixture is to be used, each admixture shall be batched in its own, batch and added to the mixing water separately before discharging into the mixer. Admixtures shall be delivered in suitably labeled containers to enable identification. Admixtures in concrete shall conform to IS: 9103. The water proofing cement additives shall conform to IS: 2645. Owner shall approve concrete Admixtures/Additives. The Contractor may propose and the Owner may approve the use of a water-reducing set-retarding admixture in some of the concrete. The use of such an admixture will not be approved to overcome problems associated with inadequate concrete plant capacity or improperly planned placing operations and shall only be approved as an aid to overcoming unusual circumstances and placing conditions. The water reducing set-retarding admixture shall be an approved brand of Ligno-sulphonate type admixture. The water proofing cement additives shall be used as required/advised by the owner. 14.0 GATES AND BOUNDARY WALL The Gate frame shall be made of medium duty MS pipe conforming to relevant IS with welded joints. The gates shall be fabricated with welded joints to achieve rigid connections. The gate frames shall be painted with one coat of approved steel primmer and two coats of synthetic enamel paint. Gates shall be fitted with approved quality iron hinges, latch and latch catch. Latch and latch catch shall be suitable for attachment and operation of pad lock from either side of gates. Hinges shall permit gates to swing through 180 degree back against fence. Gates shall be fitted with galvanized chain hook or gate hold back to hold gates open. Double gates shall be fitted with centre rest and drop bolt to secure gates in closed position. Gates shall be installed in locations shown on drawings. Next to the main gate, a men gate (1.25 m wide, single leaf) shall also be provided. Bottom of gates shall be set approximately 40 mm above ground surface and necessary guiding mechanism shall be fitted. The Contractor shall design and& construct boundary wall around substation area as per requirements. The boundary wall shall be of height 3.0M and shall be made of RCC frame construction with RCC column and plinth beam arrangement and panels filled with one brick thick wall in cement sand mortar 1 :6. The boundary wall shall be plastered on both external and internal faces with cement and sand plaster 1:6 of thickness18 mm and 12 mm respectively. An additional barbed Y -shaped arm of M8 angle 50x50x6 with 3-rows (6 nos) barbed wire A-4 18:278. Expansion joints shall be provided as per codal requirements. M8 grating shall be provided at required locations for drainage purposes. The boundary wall shall be painted with minimum two coats of color wash over a base coat of white wash with line. The front portion of boundary wall shall however be with a RC jail and 12 mm square MS bar top above brick work and pebble dash plaster finish with colour pigment. The steel work shall be given two coats of synthetic enamel paint of approved make over one coat of primer. A tentative drawing is enclosed for guidance purpose. A Security room shall be provided at the entrance of switchyard. The minimum dimension of the room shall be 3.0 m length and 3.0 m width. The roof shall be at RCC and aesthetically pleasing.

46

15.0

BUILDINGS - GENERAL REQUIREMENTS General

15.1

The scope include the design, engineering and construction including anti-termite treatment, plinth protection, DPC of Building including sanitary, water supply, electrification, false ceiling etc., of control room building, and DG set building. The buildings shall be of RCC framed structure of concrete of M20 grade (Min.) 15.2 Control Room Building Minimum floor area requirements shall be 120 Sq. Meter which may be increased at the time of detailed engineering to suit project requirements. The layout of the control room shall be finalized as per detailed engineering to suit project requirements. An open space of 1 m minimum shall be provided on the periphery of the rows of panel and equipment generally in order to allow easy operator movement and access as well as maintenance. Any future possibility of annexed building shall be taken care of while finalizing the layout of the control room building. Minimum head room of 3 M below soffit of beams/false ceiling shall be considered for rooms. The roof shall have four side sloping roof or flat roof as finalized during detailed engineering. 15.2.1 Design

The buildings shall be designed: i. To the requirements of the National Building Code of India, and the standards quoted therein. ii. For the specified climatic and loading conditions iii. To adequately suit the requirements of the equipment and apparatus contained in the buildings and in all respects to be compatible with the intended use and occupancy iv. With a functional and economical space arrangement. v. For a life expectancy of structure, systems and components not less than that of the equipment, which is contained in the building, provided regular maintenance is carried out vi. Be aesthetically pleasing. Different buildings shall show a uniformity and consistency in architectural design. vii. To allow for easy access to equipment and maintenance of the equipment. viii. With, wherever required, fire retarding materials for walls, ceilings and doors, which would prevent supporting or spreading of fire. ix. With materials preventing dust accumulation. b) Suitable expansion joints shall be provided in the longitudinal direction wherever necessary with provision of twin columns. c) Individual members of the buildings frame shall be designed for the worst combination of forces such as bending moment, axial force, shear force, torsion, etc. d) Permissible stresses for different load combinations shall be taken as per relevant IS Codes. e) All cable vaults shall be located above ground levels i.e., cable vaults shall not be provided as basements in the buildings. f) The building lighting shall be designed in accordance with the requirements. g) One emergency exit shall be provided in control room building. 15.2.2 Design loads

Building structures shall be designed for the most critical combinations of dead loads, super-imposed loads, equipment loads, crane load, wind loads, seismic loads, and temperature loads. Dead loads shall include the weight of structures complete with finishes, fixtures and partitions and should be taken as per IS: 1911. Super-imposed loads in different areas shall include live loads, minor equipment loads, cable trays, small pipe racks/hangers and erection, operation and maintenance loads. Equipment loads shall constitute, if applicable, all load of equipments to be supported on the building frame. For crane loads an impact factor of 30% and lateral crane surge of 10% (lifted weight + trolley) shall be considered in the analysis of frame according to provisions of IS: 875.the horizontal surge shall be 5% of the static wheel load. The wind loads shall be computed as per IS 875, Seismic Coefficient method shall be used for the seismic analysis as per IS 1893 with importance factor 1.5. For temperature loading, the total temperature variation shall be considered as 2/3 of the average maximum annual variation in temperature. The average maximum annual variation in temperature for the purpose shall 47

be taken as the difference between the mean of the daily minimum temperature during the coldest month of the year and mean of daily maximum temperature during the hottest month of the year. The structure shall be designed to withstand stresses due to 50% of the total temperature variation. Wind and Seismic forces shall not be considered shall not be considered to act simultaneously. Floors/slabs shall be designed to carry loads imposed by equipment, cables piping travel of maintenance trucks and equipment and other loads associated with building. Floors shall be designed for live loads as per relevant IS. Cable and piping loads shall also be considered additionally for floors where these loads are expected. In addition, beams shall be designed for any incidental point loads to be applied at any point along the beams. The floor loads shall be subject to Owner's approval. For consideration of loads on structures, IS: 875, the following minimum superimposed live loads shall, however, be considered for the design. 2 a) Roof 1.5 KN/M For accessible roofs 2 0.75 KN./M For in- accessible roofs 2 b) RCC- Floor i) 5 KN/M For offices 2 ii) 10 KN/M For equipment floors or ( Minimum) actual requirement, if higher than 2, 10 KN/M based on equipment component weight and layout plans 2 c) Toiler Room 2 KN/M ) 2 d Chequered plate floor 4 KN/M 2 e) Walkways 3 KN/M Any additional load coming in the structure shall be calculated as per IS: 875. 15.2.3 Submission

The following information shall be submitted for review and approval to the Owner: Design criteria shall comprise the codes and standards used, applicable climatic data including wind loads, earthquake factors maximum and minimum temperatures applicable to the building locations, assumptions of dead and live loads, including equipment loads, impact factors, safety factors and other relevant information. Structural design calculations and drawing (including constructions / fabrication) for all reinforced concrete and structural steel structures. Fully, dimensioned concept plan including floor plans, cross-sections, longitudinal sections, elevations and perspective view of each building. These drawings shall be drawn at a scale not smaller than 1 :50 and shall identify the major building components. Fully dimensioned drawings showing details and sections drawn to scales of sufficient size to clearly show sizes and configuration of the building components and the relationship between them. Product information of building components and materials, including walls partitions flooring ceiling, roofing, door and windows and building finishes. A detailed schedule of building finishes including colour schemes. A door and window schedule showing door types and locations, door lock sets and latch and other door hardware. Approval of the above information shall be obtained before ordering materials or starting fabrication or construction as applicable. 15.2.4 Finish Schedule

The finishing schedule is given in subsequent clauses. 15.2.5 Flooring Flooring in various rooms of control room building shall be as for detailed schedules given in Table-1. 15.2.6 Walls Control room buildings shall be of framed superstructure. All walls shall be non-load bearing walls. Min. thickness of external walls shall be 230 mm (One brick) with 1:6 cement sand mortar. 15.2.7 Plastering All internal walls shall have minimum 15 mm thick 1:6 cement sand plaster. The ceiling shall have 6mm thick 1:4 cement sand plaster. 15.2.8 Finishing All external surfaces shall have 18 mm cement plaster in two coats, under layer 12 mm thick cement plaster 1:5 48

and finished with a top layer 6 mm thick cement plaster 1:6 (DSR (13.19) with water proofing compound. The paint shall be anti-fungal quality of reputed brand suitable for masonry surfaces for high rainfall zone. White cement primer shall be used as per manufacturer's recommendation.

INTERNAL FINISH SCHEDULE IS GIVEN TABLE - 1

SI No

Location .

Flooring & Skirting 150 mm High

Wall Internal

Ceiling

Doors, Windows Ventilators

1.

Control Room & Relay room

Homogeneous PVC /Vetrified tiles 2 mm thick over 25 mm thick 1 :2:4 under bed neat cement finished flooring

Plastic 7.3 mm thick ceramic tiles (DSR 11.41 A.2.1)

False Ceiling & Under deck insulation

Anodised aluminium Jindal or equivalent extruded sections as per IS 733 & 1285 Glazing Flat (DSR 9711.64.2 drawn sheet & 11.4.1) glass (Min 5.5 mm thick) double glazing with 12 mm gap hermetically sealed. (DSR097, 24.1, 24.3, 24.4

2.

Sub-Station incharge, officers, corridor, staff, rooms

Vetrified Terrazzo tiles with white cement (DSR97) (11.29 A.1)

Oil bound plastic paint washable distemper on smooth surface applied with POP putty Smooth surface applied with POP putty. DADO acid resistant title 2.1 M high Acid resistant paint above 2.1 M high acid resistant paint above 2.1 m upto ceiling (DSR 97.11.36 C 2.2) & 13.96.1) Oil bound distemper White wash (DSR 97 13.72.1) DADO glazed tile 2.1 M high for toilet for pantry above working platform upto 750 mm (DSR 97 11.36B) Plastic/O.B. distemper Dry distemper (DSR 97.13.75)

False ceiling & under deck insulation

Teak wood frame flush doors shutter (DSR 97 9.1.3 & 9.4 A.2.2) Windows, Ventilators Aluminium as at 1.

(DSR-97) (11.48.1)

For entrance with glazing

3.

Battery room

Acid Resistant Tiles 25 mm thick (DSR 9711.36 C 12)

Acid resistant paint (DSR 97 1372.1)

Steel door 45 mm thick double sheet 18 G steel suitably reinforced and filled with mineral wool. Hot rolled steel framed glazed window and ventilators.

4.

Cable vault double sheet (if required)

IPS flooring (DSR 97 11.4.3)

White wash

Steel door double sheet as above. Ventilators as at 5.

5.

Toilet

Non-solid/ vetrified Terrazzo tiles with White cement (DSR97,11.29a.1)

White wash Weather coat

Teak wood frame flush door shutter with anodized Aluminium fixtures best quality (DSR 97 9.1.3 & 9.4 a 2) Windows, ventilators aluminium as at 1.

6.

Other areas not specified

Vetrified Terrazzo tiles with white cement (DSR 97 29 A.1)

White wash

Note : DSR item references to be read with CPWD specifications are only for material and workmanship guidance of the Contractor. 49

15.2.9

Roof

Roof of the CR. Building shall consist of Cast-in-situ RCC slab treated with a water proofing system which shall be an integral cement based treatment conforming to CPWD specification (item NO.25.8 of DSR 1997) the water proofing treatment shall be of following operations. a) Applying and grouting a slurry coat of neat cement using 2.75 kg/m2 of cement admixed with proprietary water proofing compounds conforming to IS:2645 over the RCC slab including cleaning the surface before treatment. b) Laying cement concrete using broken bricks/bricks brick bats 25 mm to 100 mm size with 505 of cement mortar 1:5 (1 cement: 5 coarse sand) admixed with proprietary water proofing compound conforming to IS: 2645 over 20 mm thick layer of cement mortar of min 1:5 (Cement: 5 coarse sand) admixed with proprietary water proofing compound conforming to IS:2645 to required slope and treating similarly the adjoining walls upto 300 mm height including rounding of junctions of walls and slabs. c) After two days of proper curing applying a second coat of cement slurry admixed with proprietary water proofing compound conforming to IS:2645. d) Finishing the surface with 20 mm thick joint less cement mortar of mix 1:4 (1 cement: 4 course sand) admixed with proprietary water proofing compound conforming to IS:2645 and finally finishing the surface with trowel with neat cement slurry and making of 300 x 300 mm square. e) The whole terrace so finished shall be flooded with water for a minimum period of two weeks for curing and for final test. All above operations to be done in order and as directed and specified by the Engineering-in-charge. With average thickness of 120 mm and minimum thickness at khurra at 65 mm. 15.2.10 Glazing

Minimum thickness of glazing shall be 5.5 mm as per IS:2835 sun film shall be provided for all window/doors of AC rooms. 15.2.11 Doors and Windows

The details of doors and windows of the control room building shall be as per finish schedule Table-1 and tender drawing with the relevant IS, code. Rolling steel shutters and rolling steel grills shall be provided as per layout and requirement of buildings. Paints used in the work shall be of best quality specified in CPWD specification. 15.2.12 i) Plumbing & Sanitation All plumbing and sanitation shall be executed to comply with the requirements of the appropriate byelaws, rules an regulations of the Local Authority having jurisdiction over such matters. The Contractor shall arrange for all necessary formalities to be met in regard to inspection, testing, obtaining approval and giving notices etc. PVC syntax or equivalent make Roof water tank of adequate capacity depending on the number of users for 24 hours storage shall be provided. Minimum 2 Nos 500 litres capacity shall be provided. Galvanized MS pipe of medium class conforming to IS: 1239 shall be used for internal & external piping work for potable water supply. Sand CI pipes with lead joints conforming to IS:1729 shall be used for sanitary works above ground level. Each toilet shall have the following minimum fittings. a) WC (Western type) 390 mm high with toilet paper roll holder and all fittings or WC (Indian Type) Orissa Pattern (580 x 440 mill) with all fittings. (Both types of WCs shall be provided at 50

ii)

iii) iv) v)

alternate locations) b) Urinal (430 x 260 x 350 mm size) with all fittings. c) Wash basin (550 x 400 mm size) with all fittings. d) Bathroom mirror (600 x 450 x 6 mm thick) hard board backing. e) CP brass towel rail (600 x 20 mm) with CP brass brackets e). Soap holder and liquid soap dispenser vi) Water cooler for drinking water with adequate water storage facility shall be provided and located near control room instead of near toilet block. vii) An Eye & [ace fountain conforming to IS:1052 shall be provided for battery room viii) 1 No. stainless steel kitchen sink with Drain board (510 x 1040 x 178 mm bowl depth) for pantry shall be provided. ix) All fittings, fastener, grating shall be chromium plated. x) All sanitary fixtures and fittings shall be of approved quality and type manufactured by well known manufacturers. All items brought to site must bear identification marks of the type of the manufacturer. xi) Soil, waste and drain pipes, for underground works shall be stone ware for areas not subject to traffic load. Heavy-duty cast iron pipes shall be used otherwise 16.0 SECURITY FENCING Security fencing shall be provided for 1.5 meter above the ground at the switchyard. Security fencing shall be provided with barbed wire mesh of 5 rows connected with the PSCC poles at 2 meters interval. 17.0 MISCELLANEOUS GENERAL REQUIREMENTS Dense concrete with controlled water cement ratio as per IS-code shall be used for all underground concrete structures such as pump-house, tanks, water retaining structures, cable and pipe trenches etc. for achieving water tightness. All joints including construction and expansion joints for the water retaining structures shall be made water tight by using PVC ribbed water stops with central bulb. However, kicker type (externally placed) PVC water stops shall be used for the base slab and in other areas where it is required to facilitate concreting. The minimum thickness of PVC water stops shall be 5 mm and minimum width shall be 230 mm. All steel sections and fabricated structures which are required to be transported on sea shall be provided with anti corrosive paint to take care of sea worthiness. All mild steel parts used in the water retaining structures shall be hot-double dip galvanized. The minimum coating of the zinc shall be 750 gm/sq. m for galvanized structures and shall comply with IS:2629 and IS:2633. Galvanizing shall be checked and tested in accordance with 18:2633.The galvanizing shall be followed by the application of an etching primer and dipping in black bitumen in accordance with B8:3416. A screed concrete layer not less than 100 mm thick and of grade not weaker than M10 conforming to IS:456-1978 shall be provided below all water retaining structures. A sliding layer of bitumen paper or craft paper shall be provided over the screed layer to destroy the bond between the screed and the base slab concrete of the water retaining structures. Bricks having minimum 75 kg/cm compressive strength can only be used for masonry work. Contractor shall 2 ascertain himself at site regarding the availability of bricks of minimum 75 kg/cm compressive strength before submitting his offer. Doors and windows on external walls of the building (other than areas provided, with insulated metal claddings) shall be provided with RCC sun-shade over the openings with 3000 mm projection on either side of the openings. Projection of sunshade from the wall shall be minimum 450 mm over window openings and 750 mm over door openings.
2

17.1

17.2

17.3 17.4

17.5

17.6

17.7

51

17.8

All stairs shall have maximum riser height of 150 mm and a minimum tread width of 300 mm. Minimum width of stairs shall be 1500 mm. Service ladder shall be provided for access to all roofs. RCC fire escape staircase shall be provided in control buildings. Angles 50 x 50 x 6 mm (minimum) with lugs shall be provided for edge protection all round cut outs/openings in floor slab, edges of drains supporting grating covers, edges of RCC cable/pipe trenches supporting covers, edges of manholes supporting covers, supporting edges of manhole precast cover and any other place where breakage of corners of concrete is expected. Anti termite chemical treatment shall be given to column pits, wall trenches, foundations of buildings, filling below the floors etc. as per IS:6313 and other relevant Indian Standards. Hand-railing minimum 900 mm high shall be provided around all floor/roof openings, projections/balconies, walk ways, platforms, steel stairs etc. All handrails and ladder pipes shall be 32 mm nominal bore MS pipes (medium class) and shall be galvanized (medium-class as per IS:277). All rungs for ladder shall also be galvanized as per IS:277 medium classes. For RCC stairs, hand railing with 20 mm square MS bars, balustrades with suitable MS flats shall be provided with black PVC sheathing.

17.9

17.10 17.11

17.12

For all civil works covered under this specification, nominal mix by volume batching as per CPWD specification is intended. The relationship of grade of concrete and ratio of ingredients shall be as below:

S.No. 1. 2. 3.

Mix M 10 M 15 M 20

Cement 1 1 1

Sand 3 2 1.5

Coarse Aggregate of 20 mm Down Grade as per IS 383 6 4 3

The material specification, workmanship and acceptance criteria shall be as per relevant clauses of CPWD specification and approved standard Field Quality Plan.

17.13 17.14

The details given in tender drawings shall be considered along with details available in this section of the specification while deciding various components of the building. Items/components of buildings not explicitly covered in the specification but required for completion of the project shall be deemed to be included in the scope.

18.0

INTERFACING The proper coordination & execution of all interfacing civil works activities like fixing of conduits in roofs/walls/floors, fixing of foundation bolts, fixing of lighting fixtures, fixing of supports/embedment, provision of cutouts etc. shall be the sale responsibility of the Contractor. He shall plan all such activities in advance and execute in such a manner that interfacing activities do not become bottlenecks and dismantling, breakage etc. is reduced to minimum.

19.0 WATER SUPPLY i) Contractor shall make its own arrangement for construction water. ii) The contractor shall carry out all the plumbing/erection works required for supply of water in control room building.

52

iii) The details of tanks, pipes, fittings, fixtures etc for water supply are given elsewhere in the specification under respective sections. iv) A scheme shall be prepared by the contractor indicating the layout and details of water supply which shall be got approved by the Owner before actual start of work including all other incidental items not shown or specified but as may be required for complete performance of the works. v) Bore wells with Min 100mm dia casing pipe & 1HP submissible pump to get a discharge of at least 1000 Litre/Hr. with zealete make iron removed filter to get iron free water. Water purifier with UV mechanism is to be provided and pumps for water supply are in the scope of contractor meeting the day-to-day requirement of the water supply. 20.0 i) ii) iii) 21.0 SEWERAGE SYSTEM Sewerage system shall be provided for control room building. The contractor shall construct septic tank and soak pit suitable for 20 users. The system shall be designed as per relevant IS Codes. STATUTORY RULES Contactor shall comply with all the applicable statutory rules pertaining to factories act (as applicable for the State). Fire Safety Rules of Tariff Advisory Committee. Water Act for pollution control etc. Provisions for fire proof doors, no. of staircases, fire separation wall, plastering on structural members (in fire prone areas) etc. shall be made according to the recommendations of Tariff Advisory Committee. Statutory clearance and norms of State Pollution Control Board shall be followed as per Water Act for effluent quality from plant. Requirement of sulphate resistant cement (SRC) for sub-structural works shall be decided in accordance with the Indian Standards based on the findings of the detailed soil investigation to be carried by the bidder. Foundation system adopted by the Bidder shall ensure that relative settlement and other criteria shall be as per provision in IS:1904 and other Indian Standard. All water retaining structures designed as an un-cracked section shall also be tested for water tightness at full water level in accordance with clause No. 10 of IS:3370 (part-I) Construction joints shall be as per IS:456 All underground concrete structures like basements, pumps houses, water retaining structures etc. shall have plasticizer cum water proofing cement additive conforming to IS:9103. in addition, limit on permeability as given in IS:2645 shall also be met with. The concrete surface of these structures in contact with earth shall also be provided with two coats of bituminous painting for water/damp proofing. In case of water leakage in the above structures, Injection Method shall be applied for requiring the leakage.

21.1 21.2 21.3 21.4 21.5 21.6 21.7 21.8

53

3.3

TECHNICAL SPECIFICATIONS FOR 33/11kV POWER TRANSFORMER

1.0 SCOPE OF SPECIFICATION: 1.1. : This specification is intended to cover design, manufacture, assembly testing at manufacturers works, supply and delivery of three phase 50HZ, 33/11 KV Delta/Star, Vector Group DY 11, two windings copper would outdoor type, oil immersed, naturally air cooled Power Transformer with off load tap changer for 10MVA , 5 and 2.5MVA transformer. 1.2. The transformer offered shall be complete with all parts and accessories which are necessary for their efficient and satisfactory operation The Transformer and all associated oil filled Equipment shall be supplied complete with insulating new oil required for first filling including 10% extra oil for future use during commissioning. The Transformer tank shall be dispatched completely filled with oil and the balance oil shall be supplied in non returnable sealed drums along with the Transformers. 1.3. Such parts and accessories shall be deemed to be within the scope of this specification whether specifically mentioned or not. Main tank body may be delivered in unpacked condition, but delicate parts like indicating meter, radiator, conservator, Pressure Relief Valve, equalizer pipe, buchholz relay etc. shall be packed to avoid damage due to transportation. 1.4 It may be noted that the Power Transformer must meet the following minimum criteria. Failure to comply with the requirements may results in rejection of the BID as non-responsive: 1.4.1 The Manufacturer must have designed, manufactured, type tested and supplied power transformers in at least two power utilities of similar rating which are in successful operation for at least 5 (Five) years as on the date of bid opening. Which should be substantiated by furnishing performance report by the official of the rank of minimum DGM/SE . 2.0 : ISOCERAUNIC CONDITION: 2.1. For the purpose of designing, the following condition shall be considered: 1. 2. 3. 4. 5. 6. 7. 8. 9. Maximum temperature of air in shade Minimum temperature of air in shade Maximum temperature of air in sun Maximum humidity Average number of thunder storm days per annum Maximum rainfall per annum Average rainfall per annum Wind pressure Altitude above MSL 40C 2C 45C 100% 45 Days 3500 mm 2200 mm 97.8 Kg/m
2

100 to 1000 M

3.0 APPLICABLE STANDARDS 3.1. Unless otherwise stated, transformer shall be designed, constructed and tested in accordance with provisions contained in latest revisions of following Indian standards and Rules. i. IS : 2026 ii) R.E.C. Manual 10/1976 iii) C.B. I.P. Manual on Transformer iv) Technical Report 1: Section : A.D. (Revised: 1987) v) C.B.I.P. Technical Report No. 72 (June: 1989) vi) Indian Electricity Rules, 1956 (Amended up to date) vii) IS : 2099 Bushing for alternating voltage above 1000 volt viii) IS : 6600 Guide for loading of oil immersed transformer ix) Specification for Transformer oil (IS-335 & IS-1866,1983) x) Other applicable Indian Standards.

54

4.0 GUARANTEES 4.1. The a) b) c) d)

bidder shall guarantee among other things the following: Quality and strength of the material used. Adequate factors of safety for all parts of equipment to withstand the mechanical and on electrical stresses developed therein. These will be stated in the tender. Suitability of the design and workmanship of the equipment for the conditions envisaged in the specification. Efficiencies, Temperature rise and other performance data on equipment which shall be furnished in the tender.

5.0 WARRANTEES 5.1. The bidder shall be responsible for replacing at site free of cost any part or parts of the equipment that may prove faulty or fail manufacturing defects on one or more of the reasons given in clause 4.1 stated above within 5 (five) years commencing from the date of commissioning 5.2. In case of failure of the transformer, the supplier shall take back the faulty transformer from its plinth for repair at their own cost (or replace the transformer with a new transformer) and deliver, at their own cost, unload at the destination sub-station transformer plinth within 45 days, from the date of intimation of defects to the satisfaction of the owner, at free of cost. If the repair/replacement will not be completed within 45 days, then the supplier shall pay penalty @ 0.5% of the contract price for each calendar week of delay from the end of 45 days from the date of intimation of defects. Also, the Purchaser reserves the right for forfeiture of the total Composite Bank Guarantee and all the Securities, available with ASEB, in case the Supplier fails to pay the penalty by one month before the expiry of the guarantee period. Also, this will be taken as adverse in all future tenders. 5.3. The bidder shall furnish copies of test certificates of materials used for manufacture and also the test certificates of the tests conducted on the equipment after manufacture. The contractor shall also furnish the test certificate of bought out components for approval by the purchaser. 6.0 MISCELLANEOUS 6.1. Padlocks along with duplicate keys as asked for various valves, marshalling box etc. shall be supplied by the contractor, wherever applicable. 6.2. Foundation bolt for wheel locking devices of Transformer shall be supplied by the bidder. 7.0 DELIVERY SCHEDULE: 7.1. The equipment shall be delivered FOR Destination as per schedule specified in the BPS 8.0 CONFLICT IN CLAUSE: 8.1. In case of any conflict between the Specific Technical Requirements and General Technical Requirements the requirements indicated as Specific Technical Requirement shall prevail over the General Technical Requirements 9.0 DEVIATION FROM SPECIFICATION 9.1. Normally the offer should be as per Technical Specification without any deviation. But any deviation felt necessary to improve utility, performance and efficiency of equipment or to secure overall economy shall be mentioned in the Schedule of deviations with full justification, supported by documentary evidence. Such deviations, suggested, may or may not be accepted. But deviations, not mentioned in the Deviation Schedule will not be considered.

10.0 DRAWINGS INCORPORATING THE FOLLOWING PARTICULARS SHALL BE SUBMITTED WITH THE BID: 10.1. The following drawings and details shall be furnished in triplicate along with the bid : 10.2. General Arrangement outline drawing with plan, elevation and end views showing various dimensions of transformer and its vital component including height of the bottom most portion of bushing from the bottom of base channel and also indicating thereon physical centre line and position of centre of gravity. 10.3. Details of various types of bushing.

55

10.4. Three copies of sketches for height of crane hook above ground for lifting and untanking core,
shipping dimensions, complete lists of fittings and devices, net weights of core, winding, tank, radiator, oil, conservator and total weight, fixing arrangement of transformer in foundation. 10.5. Illustrative & descriptive literature of the Transformer. 10.6. Maintenance and operation Instructions. 10.7. Type test certificates of similar transformers.

11.0 RATING AND GENERAL PARTICULARS: 11.1. Type: Core type, three phase, oil immersed, step down, two winding copper wound transformer for outdoor installation. 11.2. Standard Rating: Continuous with off circuit taps as mentioned in the schedule of requirement.

11.3.

Continuous Maximum Rating and Overloads:

As regards maximum rating and temperature rise, all transformers shall comply with the appropriate requirement of Indian Standards For the purpose of consideration of maximum temperature rise of oil and winding, the following ambient temperatures are assumed. i) Cooling medium : Air ii) Maximum Ambient Air temperature: 50 C. iii) Maximum daily average ambient Air temperature: 40 C. iv) Maximum yearly weighted average temperature: 32 C .

11.4. 11.5. 11.6. 11.7. 11.8. 11.9.

The transformer may be operated without danger on any particular tapping at the rated KVA provided the voltage does not vary by more than +10% of the voltage at that tapping. The transformer should be suitable for continuous operation with a frequency variation of +3% from normal 50Hz. Combined voltage and frequency variation should not exceed the rated V/f ratio by 10% DUTY UNDER FAUALT CONDITION It is to be assumed that normal voltage will be maintained on one side of the Transformer when there is a short circuit between phases or to earth on the other side. The transformer may be directly connected to an underground or overhead line and may be switched into and out of service together with or without its associated incoming/outgoing line. The thermal ability to withstand short circuit shall be Two seconds (2 Sec.) without injury for 3 phase dead short circuit at the terminals.

12.0 GENERAL TECHNICAL PARAMETERS SN 1. 2. 3. 4. 5. 6. 7. 8. Particulars Rating Number of Phases Vector group Type of installation Frequency Cooling Medium Type of Cooling Highest continuous system Voltage High Voltage Low Voltage Winding Connection Material High Voltage Winding Low Voltage Winding Method of System Earthing

10MVA Three Dyn-11 Outdoor 50HZ ( +/- )3% Insulating Oil ONAN :36kV :12kV

5MVA

2.5 MVA

9. 10. 11. 12. 13.

Electrolytic Copper DELTA STAR Solidly grounded on LV side 10 MVA 5 MVA

2.5 MVA 56

14. 15. 16. 17.

Type of Tap Changer Range of Tapping Type of Insulation and Insulation Level a) Type of insulation b) One minute power frequency withstand Voltage(kV rms) c) Lightning Impulse withstand voltage Terminal Details 33kV Termination

ON Load

OFF OFF Load Load (+) 3% to (-) 9% in steps of 3% on HV side 11kV Uniform 28kV 75

33kV Uniform 70kV 170

18. 19.

20. 21.

11 KV Termination Maximum Temperature rise over ambient of 50 C a) Temperature rise of top oil b) Temperature rise of winding C) Maximum Winding temperature in Deg. C d) Maximum Permissible value of Average temperature of winding after 3 sec Maximum Permissible short circuit:

(i) ACSR/AAAC Wolf conductor, Bus, (or IPs tube as applicable) for connecting to bushing terminals. 2 Cable 300/630 mm , 1-core Al. Armoured XLPE Cable

40 C (measured by Thermometer 45 C (measured by resistance) 105 C

250 C

Over load capacity : As per IS: 6600 NOISE LEVEL AT RATED VOLTAGE & FREQUENCY: As per NEMA Pub TR-1. 13.0 GUARANTEED LOSSES 1. Impedance at rated MVA at 75 C without (-) ve tolerance No Load Loss Load Loss at 75 C 8.35% 7.15% 6.25%

12.1. 12.2.

2. 3.

6.0KW 44.0KW

4.0KW 24KW

2.1KW 14.0.0K W

13.1. Tolerance of losses shall be guided by the relevant clauses of relevant IS standard. The bidder shall state both no load loss and load loss at rated voltage and frequency and loss figures shall be firm and guaranteed. 14.0 Evaluation of Losses: 14.1. For the purpose of comparison of bids, the capitalized cost of iron loss (KW) and load losses (KW) shall be added to the quoted price of transformer at the following rates.
Iron loss per KW Rs. 287 834.00 Copper loss per KW Rs. 86349.00

14.2. If any or all actual losses after test are found to exceed the guaranteed value, the penalty will be imposed on the excess loss over the corresponding guaranteed loss (any or all). The penalty shall be calculated for the excess of no load loss and for the excess of the load losses at rates specified above. For fraction of a KW the penalty shall be applied prorate basis. If the test figure of. losses are less than the guaranteed value, no bonus will be allowed. Any changes in the figure assigned for transformer losses will

57

not be permitted after opening of bids and bid evaluation will be carried out on the basis of information made available at the time of bid opening. 15.0 SHORT CIRCUIT CALCULATIONS 15.1. Manufacturer shall submit theoretical calculations in support of the ability to withstand short circuit on consideration of highest value that may 16.0 PERFORMANCE CERTIFICATES 16.1. Copies of performance certificates of sImilar Equipment supplied to various utilities shall have to be furnished along with Tender 17.0 LIST OF PAST SUPPLIES 17.1. The bidder shall furnish documents in support of Supply, Delivery of similar Equipment indicating thereon names of the organization, quantity ordered, quantity supplied along with tender. 18.0 DESIGN, STANDARDIZATION AND GENERAL CONSTRUCTION FEATURES 18.1. .All material used shall be best quality and of the class most suitable for working under the conditions specified and shall withstand the variations of temperature and atmospheric conditions without distortion or deterioration or the setting up of undue stresses which may impair suitability of the various parts for the work which they have to perform. 18.2. Large parts, particularly removable ones, shall be interchangeable. Pipes and pipe fittings, screws, studs, nuts and bolts used for external connections shall be as per the relevant standards. Steel bolts and nuts exposed to atmosphere shall be of hot deep galvanized 18.3. Nuts, bolts and pins used inside the transformers and tap changer compartments shall be provided with lock washers or locknuts. Exposed parts shall not have pockets where water can collect. 18.4. Internal design of transformer shall ensure that air is not trapped in any location. Material in contact with oil shall be such as not to contribute to the formation of acid in oil. Surface in contact with oil shall not be galvanized or cadmium plated. 18.5. Labels, indelibly marked shall be provided for all identifiable accessories like relays, switches, current transformers etc. All label plates shall be of in corrodible material. 18.6. All internal connections and fastening shall be capable of operating under overloads and over-excitation, allowed as per specified standard without injury. 18.7. Transformers and accessories shall be designed to facilitate proper operation, inspection, maintenance and repairs. No patching, plugging, shimming or other, such means of overcoming defects, discrepancies or errors will be accepted. 19.0 CORES :

19.1. 19.2.
i) ii)

Core shall be constructed from high grade cold rolled non-aging grain oriented silicon steel laminations having magnite coating as insulation. Successful bidder will offer the core for inspection and/or approval by the purchaser during manufacturing stage. Manufacturers call notice for the purpose should be accompanied with the following documents as applicable as a proof towards use of prime core materials: Invoice of the supplier Mills Test Certificate

iii) Packing Lists iv) Bill of landing v) Bill of entry Certificate to Customs Core materials shall be procured either from the core manufacturer or through their accredited marketing organisation of repute. Bidder should preferably have in-house Core cutting facility for proper monitoring and Control on quality. The materials used for insulation shall have high inter lamination resistance and rust inhibiting property. It shall not have any tendency to absorb moisture or to react with insulating oil. The assembled core shall be securely clamped on the limbs and yoke with uniform pressure so as to minimise noise emission form it. The top main core clamping structure shall be connected to the tank body by a copper strap. The bottom clamping structure shall be earthed by one or more of the following methods (i) (ii) by connection through vertical tie rods to the top structure by direct metal to metal contact with the windings, tank base by the weight of the core and

19.3. 19.4.

58

19.5. 19.6. 19.7. 19.8. 19.9.


.

by a connection to the top structure on the same side of core the main earth connection to the tank. All parts of the cores shall be robust design capable of withstanding any shocks to which they may by subjected during lifting, transport, installation and service. Adequate lifting lugs shall be provided to enable the core and winding to be lifted. 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. 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 of air during filling. The insulation structure for the core to bolts and core to clamp plates shall be such as to withstand a voltage of 2000 VAC at 50HZ for one minute

(iii)

20.0 FLUX DENSITY OF CORE 20.1. The maximum flux density in any part of the core and yokes at principal (normal) tapping and at rated frequency shall not exceed 1.6 Tesla (16000 lines per sq.cm) at normal voltage and 1.9 Tesla (19000 lines per sq.cm) under overvoltage condition as specified in this specification. 20.2. Prior to inspection and testing of the Transformer the supplier shall submit on request following curves of the core manufacturer. i) Flux density vs Core loss. ii) Flux density vs Excitatioin 21.0 WINDING:

21.1. 21.2. 21.3. 21.4. 21.5. 21.6. 21.7. 21.8.

All windings shall be fully insulated. 12.02 Power transformer shall be designed to withstand the impulse and power frequency test voltages specified in clause no. 9.01. The windings shall be designed to reduce to a minimum the out of balance forces in the transformer at all voltage ratios. The insulation of Transformer winding and connections shall be free from insulating material liable to soften, ooze out shrink or collapse and shall be non-catalytic and chemically inactive to transformer oil during service. The stacks of windings shall receive adequate shrinkage treatment before final assembly. Adjustable device shall be provided for taking up any possible shrinkage of coils in service. All the insulating materials to be used in the transformer shall preferably be of class- A insulation as specified in Indian Standards. The test certificate of the raw materials shall be made available by the Transformer manufacturer on request during inspection and testing. The coil clamping arrangement and the finished dimensions of any oil ducts shall be such that it will not impede the free circulation of oil through the ducts. The windings and connection of transformer shall be braced to withstand shocks which may occur during transport or due to switching short circuit and other transient conditions during service. Coil clamping rings, if provided shall be of steel or suitable insulating material. Axially laminated material other than bakelised paper shall not be used.

22.0 INTERNAL EARTHING ARRANGEMENTS: 22.1. 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 fixed potential. 22.2. 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 connection. 23.0 TANKS: 23.1. Construction : Conventional type tank shall be constructed. The Transformer tank and cover shall be fabricated from good commercial grade low Carbon steel suitable for welding and of adequate thickness. 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 rail, road without overstraining any joint and without causing subsequent leakage of oil. 23.2. The main tank body shall be capable of withstanding vaccum gauge pressure 68.0 KN per Sq, metres ( 500 mm. of HG). 59

23.3. 23.4. 23.5. 23.6.

The under carriage of the tank shall be made of channel of suitable size and design. 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 plate or rails. Where the base is of a channel construction, it shall be designed to prevent retention of water. Tank stiffeners shall be designed to prevent retention of water. Wherever possible the Transformer tank and its accessories shall be designed without pockets wherein gas may accumulate. Where pockets cannot be avoided, pipes shall be provided to vent the gas into the main expansion pipe. All joints other than those which may have to be broken shall be welded when required they shall be double welded. All bolted joints to the tank shall be fitted with suitable oil tight gaskets which shall give satisfactory service under the operating conditions and guaranteed temperature rise conditions. Special attention shall be given to the methods of making hot oil tight joints between the tank and the cover as also between the cover and bushing and all other outlets to ensure that the joints can be remade at site satisfactorily.

24.0 TANK COVER 24.1. :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 or changing ratio or testing the earth connection. Each inspection opening shall be of ample size for the purpose for which it is provided. The tank cover and inspection cover shall be provided with suitable lifting arrangement. 24.2. The tank cover shall be fitted with pockets for thermometer and for the bulbs of Oil and Winding temperature indicators. The thermometer pocket shall be fitted with a captive screwed top to prevent the ingress of water. Protection shall be provided, where necessary, for each capillary tube. The pocket shall be located in the position of maximum oil temperature and it shall be possible to remove the instrument bulbs without lowering the oil in the tank. 24.3. Turrets should provided on tank cover to house the bushings. The turrets of both HV & LV bushings should be connected through pipes with main tank Buchholtz Relay pipe to drive out trapped air or should have air release plug to drive out trapped air as the case may be. 25.0 OFF LOAD TAP CHANGER. 25.1. The transformers shall be provided with voltage control equipment of the tap changing type on the HV side for HV variation of +3% to (-) 9% in equal 5 steps of 3.0% for varying its effective transformation ratio whilst the transformers are off-load. The tap changing device shall be offcircuit type. The tap changing shall be carried out by means of an externally operated tapping switch capable of being located and locked in any required position. 25.2. The location of tap changing device shall be such that an operator can very easily change the tap, while standing on the ground without the aid of any climbing platform. A warning plate indicating that switch shall not be operated in ON position is to be provided. 25.3. The contact resistance between the contact points should be less than 20. The manufacturer should show the resistance to the inspector at the time of inspection. 26.0 CONSERVATOR VESSELS. 26.1. Conservator vessels : The conservator should be air cell/ atmoseal type to prevent direct contact of Transformer oil with atmospheric air for retarding oxidation contamination of oil. The Air cell shall be made from suitable material with inner coating resistant to transformer oil & outer coating resistant to ozone & weathering. 26.2. The conservator shall be provided with necessary valves to drive out the air in the space between conservator wall & air cell during filling of oil, drain valves for complete draining of oil and cut off valves etc. 26.3. The conservator complete with necessary valves shall be provided in such a position as not to obstruct the electrical connections to the transformer from H.V & L.V SIDE. 26.4. The conservator shall be a capacity to meet the requirement of expansion of the total cold oil volume in the Transformer & cooling equipment. 26.5. The conservator shall be designed so that it can drain oil completely by means of the drain valve provided when mounted. One end of the conservator shall be bolted into position so that it can be removed for cleaning purpose. 26.6. The conservator shall be provided with different valves for filling of oil manually at site. 27.0 OIL GAUGES 27.1. Normally one Magnetic type oil gage shall be provided. The oil level at 30 Deg. C. shall be marked on the guage.

60

27.2. 27.3.

28.0

28.1.

CONNECTION : The oil connection from the transformer tank to the conservator vessel shall be arranged at a raising angle of 3 to 9 degrees to the horizontal up to the Buchholtz Relay and shall consist of pipe with inside diameter 50 mm./80 mm. as per capacity of the Transformer and as per IS:3639. Two valves shall be provided between the conservator & Transformer main tank to cut off the oil supply to the transformer after providing a straight run of pipe for at least a length of five times the internal diameter of the pipe on the tank side ofthe Gas and Oil actuated Relay and at least three times the internal diameter of the pipe on the conservator side of the Gas and Oil actuated Relay. The valves should be fitted on both side of the Gas and Oil Actuated Relay. BREATHER : Each conservator vessel shall be fitted with a glass container type breather in which silicagel is dehydrating agent and so designed that the passage of air through the silicagel the external atmosphere is not continuously in contact with the oil.

28.2. 28.3.

The moisture absorption indicated by a change in colour of the tinted crystals can be easily observed from the distance. All breathers shall be mounted at approximately 1400 mm above ground level and shall be connected to the air cell of the conservator through pipe for the purpose of breathing during contraction or expansion of the air cell. BUSHINGS Bushings for 36 KV and below shall be of solid porcelain type. These bushings shall be suitable for bare ACSR conductor connections. The bushing shall have sufficient insulation to avoid leakage to ground and shall be so located as to provide adequate electrical clearance between bushing or various voltages and between bushings and grounded parts. The insulation class of the high voltages neutral bushing shall be properly co-ordinated with the insulation class of the neutral of the high voltage winding. Stresses due to expansion and contraction in any part of the bushing insulator shall not lead to the development of defects. Outdoor insulators and fittings shall be unaffected by atmospheric conditions due to weather, fuses, ozone, acids, dust and rapid changes of air temperature. Any stress shield shall be considered as integral part of the bushing assembly. Porcelain shall not engage directly with hard metal and where necessary gaskets shall be interposed between the porcelain and the fittings. All porcelain clamping surface in contact with gasket shall be accurately grounded and free from glaze Fixing material used shall be of suitable quality and properly applied and shall not enter into chemical action with the metal parts or cause fracture by contraction expansion in service. Cement thickness shall be as small and even as possible and proper care shall be taken to centre and locate individual parts correctly during cementing. All porcelain insulators shall be designed to facilitate clearance. Each porcelain bushing or insulator, and paper bushing shall have marked upon it the manufacturers identification mark, and such other marks as may be required to assist in the representative selection of batches for the purpose of the sample tests. Clamps and fittings shall be made of steel and galvanized. The bushing flanges shall not be re-entrant type (shape) which may trap air. Each bushing shall be so coordinated with the transformer insulation, that the flashover will occur outside the tank. All porcelain used in bushings shall be of wet process, homogeneous and free from cavities or other flaws. The glazing shall be uniform in colour (brown) and free from blisters, burns and other defects. Porcelain shall be thoroughly vitrified and shall be impervious to moisture. All bushing shall have puncture strength greater than dry flashover value. Creepage distance will be kept 27 mm/KV. Bushings may be provided with weather shield. The bidder is requested to give the guarantee withstand voltage for the above and also furnish a calibration curve with different settings of the co-ordination gap to enable the purchaser to decide the actual gap settings. Tenderers recommendations are also invited to this respect. During spark gap flashover, the arc shall remain away from the housing insulator. Each terminal (including neutral) shall be distinctly marked and coloured for phase voltage and phase rotation on the primary secondary and tertiary sides in accordance with the diagram of connection supplied with the transformer, the system of marking shall conform IS 2026-1962 amended upto date. Stress due to expansion and contraction in any part of the bushing shall not lead to deterioration. Bushing shall be designed and tested to comply with the applicable standards.

29.0

29.1. 29.2.

29.3.

29.4. 29.5.

29.6. 29.7. 29.8. 29.9. 29.10. 29.11. 29.12.

29.13. 29.14. 29.15.

61

29.16. 29.17. 29.18. 29.19. 29.20.

29.21. 29.22.

Bushings rated for 400A and above shall have non-ferrous flanges and hardware. Fittings made of steel or malleable iron shall be galvanized. Bushing shall be so located on the transformer that full flashover strength will be utilized. Minimum clearances as required for the BIL shall be realized between live parts and live parts to earthed structures. All applicable routine and type tests certificates of the bushings shall be furnished for approval. Bushings shall be supplied with bimetallic/terminal connectors/ clamp suitable for fixing to bushing terminal and the PURCHASERS specified conductors. The connectors/clamp shall be rated to carry the bushing rated current without exceeding a temperature rise of 55 C over an ambient of 40 C. the connector/ clamp shall be designed to be corona free at the maximum rated line to ground voltage. Bushing of identical voltage rating shall be interchangeable. Each bushing shall be so coordinated with the transformer insulation that all flashover will occur outside tank.

30.0

30.1. 30.2.

FILTER AND DRAIN VALVES, SAMPLING DEVICES AND AIR RELEASE PLUGS : Each Transformer shall be fitted with the following : The filter and drain valves as specified. A drain valve as below shall be fitted to each conservator. For diameter upto 650 mm : Size of the valve 15 mm : for diameter above 650 mm : Size of the valve 25 mm. Suitable 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 valves specified above. One 15mm air release plug on the main tank of the Transformer. All other valves opening to atmosphere shall be fitted with blank flanges. Valves shall be of forged carbon steel upto 50 mm size and of gun metal or of cast iron bodies with gun metal fittings for sizes above 50 mm. They shall be of full way type with screwed ends and shall be opened by turning counter clock wise when facing the hand wheel. There shall be no oil leakage when the valves are in closed position. Each valve shall be provided with an indicator to show the open and closed position and shall be provided with facility for padlocking in either open or closed position. All screwed valves shall be furnished with pipe plugs for protection. Padlocks with duplicate keys shall be supplied along with the valves. All valves except screwed valves shall be provided with flanges having machined faces drilled to suit the applicable requirements. Oil tight blanking plates shall be provided for each connection for use when any radiator is detached and for all valves opening to atmosphere. If any special radiator valve tools are required, the Contractor shall supply the same. Each transformer shall be provided with following valves on the tank so located as to completely drain the tank. Two filter valves on diagonally opposite corners, of 50 mm size. Oil sampling valves not less than 8 mm at top and bottom of main tank Valves between radiators and tank. Valve prior to and after the Buchholz Relay. COOLING PLANT General :Radiators shall be so designed as to avoid pockets in which moisture may collect and shall withstand the pressure tests. The radiator tubes / fins shall be seamless, made of mild steel having as minimum wall thickness of approx. 1.2mm and a clean bright internal surface free from dust and scale. They shall be suitably braced to protect them from mechanical shocks, normally met in transportation and to damp the modes of vibration transmitted by the active part of the transformer in service. Each cooler unit shall have a lifting eye. Radiator Valves: The butterfly or similar metal valves shall be provided for isolating detachable radiator assembly. One cock each at the bottom of radiator stack shall be provided for draining oil from radiator stacks. 62

30.3.

30.4.

30.5.

30.6.

30.7. 30.8.
31.0

31.1. 31.2.

31.3. 31.4. 31.5.

31.6. 31.7. 31.8.


32.0

32.1. 32.2. 32.3.

32.4.
33.0

33.1.

33.2.
34.0

34.1.

34.2. 34.3. 34.4.


35.0

35.1.
.

Air release plug each at the top of radiator stack shall be provided for release of air from radiator stack. Removable blanking plates shall be provided to permit the blanking off the main oil Connection of each cooler. Radiator fixing bands in top & bottom of radiators are to be provided to minimise the vibration of the same. LIFTING AND HAULAGE FACILITY : Each tank shall be provided with Lifting lugs suitable for lifting of transformer complete with oil. A minimum of four jacking lugs, in accessible positions to enable the transformer complete with oil to be raised or lowered using hydraulic or screw jacks . The minimum height of the lugs above the base shall be as follows (a) for transformers up to and including 10 tones weight-300mm (b) for Transformers above 10 tones weight 500 mm Suitable haulage holes shall be provided. INSULATING OIL : The Transformer and all associated oil filled Equipment shall be supplied complete with insulating new oil required for first filling including 10% extra oil for future use during commissioning. The Transformer tank shall be dispatched completely filled with oil and the balance oil shall be supplied in non returnable sealed drums along with the Transformers. The Insulating oil shall conform to the requirement of IS:335. PRESSURE RELIEF DEVICE : Pressure relief device shall be provided of sufficient sizes for rapid release of pressure that may by generated within the tank, and which might result in damage to the equipment. The device shall operate at a static pressure of less than the hydraulic test pressure for transformer tank. Means shall be provided to prevent ingress of rain. It shall be mounted on the cover of the main tank and shall be designed to prevent gas accumulation. Spring loaded setting type Pressure Relief Valve having suitable opening Port hole according to the capacity of the transformers should be provided. The pressure relief valve should have provision of visual indication for opening of the valve and also Contract/Micro Switch arrangement for alarm/Tripping Function. AXLES AND WHEELS : The Transformer shall be provided with flanged bi-directional wheels as mentioned below : Flanged wheel suitable for use on a 1435 mm / 1676 mm guage track. The wheels shall be suitable for being turned through an angle of 90 Deg. and locked in that position when the tank is jacked up. All wheels shall be detachable and shall be made of Cast Iron or Steel. Suitable locking arrangement shall be provided to prevent the accidental movement of the transformer. CLEANING & PAINTING Before painting or filling with oil all galvanised parts shall be completely cleaned and free from rust, scale and grease and all external 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 thoroughly cleaned of all scale and rust by sand blasting or other approved method. These surfaces shall be painted with hot oil resisting varnish or paint. Unexposed welds need not be painted. 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 oil paint of weather resisting nature and preferably of a shade or colour easily distinguishable from the primary and final coasts shall be applied after the primarycoats have been touched up where necessary. The final coat shall be of glossy oil and weather resisting non fading paint of Dark Admiralty Grey shade no. 632 of IS:5. Primer paint shall be ready made zinc chrome as per IS: 104: Intermediate and final costs of paint shall be as per IS: 2932.

35.2. 35.3.

36.0

36.1. 36.2.

36.3. 36.4.

36.5. 36.6.

63

36.7.

36.8.

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 thoroughly cleaned metal surface as per procedure mentioned above. The final coat shall be of a light coloured anti-condensation mixture. Any damage to paint work incurred during delivery shall be made good by the manufacturer by thoroughly cleaning the damage portion and applying the full number of coats of paint that had been applied before the damage was caused. EARTHING TERMINAL Two earthing terminals capable of carrying the full amount of lower voltage short circuit current of transformer continuously for a period of 5 Second Provision 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 condition. TEMPERATURE INDICATING DEVICE: Oil temperature indicator with two electrical contacts for alarm and trip purposes, shall be provided with anti vibration mounting. The oil temperature indicator shall be housed in the marshalling box. The winding temperature indicator with two electrical contacts for alarm & trip purposes shall be provided with anti vibration mounting. The winding temperature indicator shall be housed in the marshalling Box. The Oil and Winding temperature indicator should be of renowned make preferably of Perfect Control or Precimeasure. The scale on the dial of the thermometer should be 0C to 150C. The angular displacement of thermometer should be 270 Deg. The signaling contact of WTI & OTI shall be set to operate at the following temperature: OIL : Alarm-85 C, Trip 95 C

37.0

37.1.

38.0

38.1. 38.2.

38.3.

38.4.

WINDING : Alarm-100 C, Trip 110 C 38.5. The tripping contacts of indicator shall be adjustable to close the winding temperature indicator between 60 Deg.C and 120 Deg.C. The alarm contacts of indicator shall be adjustable to close between 50 deg.C & 100 Deg.C. 38.6. All contacts shall be adjustable on a scale and shall be accessible on removal of the cover. The Temperature indicators shall be so designed that it shall be possible to check the operation of contacts and associated Equipments. 38.7. For measuring winding temperature a heater coil fed from a C.T. has to be provided on the pocket for winding temperature indicator bulb. The connection from C.T. to heater should be through a link arrangement on the tank cover suitably housed in a weather proof box so that C.T. current and heater coil resistance can be checked. WTI C.T. secondary should be of 5 Amps, rating. 38.8. Accuracy class of both OTI and WTI shall be 1% or better. 39.0 MARSHALLING BOX A sheet steel 3.15mm thick vermin proof, well ventilated and weather proof marshalling box of a suitable construction shall be provided for the transformer ancillary apparatus. The box shall have domed or sloping roofs and the interior & exterior painting shall be in accordance with painting clause specified. The degree of protection shall be IP-55. The marshalling box shall accommodate. Winding and oil temperature indicator. Terminal Blocks and gland plates for incoming and outgoing Cables. One space heater operated by 220 V.A.C. Aux. Supply, Cubicle illuminating lamp with door switch. All incoming cables shall enter the kiosk from the bottom and the gland plate shall not be less than 450 mm from the base of the box. The gland plate and associated compartment shall be sealed in suitable manner to prevent the ingress from the cable trench All the above equipment shall be mounted on panels and back of panel wiring shall be used for Interconnection. The temperature indicators shall be so mounted that the dials are visible by standing at ground level. 64

39.1.

39.2.

39.3.

39.4.

39.5. 39.6.

Door of the compartment shall be provided with glass window of adequate size. Ventilation louvers shall be provided. The schematic diagram of the circuitry inside the marshalling box be prepared and fixed inside the door

40.0

40.1.

40.2. 40.3.

41.0

41.1. 41.2.

41.3.

42.0

42.1. 42.2.
. 43.0

GAS AND OIL ACATUATED RELAYS Each transformer shall be provided with gas and oil actuated Relay (Buchholtz Relay) equipment conforming of IS:3637 double float type with one set of alarm contacts, one set of trip contacts and a testing pet cock. The contacts shall be wired with a P.V.C. armoured cable. A machined surface shall be provided on the top of Relay to facilitate the setting of Relay and to check the mounting angle in the pipe and cross level of the Relay. The pipe work shall be so arranged that all gas arising from the Transformer shall pass into the gas and oil actuated Relay. The oil circuit through the Relay shall not form a delivery path in parallel with any circulating oil pipe. RATING DIAGRAM AND PROPERTY PLATES : The following plates shall be fixed to the transformer tank at a suitable height so that the particulars could be read by standing at ground level. A rating plate bearing the data specified in the relevant clauses of IS:2026 including figures of temperature rise of oil and winding and high voltage test values. that the equipment belongs to APDCL with reference of purchase order is also to be indicated. A diagram plate showing the internal numbering of taps, tapping switch connection of windings and also the voltages vector relationship in accordance with IS:2026 and in addition a plan view of the transformer giving the correct physical relationship of the terminals. No load voltage shall be indicated for each tap. Details of C.T particulars w.r.o phase, Neutral &WTI CT. CENTRE OF GRAVITY : : The centre of gravity of the assembled transformer shall be low and as near the vertical centre line as possible. The transformer shall be stable with or without oil. If the centre of gravity is eccentric relative to track either with or without oil, its location shall be shown on the outline drawing. FOUNDATION : The tenderer shall furnish foundation plan of the transformer showing the fixing arrangement of the transformer so that the purchase may be able to finalise the foundation drawings. TEST AND INSPECTION : Routine Tests : All transformers shall be subjected to the following routine tests at the manufacturers works. The tests shall be carried out in accordance with the details specified in IS:2026. i) Measurement of winding resistance. ii) Measurement of turns ratio for all sets wndings on each tap iii) Polarity and phase vector relationship. iv) Measurement of no load loss and no load current. v) Measurement of impedance voltage at normal , maximum and minmum tap vi) Measurement of insulation resistance between windings and between windings and earth vii) Measurement of load loss. viii) Induced over voltage withstand test. ix) Separate source voltage withstand test. x) Oil Leakage gas collection, oil surge and voltage test on gas and oil actuated relay for on load tap changer. xi) Magnetic balance test. xii) Testing of Phase & Neutral C.T., as applicable, in accordance with provisions in the relevant I.S. xiii) Oil leakage test of tnansformer tanks at a pressure equals to the normal pressure plus 35 KN/ sq.M measured at the base of tank.

43.1.

44.0

44.1. 44.2.

65

44.3. 44.4. 44.5.

Type Test In addition to routine Tests mentioned above the transformer shall be subjected to all kinds of Type and Acceptance Test in accordance with Relevant I.S. (IS:2026) with latest amendment if any. Bidder should submit Type Test report from NABL/Govt. approved Laboratories along with their offer having identical technical parameters as that of the tendered item failing which their offer may not be technically accepted. However, if it is found that the bidder has submitted Type tests Report but those have not been conducted on identical Design of equipment/material as per specification of APDCL, the same may be accepted subject to the following conditions: APDCL at his discretion request the successful bidders to conduct Type Tests on identical design as per specification . Such Type tests/special tests, if required to be carried out at NABL/Govt. approved Laboratories in presence of APDCL engineers for which no extra cost shall be charged to the APDCL. However, the bidders who have not submitted such Type Test/Dynamic Short Circuit Test report but if their offer is considered technically acceptable by the purchasers on the basis of other credentials, they will have to carry out such tests at NABL/Govt. approved Laboratories in presence of APDCL engineers before effecting physical delivery against Purchase Order for which no extra cost shall be charged to the APDCL. Routine Test have to be carried out in presence of APDCL engineers before carrying out type test. INSPECTION AND TESTING Inspection and testing as already mentioned the equipment shall be subjected to routine and other acceptance tests as per provisions in the relevant I.S. The APDCL reserves the right to send its Engineers if so desires to witness manufacturing process and to reject either raw materials or finished products found to be not complying with the requirement of the specification and also shall have the right to select any/all equipment from the lot offered for tests. The manufacturer shall give at least (21) twenty one days advance notice regarding readiness of such inspection and testing and shall submit six sets of the works test certificates of the materials/equipment offered for inspection and testing indicating probable date of inspection and testing. The manufacturer shall arrange all possible facilities for such inspection and testing at any time during the course of manufacture free of cost. TEST CERTIFICATE Five copies of the approved Test Certificates as mentioned above are to be furnished to the APDCL before dispatch of the equipment. DRAWINGS AND MANUALS TO BE SUBMITTED BY SUCCESSFUL BIDDER The bidder shall furnish, within fifteen days after issuing of letters Award, six copies each of the following drawings/documents incorporating name of project and transformer rating for approval. i. Detailed overall general arrangement drawing showing front and side elevations and plan of the transformer and all accessories including radiators and external features with details of dimension, spacing of wheels in either direction of motion, net weights and shipping weights, crane lift for untanking, size of lugs and eyes, bushing lifting dimensions, clearances between HV and LV terminals and ground, quantity of insulating oil etc. ii. Foundation plan showing loading on each wheel and jacking points with respect to centre line of transformer. iii. GA drawing/details of bushing and terminal connectors. iv. Name plate drawing with terminal marking and connection diagrams. v. Wheel locking arrangement drawing. vi. Transportation dimension drawings. vii. Interconnection diagrams. viii. Over fluxing withstand time characteristics of transformer. ix. GA drawing of marshalling box. x. Control scheme/wiring diagram of marshalling box. xi. Technical leaflets of major components and fittings.

44.6.

44.7. 44.8.

45.0

45.1. 45.2.

45.3.

45.4.
46.0

46.1.
47.0

47.1.

66

47.2. 47.3.

47.4.

47.5. 47.6.

xii. As built drawing of schematic, wiring diagrams etc. xiii. Setting of oil temperature indicator, winding temperature indicator. xiv. Completed technical data sheets. xv. HV/LV conductor bushing. xvi. Bushing assembly. xvii. Bi-metallic connector for connection to Wolf/PANTHER ACSR/AAAC conductor xviii. Radiator type assembly. All drawings/documents, technical data sheets and test certificates/results/calculations shall be furnished. Any approval given to the detailed drawings by the purchaser shall not relieve the contractor of the responsibility for correctness of the drawing and in the manufacture of the equipment. The approval given by the purchaser shall be general with overall responsibility with contractor. Installation, operation and maintenance manual of transformer, associated equipment like buchholtz Relay, temperature indicators, oil level indicator etc. The manual shall clearly indicate the installation method, check-ups and tests to be carried out before and after commissioning of the transformer. One copy of manual, set of approved drawings shall be submitted to the CGM(PPD)/APDCL before dispatch of the Transformer. In addition one set of approved drawing, manual for transformer shall be send to the respective consignee officer in water proof folder at the time of delivery of the transformer. GUARANTEED TECHNICAL PARTICULARS Bidder shall furnish guaranteed technical particulars of equipment offered as per Schedule B To be provided along with final NIT specification), ACCESSORIES All accessories as specified in the schedule A are to be provided. Any other part necessary for smooth operation of the transformer if omitted it is the manufacturers responsibility to include the same. SPARE PARTS: The Tenderer shall submit a recommended list of spare parts for five years of operation along with item wise price for each item of spares as stated in Schedule B SCHEDULE A FITTINGS & ACCESSORIES The following fittings and accessories shall be supplied with each Transformer : a) Outdoor type bushing 11V-3 Nos. and LV-4 Nos. b) Conservator with aircell and supporting bracket or structure as the case may be. c) Isolating valve for conservator in between conservator and Buchholtz Relay and in between Buchholtz relay and main tank.. d) Conservator valves for driving out air between air cell & wall of conservator & connection to breather. e) Conservator drain valve. f) Dial type oil level indicator complete with alarm contact. g) Silica gel breather with oil seal and connecting pipe. The breather shall be accessible for inspection from ground. h) Spring loaded setting type pressure relief Valve having suitable opening Port. Hole & provision of visual indication for opening of the valve & Alarm/Trip contact arrangement. i) Access/inspection holes with bolted cover for access to inner ends of bushing. j) Cover lifting eyes. k) Lifting eyes for core frame with windings. l) Tap changing arrangement with hand wheel for Off-Load tapm) Air release plugs on top of cover and pressure equalizer pipe for bushing turret. n) Upper filter valve and bottom filter valve. o) Drain valve.

48.0

48.1.
49.0

49.1.
50.0

50.1.

67

p)

2.

3. 4. 5.

q) r) s) t) u) 1. 22 Buchholtz relay double float type with one set of alarm contacts, one set of trip contacts and testing pet cock. The contacts should be wired with a PVC armoured cable. 1. Dial thermometer for winding temperature with alarm contacts and Trip contacts. 2. Dial thermometer for oil temperature with alarm contacts and Trip Contacts. 3. An additional pocket for inserting thermometer for oil temperature indication. 4. Weather proof control cabinet for marshalling terminal connections from protective and indicative devices. The cabinet shall be provided with incandescent filament lighting, heater and plugs etc. 28. Rating plate, as per I.S.S. 29. Diagram Plate : As per clause 28. 30. Property label. SCHEDULE B SPARE PARTS:

Top and bottom oil sampling devices. Provision for oil sample collection during process of filtration should be made. Lifting lugs. Jacking pads with handling holes at four corners. Transport lugs. Under carriage base channel. Tank earthing terminals 2 Nos.

The mandatory spare parts shall include but not be limited to the following for each rating of transformer. (i) Bushings: a. High Voltage - 1 No. b. Low Voltage - 1 No. c. Neutral Bushing - 1 No. (ii) Complete set of gaskets for all - 1 Set openings on the tank requiring gasket. (iii) Magnetic oil level gauge with low oil - 1 No. level alarm contacts. (iv) Oil temperature indicator with alarm - 1 No. and trip contacts and maximum reading pointer. (v) Winding temperature indicator with alarm and trip - 1 No. contacts and maximum reading pointer (vi) Set of all types of valves comprising one in each type. - 1 Set (vii) Silicagel breather - 1 No. (viii) Buchholz Relay - 1 No. Note: The quantities indicated above are for each transformers.

68

TECHNICAL SPECIFICATIONS FOR 36 KV VACUUM CIRCUIT BREAKER 1.0 SCOPE 1.1 This section of specification covers the design, manufacture, assembly under stringent quality control at every stage of manufacturing, testing at manufacturer's works before dispatch, supply and delivery at destination store and supervision of erection, testing and commissioning of 36 KV outdoor type vacuum circuit breakers at various substations in SEB. The scope of supply shall also include necessary special tools and plants required for erection, maintenance and necessary spares, required for normal operation and maintenance of the circuit breakers for a period of five years. The circuit breakers should be complete in all respects with insulators, bimetallic connectors, interrupting chamber, operating mechanism control cabinet, interlocks, auxiliary switches indicating devices, supporting structures, accessories, etc., described herein and briefly listed in the schedule of requirements. The spares/attachments which are meant necessary for the smooth functioning of the equipment and specifically are not mentioned here shall be assumed to be included the scope of supply. It may be noted that the Vacuum Circuit Breaker must meet the following minimum criteria. Failure to comply with the requirements may results in rejection of the BID as non-responsive: The Manufacturer must have designed, manufactured, type tested and supplied vacuum circuit breaker in at least two power utilities of similar rating which are in successful operation for at least 5 (Five) years as on the date of bid opening which should be substantiated by furnishing performance report from the official of the rank not below DGM/SE 2.0 STANDARDS 2.1 The circuit breaker shall conform in all respects to the requirements of latest issue of IS/IEC specifications except for modifications specified herein. The equipment manufactured according to any other authoritative standards which ensure an equal or better quality than the provision of IS/IEC specifications shall also be acceptable. The salient point of difference between the proposed standard and provision of these specifications shall be clearly brought out in the tender. A copy of English version of such specifications shall be enclosed with the tender. The list of standards mentioned in this specification and to which the circuit conform is given below: IEC-56 IEC-137 IEC-71 IEC-694 IEC-815 IS-13118 IS-2099 IS-4379 IS-3072 IEC-267 IS-802 IEC-17A 5tudy Group IS-1554 Dec.1981 IS-5 High Voltage A.C. Circuit Breakers Bushing for alternating voltage above 1000 volts Insulation Co-ordination Common clauses for high voltages switchgear and control gear standards Specification for Creepage distance Specifications for high voltage alternating current circuit breakers High voltages porcelain bushings Identification of the contents of industrial gas cylinders Installation and maintenance of switchgear Guide for testing of circuit breakers with respect to out of phasepractice for use of structural steel in overhead Code of switching transmission lines Sealing of interrupters I breakers PVC insulated cables upto and including 1000 volts Colors for ready mixed paints and channels

1.2

1.3

1.4

2.2

1. 2 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

69

3.0

CLIMATIC CONDITONS The breakers and accessories to be supplied against this specification shall be suitable for satisfactory continuous operation under the tropical conditions specified in this bidding document. AUXILIARY POWER SUPPLY 4.1 Auxiliary electrical equipment shall be suitable for operation on the following supply system. a. Power Devices (like drive motors) 415 V, 3 phase 4 wire 50 hz, neutral grounded AC supply b. DC Alarm, Control and Protective Devices 110 V DC, c. Lighting 240 V, single phase 50 Hz AC supply 4.2 Each of the foregoing supplies shall be made available by the Purchaser at the terminal point for each circuit breaker for operation of accessories and auxiliary equipment. Bidder's scope includes supply of interconnecting cables, terminal boxes, etc. The above supply voltage may vary as indicated below and all devices shall be suitable for continuous operation over the entire range of voltages 1) AC Supply 2) Frequency 2) DC Supply 415V (+ 10% /-- 15%) 50Hz ( 5%) 110V ( - 15% to + 10%)

4.0

5.0 5.1

GENERAL REQUIREMENT OF 36 KV/OUTDOOR VACUUM CIRCUIT BREAKERS The vacuum type circuit breaker shall have vacuum interrupters, designed to provide a long contact life at all currents upto rated making and breaking current during switching operation: The vacuum interrupters sealed for life shall be encapsulated by porcelain insulators for out door installation requirement of the circuit breakers. The offered breakers shall be suitable for out door operation under climatic conditions specified without any protection from sun, rain and dust storm. The vacuum interrupters of each phase shall be housed in a separate porcelain insulator. The three identical poles shall be mounted on a' common base frame and the contact system of three poles should be mechanically linked to provide three pole gang opening/closing for all type of faults. i. ii. iii. The performance of breakers shall be adequately proven by type tests for the designed rating at internationally reputed independent testing station. The offered equipment shall be practically maintenance free over a long period. All mechanical parts and linkages shall be robust in construction and maintenance free, over at least 30,000 switching operations except for lubrication of pins/articulated joints at interval of 5 years or 5000 operations. Similar parts shall be strictly interchangeable without special adjustment of individual fittings. Parts requiring maintenance shall be easily accessible, without requiring extensive dismantling of adjacent parts. The operating mechanism will be self maintained and of proper operation endurance not less than the mechanical life of circuit breaking unit. It shall be spring operated type described hereinafter. The circuit breaker shall be supplied complete with all auxiliary equipment meant necessary for the safe operation, routine and periodic maintenance. All internal wiring including those of spare auxiliary contacts shall be complete and wired upto terminal blocks situated near cable gland plate. The breaker shall be totally restrike free under all duty conditions and shall be capable of performing the duties without opening resistor. The details of any device incorporated to limit or control the rate of rise of restriking voltage across the circuit breaker contacts shall be stated.

5.2

iv)

v) vi)

vii)

70

viii) ix) x)

The breaker shall be reasonably quiet in operation and the noise level shall not exceed 140 decibels. The breaker shall be suitable for three phase reclosing operation. An operation counter, visible from the ground level even with the mechanism housing closed shall be provided.

6.0

VACUUM INTERRUPTER ASSEMBLY 6.1 Each pole of the circuit breaker shall be provided with vacuum interrupter, one for each phase, hermetically sealed for life and encapsulated by ceramic insulators. The interrupter shall be provided with steel chromium are chamber to prevent vaporized contact material being deposited on the insulating body. A further shield giving protection to the metal bellows shall also follow the travel of the moving contacts to seal the interrupter against the surroundings atmosphere. It shall have high and consistent dielectric strength of vacuum unaffected by environment and switching operations. Bronzed joints should ensure retention of vacuum for life time. It shall have low and stable contact resistance due to absence of oxidation effects and shall ensure low power loss. The arcing voltage shall be low with minimum contact erosion. The manufacturer of VCB should use their own Vacuum interrupter so that the drive mechanism is matched perfectly with that of the requirement of Vacuum Interrupter. The vacuum bottles should be capable of withstanding minimum 100 full short circuit operations as per test duty 1 to 5 of IEC-56. The vacuum bottles, capable of withstanding less than 100 full short circuit faults, would not be considered and therefore should not be offered. A manufactures type test reports / literature for vacuum bottles, may, therefore be supplied along with tender in duplicate. Vacuum Interrupters of China make should not be offered.

6.2

6.3 6.4

6.5 6.6 7.0

FIXED AND MOVING CONTACT 7.1 The fixed and moving contacts of the breaker have to ensure permanent full contact during closing without unusual maintenance. All making and breaking contacts shall be hermetically sealed and free from atmospheric effects. The contacts metallurgy and geometry shall be such that there is minimum contact burning and wear. Main contact shall have ample area and contact pressure for carrying the rated current and rated short time current without excessive temperature rise which may cause pitting or welding of the contacts. The main contacts should have low contact resistance. The contact should be self cleaning type, i.e., the layer of copper oxide should be cleaned during rubbing of contacts. The contact area should be well defined, spring used for contact shall be of gradually rising characteristic i.e., they should be soft. The contacts should not provide contact grip, ie., electro-magnetic forces should not grip the contacts and oppose the opening process. It would be desirable to have separate main contacts and arcing contacts in order to have longer life of the contacts. The contours of the energized metal parts of the breaker shall be such as to eliminate areas or points of high electrostatic flux concentration. Surfaces shall be smooth with no projection or irregularities which may cause visible corona. No corona shall be visible in complete darkness when the equipment is subjected to the specified test voltage. The circuit breaker units shall be suitable for installation on outdoor R.C.C. foundations. Ground clearance of the live parts of the breakers should be 3700 mm from foundation. The circuit breakers shall be spring operated.

7.2

7.3

7.4

71

8.0

RECOVERY VOLTAGE AND POWER FACTOR 8.1 The circuit breaker shall be capable of interrupting rated power with recovery voltage equal to the rated maximum line to line service voltage at rated frequency and at a power factor equal to or exceeding 0.15.

9.0

RESTRIKING RECOVERY and LINE CHARGING INTERRUPTING CAPACITY

9.1 9.2

The complete data for the phase factor, amplitude factor, etc., for rate of rise of restriking voltage shall be furnished in the tender. The circuit breaker shall be designed so as to be capable of interrupting line charging currents without undue rise in the voltage on the supply side without restrike and without showing sign of undue strains. The maximum permissible switching over voltage shall not exceed 2.5 p.u. The guaranteed over voltage, which will not be exceeded while interrupting the rated line charging current for which the breaker is designed to interrupt shall also be stated. The results of the tests conducted along with the copies of the oscillographs to prove ability of the breakers to interrupt the rated as well as lower values of the line charging current shall be furnished with the tender.

9.3

10.0

TRANSFORMER CHARGING CURRENT BREAKING CAPACITY 10.1 The breaker shall be capable of interrupting inductive currents, such as those occurring while switching off unloaded transformers, without giving rise to undue over voltage and without restrikes. The maximum over voltage value, which will not be exceeded under such conditions, shall be stated in the tender.

11.0

BREAKING CAPACITY FOR SHORTLINE FAULTS 11.1 The interrupting capacity of the breaker for short line faults shall be stated in the tender. The details of the test conducted for proving the capability of the breaker under a short line fault occurring from one phase to earth conditions shall also be stated in the tender. The rated characteristics for short line faults shall be in accordance with stipulation contained in clause 8.0 of IEC-56(2)-1971.

12.0

AUTOMATIC RAPID RECLOSING and OUT OF PHASE SWITCHING

12.1 12.2

36 KV circuit breaker shall be suitable for 3 pole rapid reclosing. The dead time of the breaker shall be adjustable and the limits of the adjustment shall be stated in the tender. The circuit breaker shall be capable of satisfactory operation even under conditions of phase opposition that may arise due to faulty synchronization. The maximum power that the breaker can satisfactorily interrupt under "Phase Opposition" shall be stated in the bid".

13.0

TEMPERATURE RISE 13.1 The maximum temperature attained by any part of the equipment when in service at side and under continuous full load conditions and exposed to the direct rays of the sun shall not exceed the permissible limits fixed by IEC. When the standards specify the limits of temperature rise these shall not be exceeded when corrected for the difference between ambient temperature specified in the approved specification. The limits of temperature rise shall also be corrected for altitude as per IEC and stated in the bid.

13.2

72

14.0

INSULATORS SUPPORTS AND HOUSING 14.1 The basic insulation level of the external insulator supporting shall be as stated in the "Technical Parameters" and these shall be suitable for use under climatic conditions as stated elsewhere in the specification. The porcelain used shall be homogenous, free from cavities and other flaws. The insulators shall be designed to have ample insulation, mechanical strength and rigidity for satisfactory operation under conditions specified above. All bushings of identical rating shall be interchangeable. The puncture strength of bushing shall be greater than the flash over value. The design of bushing shall be such that the complete bushing in a self-contained unit and no audible discharge shall be detected at a voltage upto a working voltage (Phase Voltage) plus 10%. The support insulator shall conform to IEC-137. Minimum clearance between phases, between live parts and grounded objects shall be as per IS3072-1975 and should conform to Indian Electricity Rules-1956. The minimum creepage distance for severely polluted atmosphere shall be 27 mm/KV. . The air clearance of bushing should be such that if the bushings were tested at an altitude of less than 1000 meters, air clearance would withstand the application of higher voltages (IS-2099-1973 para 6.1). In order to avoid breakdown at extremely low pressures the support insulators should not be covered by moisture and conducting dust. Insulators should therefore be extremely clean and should have anti-tracking properties. Sharp contours in conducting parts should be avoided for breakdown of insulation. The insulators shall be capable to withstand the seismic acceleration of 0.5 g in horizontal direction and 0.6g in vertical direction.

14.2 14.3

14.4

14.5

15.0

OPERATING MECHANISM GENERAL REQUIREMENTS 15.1 The operating mechanism shall be stored energy type and capable of giving specified duty of the breaker The breaker shall also pass the operational test which ascertain the capabilities of operating mechanism. The operating mechanism shall be capable to perform the following functions efficiently. i) ii) iii) iv) v) vi) To provide means where the circuit breaker can be closed rapidly, without hesitation at all currents from zero to rated making current capacity. To hold the circuit breaker in closed positions by toggles or latches till the tripping signal is received. To allow the circuit breaker to open without delay immediately on receiving tripping signal. Operating mechanism should also be suitable for three phase auto reclose duty. The closing spring shall be automatically charged by motor immediately after closing operation. In case of failure of supply to the spring charging motor, the spring shall be chargeable by hand crank. The contact pressure spring and tripping spring shall be chargeable during closing operation to ensure the breaker is ready to open.

vii) Mechanically ON/OFF indicator, spring charged indicator and operation counter shall be provided on the front of the control cubicle. For tripping, the spring provided shall ensure the trippings. 16.0 Tripping/Closing Coils 16.1 The circuit breakers shall be provided with two trip coils and one closing coil per breaker. First trip coil shall be utilized for tripping the breaker on main protection fault detection. Whereas second trip coil shall be used to trip the breaker when first trip coil fails to trip the breaker and backup protection comes into operation and shall also be used to trip the breaker on command. 73

16.2

The trip coils shall be suitable for pre-closing and after closing trip circuit supervision. All the breakers shall have provision for independent electrical operation of trip coils from local as well as remote through local/remote selector switch. The breaker shall be provided with suitable protection device against discrepancies in the operation of individual pole. Closing coil shall operate correctly at all value of voltage between 85% and 110% of the rated voltage. Shunt trip coils shall operate correctly under all operating conditions of the circuit breaker upto the rated breaking capacity and at all values of supply voltage between 70% and 110% of rated voltage. Trip Free Features a. When the breaker has been instructed to close by manual instructions by pushing of push button, the operating mechanism will start operating for closing operations. If in the mean time a fault has taken place, the relay provision shall be such that it should close the trip circuit simultaneously interrupting the live circuit of closing coil which has been instructed for close command. b. The trip free mechanism shall permit the circuit breaker to be tripped by the protective relay even if it is under the process of closing. An antipumping device to prevent the circuit breaker from reclosing after an automatic opening shall be provided to avoid the breaker from pumping i.e., anti pumping relay should interrupt the closing coil circuit.

16.3

16.4

17.0

Controls 17.1 The circuit breaker shall be controlled by a control switch located in the control room. The control arrangement shall be such as to disconnect the remote control circuits of the breaker, when it is under test. Local control devices, selector switch and position indicator shall be located in weather and vermin-proof cabinet. The circuit breaker control scheme shall incorporate trip circuit supervision arrangement. Local/remote selector switch shall be provided for all breakers for selection of "Local" control/remote control. Provision shall be made for local manual, electrical and spring controls. Necessary equipment's for local controls shall be housed in the circuit breaker cabinet of weatherproof construction. In addition to this, a hand closing device for facilitating maintenance shall also be provided. Each circuit breaker shall have a mechanical open/closed and spring charge indicator in addition to facilities for provisions for semaphore indicators for breakers which are required for the mimic diagram in the control room. Lamps for indicating, 'close/open' position of the breaker shall also be provided. Mechanical indicator, to show the 'open' and 'close' position of the breaker shall be provided in a position where it will be visible to a man standing on ground with mechanism housing open. An operation counter, visible from the ground even with the mechanism housing closed, shall be provided. Electrical tripping of the breaker shall be performed by shunt trip coils. Operating mechanism and all accessories shall be enclosed in control cabinet. A common marshalling box for the three poles of the breaker shall be provided, along with supply of tubing, cables from individual pole operating boxes to the common marshalling box, local.

17.2 17.3

17.4

17.5 17.6

17.7

18.0

SPRING OPERATED MECHANISM and MOTOR 18.1 The motor compressed spring mechanism shall consist of a closing spring which is wound or compressed by an electric motor immediately after the breaker closes. The closing action shall also wind or compress a tripping springs shall be wound. After the breaker has tripped, the tripping spring shall remain in the released position as long as the breaker is open, but the closing spring shall remain wound and ready for closing operation. 74

18.2

Spring charging motor shall be standard single phase universal motor suitable for 220 volts supply. i) Operating voltages for closing/tripping coils shall be 110 Volts DC.

ii) Operating voltages for heater elements shall be 220V AC 50 HZ. Other features of the spring operated mechanism shall be as follows. 18.3 The spring operating mechanism shall have adequate energy stored in the operating to close and latch the circuit breaker against the rated making current and also to provide the required energy for tripping mechanism in case the tripping energy is derived from the operating mechanism. The mechanism shall be capable of performing the rated operating duty cycle of 0-0.3Sec-CO-3 Min-CO as per IEC-56. The spring charging motor shall be AC/DC operated and shall not take more than 30 sec., to fully charge the closing spring made for automatic charging. Charging of spring by the motor should not - interfere with the operation of the breakers. The motor shall be adequately rated to carry out a minimum of one duty cycle. Also provision shall be made to protect the motor against overloads. In case of failure of power supply to spring charging motor, the mechanism shall be capable of performing one open-close-open operation. Mechanical interlocks shall be provided in the operating mechanism to prevent discharging of the closing springs when the breaker is already in closed position. Provision shall be made to prevent a closing operation to be carried out with the spring partially charged. Facility shall be provided for manual charging of closing springs.

18.4 18.5

18.6 18.7

18.8

18.9 19.0 19.1

CONTROL CABINET The switchgear operating mechanism, the control equipment such switch for closing and tripping the breakers, various control relays, antipumping device, timer for adjusting breaker reclosing, a set of terminal blocks for wiring connections, MCB's for disconnecting the control auxiliary power supplies. Including relays, etc., shall be enclosed in a cabinet to 'be mounted on a suitable structure at a convenient working height at the end of the breaker in the outdoor switchyard. The supporting structure and the enclosure shall be capable of withstanding the typical tropical climatic conditions, change of ambient temperature, severe dust-storms, very high relative humidity those are prevailing at the site of location of switchgear . The enclosure shall be made out of stretched level steel plates not less than 3.15 mm thick and of light section structural steel. It should be weather proof as well as vermin proof and conforming to IP: 55 degree of protection. Each cabinet section shall have full width and full length hinged doors mounted on the front that swing fully open. The doors shall be provided with latches to securely hold it with the cabinet. Doors shall be of sturdy construction, with resilient material covering, to provide dust protection and prevent metal to metal contact except at the latch points. Filtered ventilation shall be provided along with the rigid supports for control and other equipment, measuring instruments, mounting cabinet members and equipment shall not restrict easy access to terminal blocks for terminating and testing external connection or to equipment for maintenance. All screws and bolts used for assembling and mounting wire and cable termination, supports, devices and other equipment shall be provided with lock washers or other locking devices. All metal parts shall be clean and free of weld splatter, rust and mill scale prior to application of double coat of zinc chromate primer which should be followed by an Polyurethane paint to serve as base and binder for tile finishing coat. The exterior of the cubicle shall be painted matty grey to shade NO.692 of IS-5 or shade No.631 and interior to white shade. Sufficient quantity of paints shall also be supplied along with the cubicle to restore at site any damage during transportation. The mounting structure shall be galvanized and shall be as per IS-802-11-1978. Suitable heaters shall be mounted in the cabinet to prevent condensation. Heaters shall be 75

19.2

19.3

19.4

19.5

controlled by thermostat ON/OFF switches and fuses shall be provided. Heaters shall be suitable for 240 V AC supply voltage. 19.6 At least one 20 watts fluorescent tube fixture and lamp holder working on 240V, 50 c/s AC supply shall be provided in each switchgear control cubicle section and shall be located to provide adequate interior lighting of the cubicle. Ballasts shall be rated at not less than 0.90 power factor. A single pole 20 Amp. T rated lighting switch shall be provided for each cubicle, flush-mounted on the left end. One duplex 220 volt convenience outlet shall be provided inside each door or pair of doors inside each cubicle. The lighting and convenient outlet circuits shall be completely wired in conduit and terminated on cubicle terminal blocks. Unless otherwise specified control wire shall be stranded tinned copper stranded wire with 1.1 KV PVC insulation conforming to the requirements of IS-1554. All the control circuit and secondary wiring shall be wired completely and brought out preferably to a vertical terminal block ready for external connections in the control cabinet. The control wire shall not be of cross2 section less than 2.5 mm copper. All spare auxiliary contacts of the circuit breaker shall be supplied wired upto terminal block.At least 20 number spare terminals shall be provided over and above the number required. All wiring termination on terminal blocks shall be made through lugs. For current and DC supply circuits disconnecting sturdy type terminal blocks will be provided. For other control circuits, non-disconnecting snap on type terminal blocks shall be provided. All wires shall be identified with non-metallic sleeve or tube type markers at each terminations. Terminal blocks shall be made up of molded non-inflammable plastic material with blocks and barriers molded integrally have white marking strips for circuit identification and moulded plastic covers. A ground bus of copper bar not less than 6 mm by 25 mm shall be provided along the inside of the front or rear of the each cubicle and equipment rack. The ground bus shall be bolted to the frame of each panel in such a way as to make good electrical contact with each panel or section. Lugs shall be provided for connection of the ground bus to the station ground bus/earth mat. ACCESSORIES Each circuit breaker assembly shall be supplied with the following accessories. i) Line and earthing terminals and terminal connectors. ii) Control housing with: One auxiliary switch with adequate number of auxiliary contacts, but not less than 12 nos. (6 No + 6 NC) for each breaker. These shall be over and above the No. of contacts used for closing, tripping and 'reclosing' and interlocking circuit of the circuit breaker. All auxiliary contacts shall be capable of use as "Normally closed" or "Normally open" contacts. Special auxiliary contacts required for the reclosing circuit if any, shall also be provided. There shall be provision, to add more auxiliary contacts at a later date, if required. Operation counters Position indicator (Close/Open) Necessary cable glands Fuses Manual trip device and local test push buttons Terminal blocks and wiring for all control equipment and accessories Adequate number of heaters for continuous operation to prevent moisture condensation in the housing of operating mechanism Selector switch for local/remote control.

19.7

19.8

19.9 19.10

20.0 20.1

a)

b) c) d) e) f) g) h) i) 21.0

SUPPORTING STRUCTURE 21.1 The circuit breakers shall be supplied complete with necessary galvanized steel supporting structures, foundation and fixing bolts, etc., the galvanizing shall be as per IS. The mounting of the breaker shall be such as to ensure the safety of the operating staff and should conform to Indian Electricity Rules, 1956. Minimum ground clearance of live part from ground level shall be

76

4000 mm inclusive of foundation (300mm above GL). 21.2 The bidder shall submit detailed design calculations and detailed drawings in respect of supporting structures suitable for the equipment offered. The tenders shall specify the loads which shall be transmitted to the equipment foundation under most adverse operating conditions of the breaker. Facility to earth the circuit breaker structure at two points shall be provided.

21.3 22.0

GALVANISING All ferrous parts including all sizes of nuts, bolts, plain and spring washers, support channels, structures, shall; be hot dip galvanized conforming to latest version of 18:2629 or any other equivalent authoritative standard.

23.0

CABLE TERMINATION Suitable cable glands for terminating the multi-core cable shall be provided wherever required.

24.0

TERMINAL CONNECTIONS AND EARTH TERMINALS 24.1 Each circuit breaker connected with incoming and outgoing feeders shall be provided with solder less clamp type bimetallic connectors suitable for ACSR/AAAC conductor mentioned in 'Technical Parameter'

25.0

INTERTERLOCKS 25.1 Necessary interlocks to prevent closing or opening of the breaker under low pressure of the contact spring and devices for initiating alarm shall be provided. Provision shall also be made to enable electrical interlocking with the isolators associated with the breaker to prevent opening or closing of the isolators.

26.0

TYPE TESTS 26.1 Type test certificates for the following tests, as per IS:13118 or IEC 62271-100 with latest amendment thereof, from any of the NABL accredited Laboratory shall invariably be furnished a. Short circuit duties test b. Short time withstand current and peak withstand current tests c. Temperature rise test d. Mechanical endurance test e. Lightning impulse voltage withstand test f. Power Frequency withstand voltage test (dry & wet) g. Single Capacitor bank switching test h. Degree of protection IP-55 as per IS:13947:93(Part-I)/IEC 60529:89 26.2 26.3 26.4 Type test certificates must accompany drawing of type tested equipment, duly sealed & signed by type testing authority. Type tests conducted on the equipment should not be earlier than 3 years from the date of opening of bids. In case of any change in design/type of breaker already type tested and the one being offered against this specification, the Employer reserves the right to demand repetition of some or all tests without any extra-cost at NABL accredited lab.

27.0

ACCEPTANCE AND ROUTINE TEST :27.1 Employer shall have access at all times to the works and all other places of manufacture where the Circuit Breakers are being manufactured and the Bidder shall provide all facilities for unrestricted inspection of the Bidder/manufacturers works, raw materials, manufacture of all the accessories and for conducting necessary tests as detailed herein. The Employer reserves the right to insist for witnessing acceptance/routine testing of the bought out items. The 77

27.2 27.3

27.4

27.5

27.6

27.7

Bidder/manufacturer shall submit the routine test certificates of bought out items and raw material also, at the time of routine testing of the fully assembled breaker No material shall be dispatched from its point of manufacture unless the material has been satisfactorily inspected and tested. Bidders shall indicate the inspections and checks carried out at various stages of manufacture of the circuit breakers. Complete record of stage inspection would be kept by the Bidder/manufacturer and this record should be made available for inspection by the representative of the Employer. Bidder/manufacturer should indicate the manufacturing programme and the The Employer will have a right to depute inspecting officers during the manufacture of the equipment. The Employer reserves the right to carry out stage inspections at all stages, for which advance intimation shall be given and all necessary cooperation shall be rendered by the manufacturer. At the time of inspection, Bidder/manufacturer shall identify each and every item/accessories of the particular Circuit Breaker under testing. Unless all the items are identified, the manufacture will not be treated as complete. Various tests stipulated in IS/IEC shall be performed in the presence of the Employers engineers or when the inspection waiver has been given, in such a case, testing shall be done at the manufacturer's works as per IS/IEC stipulations and same should be confirmed by documentary evidence by way of Test Certificate which shall be got approved by the Employer. It is expected that before circuit breaker is finally offered for inspection, internal testing of the same for various important parameters are already done. Routine test report for such tests shall also accompany the letter of inspection call so that the Inspecting Officer at the time of inspection may verify the parameters brought out in the preliminary report. Details of all tests should be clearly brought out. In case for any reason, inspection is not completed or equipment is not found to be complete with all accessories as per confirmation given with the letter of inspection call, the Employer will reserve the right to recover complete cost of deputation of inspecting team to the works of the manufacturer. Acceptance of any quantity of circuit breaker & its accessories shall in no way relieve the successful bidder of his responsibility for meeting all the requirement of this specification and shall not prevent subsequent rejection if such equipments are later found to be defective.

28.0

RATING PLATES & SURFACE FINISH PAINTING & GALVANISING:28.1 Each circuit breaker shall be provided with a detailed rating plate. Details on the rating plate shall be as per ISS and shall also indicate manufacturer name, serial no., order no. and month & year of dispatch. 28.2 All interiors and exteriors of tanks, mechanism, enclosures, cabinets and other metal parts shall be thoroughly cleaned to remove all rust, scales, corrosion, greases or other adhering foreign matter. All steel surfaces in contact with insulating oil, as far as accessible, shall be painted with not less than two coats of heat resistant, oil insoluble, insulating paint. 28.3 All metal surfaces exposed to atmosphere shall be given two primer coats of zinc chromate and two coats of epoxy paint with epoxy base thinner or hot dip galvanized or two packs of aliphatic polyurethane finished paint. All metal parts not accessible for painting shall be made of corrosion resistant material. All machine finished or bright surfaces shall be coated with a suitable preventive compound and suitably wrapped or otherwise protected. Paints shall be carefully selected to withstand tropical heat and extremes of weather within the limits specified. 28.4 Paint shall not scale off or wrinkle or be removed by abrasion due to normal handling. All external paintings shall be as per shade no. 697 or any other suitable shade of IS:5 or polyurethane paint 28.5 All ferrous parts & steel structure including all sizes of nuts, bolts, plain and spring washers, support channels, structures, etc. shall be hot dip galvanized or stainless steel or electrogalvanized. DOCUMENTATION: 29.1 List of Drawings and Documents: Bidders shall furnish four sets of relevant descriptive and illustrative published literature, pamphlets and following drawings for preliminary study; (a) General outline drawings showing dimensions and shipping weights. (b) Sectional views showing the general constructional features of the circuit breaker including operating mechanism, arcing chambers, contacts with lifting dimensions for maintenance. (c) All drawings & data typical and recommended schematic diagram for control 78

29.0

supervision & reclosing shall be annotated in English. . (d) Schematic diagrams of breaker offered for control supervision and reclosing. (e) Structural drawing, design calculations and loading data for support structures. (f) Short circuit oscillogram & certificates for similar type tested breakers. General arrangement of foundation and structure mounting plan including weights of varnish components and impact loading data for foundation design. (g) Type test reports. 29.2 Successful bidders shall, within two weeks of placement of order, submit four sets of final version of all the above drawings for the Employer's approval. The Employer shall communicate his comments/approval on the drawings to the Bidder/manufacturer within two weeks. Bidder/manufacturer shall, if necessary, modify the drawings and resubmit four copies of the modified drawings for the Employer's approval within two weeks from the date of comments. After receipt of the Employer's approval, the Bidder/manufacturer shall, within three weeks, submit 4 prints per breaker and two set of good qualities reproducible of the approved drawings for the Employer's use. Successful bidders shall also furnish two sets each of bound manuals covering erection, commissioning, operation and maintenance instructions and all relevant information and drawings pertaining to the main equipment as well as auxiliary devices along with each breaker. Marked erection drawings shall identify the component parts of the equipment as shipped to enable erection by the Employers own personnel. Each manual shall also contain one set of all the approved drawings, type test reports as well as acceptance reports of the corresponding consignment dispatched. Manufacturing of equipments shall be strictly in accordance with the approved drawings and no deviation shall be permitted without the written approval of the Employer. Approval of drawings/work by the Employer shall not relieve the bidders of any of his responsibility and liability for ensuring correctness and correct interpretation of the drawings for meeting the requirements of the latest revision of the applicable standards rules and codes of practices. Equipment shall conform in all respects to high standards of engineering, design, workmanship and latest revisions of relevant standards at the time of supply and the Employer reserves the right to reject any equipment or material which, in his judgment, is not in full accordance therewith.

29.3

29.4 29.5

30.0

PACKING AND FORWARDING: 30.1 Equipment shall be prepared for ocean shipment (foreign equipment) or rail road transport (local equipment). Equipment shall be packed in suitable crates in such a manner to protect it from damage and withstand handling during transit. Bidder/manufacturer shall be responsible for and make good at his own expense any or all damage to the equipment during transit, due to improper and inadequate packing and handling. Easily damageable materials shall be carefully packed and marked with the appropriate caution symbols. Wherever necessary, proper arrangement for lifting such as lifting hooks etc. shall be provided. Any material found short inside the packing cases shall be supplied by the Bidder/manufacturer without any extra cost. Each consignment shall be accompanied by a detailed packing list containing the following information: (a) Name of the consignee. (b) Details of consignment. (c) Destination. (d) Total weight of consignment. (e) Sign showing upper/lower side of the crate. (f) Handling and unpacking instructions. (g) Bill of material indicating contents of each package and spare material.

79

31.0

COMPLETENESS OF EQUIPMENT AND BOUGHT OUT ITEMS: 31.1 Bidders must furnish following information along with technical bid. A list of all the accessories which will be supplied with the breakers should be furnished. While furnishing the list of accessories, items which will be manufactured by the Bidders and balance items, which will be procured from sub-Bidder/manufacturers should be clearly identified and stipulated in the bid. GUARANTEED TECHNICAL PARTICULARS: 32.1 It is obligatory on the part of bidders to furnish Guaranteed Technical Particulars enclosed with the bid document duly filled in complete in all respects. In case Guaranteed Technical Particulars duly filled in complete in all respects is not furnished, the bid may be treated as non-responsive. 32.2 The salient technical particulars of the VCB should be as follows: S N Type of Circuit Breaker Standards Applicable Nominal System Voltage (KVrms) Highest system voltage Rated continuous current at design temperature of 50 deg.C (Amps) Rated Frequency (Hz) Design ambient temperature Maximum temperature rise for main contacts over desugn ambient temperature of 50 deg.C Short time current rating (kA) Rated Operating Duty Vacuum ,Outdoor IEC 62271-100 & IS 13118 33 kV 36kV 1250A 50 50 deg 40 deg.C 25 kA for 3 sec 0-0.3 sec-CO-3 min-CO

32.0

Operating Mechanism a) Type of operating mechanism for i) Closing ii) Opening Dielectric withstand voltage i) One minute dry & wet power frequency withstand voltage a) Between live terminal and ground (kVrms) b) Between terminals with breaker contacts open (kVp) ii) 1.2/50 micro second impulse withstand test voltage a) Between live terminal and ground (kVp) b) Between terminals with breaker contacts open (kVp) 70 70 Spring Charging Spring Charging

170 170

80

3.4

TECHNICAL SPECIFICATION FOR 33 KV CONTROL AND RELAY PANELS FOR TRANSFORMERS & FEEDERS

1.0 SCOPE 1.1. This specification provides for design, engineering, manufacture, assembly, shop testing, inspection and testing at works, transport to site, insurance, storage, erection and commissioning of Control, Relay, Alarm and Annunciation Panels for 33/11 KV, Substations. 1.2. It is not the intent to specify completely herein all details of the design and construction of equipments. However, the equipment shall conform in all respects to high standards of engineering, design and workmanship and shall be capable of performing in continuous commercial operation acceptable to the purchaser, who will interpret in a manner the meanings of drawings and specifications and shall have the power to reject any material which in his judgment is not in accordance therewith. The equipment offered shall be complete with all components necessary for its effective and trouble free operation. Such components shall be deemed to be within the scope of Bidder's supply, irrespective of whether these are specifically brought out in this specification and/or the commercial order or not. 1.3. It may be noted that the Control & Relay Panels must meet the following minimum criteria. Failure to comply with the requirements may results in rejection of the BID as non-responsive: 1.3.1. The Manufacturer must have designed, manufactured, type tested and supplied Control 7 Relay Panels in at least two power utilities of similar rating which are in successful operation for at least 5 (Five) years as on the date of bid opening. Which should be substantiated by furnishing performance report by the official of the rank of minimum DGM/SE 2.0 STANDARDS All equipment provided under this specification shall in general conform to the latest revision/amendment etc. of the following: Sl No. 1 2 3 4 Standard IS: 3231, IEC 255 Part-I to III, BS: 89 IS: 1248; IS: 2419; BS: 89 IS-13010; IS: 722(Part-I to IX) IEC 521; BS 3T IS: 4237 Title Electrical relays for power system protection. Indicating instruments Energy meters General requirement of switchgear and control gear for voltages not exceeding 1 KV Marking arrangement for switchgear, busbars, main connection & auxiliary wiring. Specification for static protective relays and tests Control switches ( LV switching devices for control and auxiliary circuits) MCCB sand load break switches having a break capacity of 30 KVA rms at 415 V. Fuse switching units HRC fuse links Current transformers Potential transformers Factory built assemblies of switchgear & control gear for voltages upto & including 1000V AC & 1200 V DC Low voltage switchgear and control 81

IS: 375

6 7

IS: 8686, IEC-255 Part V &VI IEC 801-4 IEC 337; IEC: 337-1; IS: 6875

8.

IS: 2516

9 10 11 12 13

IS: 4047 IS: 2208 IS: 2705; IEC-185 IS: 3156; IEC: 186 IS: 8623

14

IEC: 439

15

IS: 4237

16

IS: 2147

17 18 19 20

IS: 5028 IS: 1897 IS: 3618; IS : 6005 IS: 4064

21 22 23

IS: 9224 Part II IS: 5578 IS: 2032

24

IEC

25

ISO

26

IS

gear assemblies General requirement of switchgear & control gear for voltages not exceeding 1000V Degree of protection provided by enclosures for low voltage switchgear and control gear Aluminium alloy bars Copper strips for electrical purpose Code of practice for phosphate Air break switches, air break disconnectors, air break disconnectors & fuse combination units for voltages not exceeding 1000 V AC or 1200 V DC. HRC cartridge fuses Guide for making of insulated conductors Graphical symbols Ref-abbreviations Name and Address Institution Electro Technical Bureau. Central dale commission Electro Technique International. 1. Rue de vermbe Geneva Switzerland International Organization for standardization. Danish Board of Standardization..Danish Standardizating Sruat Aurehoeqvaj-12 DK- 2990, Heel prup Denmark Bureau of Indian Standard Standards Manak Bhawan 9, Bahadur Shah Zafar Marg, New Delhi- 110 002, India.

2.1. Equipment meeting with the requirements of other authoritative Standards, which ensure equal or better performance than the standards mentioned above, shall also be considered. When the equipment offered by the Bidder conforms to other standards, salient points of difference between standards adopted and the standard specified in this specification shall be clearly brought out in the relevant schedule. Four copies of such standards with authentic translation in English shall be furnished along with the offer.

3.0 CLIMATIC CONDITIONS 3.1. The climatic and isoceraunic conditions at site under which the equipments shall operate satisfactorily under the tropical conditions specified in this bidding documents. 3.2. The reference ambient temperature assumed for the purpose of this specification are as follows: i. Maximum ambient temperature ii. Maximum average daily ambient temperature iii. Maximum average yearly ambient temperature 4.0 PRINCIPAL PARAMETERS 4.1. The details of Current Transformer are given below: : 40 C : 35 C : 30 C

82

Core No.

1 2 3

Minimum knee Purpose point voltage as per Formula 33 KV side Transformer CT Ratio: 200-100/5-5-5 A 5 P 20 20 VA ---O/L & E/F Protection PS ---Min. Vk = 100 V Transformer differential Max. Im= 0.03 A protection accurac 15 VA -----Metering y0.5, Instrume nt security factor < 5 33 KV side Feeder CTs Ratio: 400-200/5-5 A 11 KV side Transformer CT Ratio: 600-300/5-5 -2.89 A

Accurac y class

Burden

1 2 3

5 P 10 PS Accurac y 0.5

20 VA ---15 VA

---Min. Vk = 200 V Max. Im= 0.03 A ------

O/L & E/F Protection Transformer differential protection Metering

11 KV side Feeder CT Ratio: 400-200/5-5 A

4.2. Breakers for HV & LV sides of transformer HV side breaker : VCB, Outdoor LV (11KV ) side breaker : Vacuum type, Indoor/Outdoor Rating of closing coil & Trip coil : 110 V DC, Number of auxiliary contact : 6 N/O and 6 N/C Both HV & LV breakers are provided with two sets of trip coils( Each set common to all three phases) 5.0 Drawing, Manuals, Literatures etc. 5.1. The tenderer shall furnish along with his tender fully dimensioned drawings of the equipments offered, along with illustrated and descriptive literatures, for various component parts like relays, meters, control switches etc. to enable the purchaser for proper evaluation of the offer. The tenders shall also be accompanied with the schematic drawings showing protection, indicating metering schemes etc

5.2. Soon after the award of the contract and before proceeding with the manufacturing works, the successful tenderer shall furnish drawings in quadruplicate which shall include but not limited to the followings for approval of the purchaser: i) Principal layout drawings for the Boards showing the equipments on the panels with dimensions. A list of the equipments mounted on each panel shall be prepared and tabulated in the same drawings. The drawings shall also show the constructional details, foundation details indicating foundation bolts, cable entries etc.

ii) Elementary control drawings and other schematics for the equipments furnished, including protection, metering, annunciating and indicating circuit, breaker control ,circuits etc. All wires terminals shall be clearly marked and numbered as per general practice. iii) Single line and three line diagrams showing all AC and D.C power connections and all secondary connectors for relays, meters etc. iv) Internal wiring diagrams of all the panels and boards giving internal wiring connections for all the equipments in the panels. The drawings shall also clearly indicate the connections to be made at 83

site or to the external equipments or between boards etc. with wires terminals marked properly. v) After approval of the drawings the tenderer shall furnish six copies of the each of the final drawings along with the literatures, instruction manuals etc. for purchaser's reference.

5.3. In addition to the above the successful bidders shall supply three sets each of the following relevant equipments supplied to each substation: a. All final drawings mentioned above. b. Literature describing construction, operation, adjustment, testing, calibration, maintenance of all protective and auxiliary relays, instruments, control switches etc. c. List of spare parts giving identification numbers of the parts. 6.0 GENERAL TECHNICAL REQUIREMENT 6.1. Control & Relay panels: Detailed Description The control and relay panels shall be of Simplex type. Each Simplex panel shall consist of a vertical front panel with equipment mounted thereon and having wiring access from the rear. It shall have double leaf door with lift off hinges at the back for panels of width more than 800 mm. Doors shall have handles with built-in locking facility. 7.0 Constructional Features 7.1. Panels shall be completely metal enclosed and shall be dust, moisture and vermin proof. The enclosure shall provide a degree of protection not less than IP-51 in accordance with IS:2147. 7.2. Panels shall be free standing, floor mounting type and shall comprise structural frames enclosed completely with specially selected smooth finished, cold rolled sheet steel of thickness not less than 3 mm for weight bearing members of the panels such as bass frame, front sheet and door frames, and 2.0 mm for sides, door top and bottom portions. There shall be sufficient reinforcement' to provide level Surface resistance to vibration and rigidity during transportation and installation. 7.3. All doors, removable covers and panels shall be gaskets all around with neoprene gaskets. Ventilation louvers to be provided having screens and filters. The screens shall be made of brass wire mesh. 7.4. Design, materials selection and workmanship shall be such as to result in neat appearance inside and outside with no welds, rivets or bolt head apparent from outside, with all exterior surfaces true and smooth. 7.5. All necessary anchor bolts and other materials required for foundation of panels shall be supplied 7.6. Cable entries to the panel shall be from the bottom. The plates of the panel shall be fitted with removable gland plates for fixing the cable glands. Necessary number of cable glands of sizes to suit owner's external cables to the panels shall be supplied by the bidder. Cable glands shall be screwed type, and shall be suitable for PVC cables. Cable gland plate fitted in the bottom of the panel shall be connected to the earthing Panel / Station through a flexible braided copper conductor rigidly. 7.7. Relay panels of modern, modular construction would also be acceptable. 7.8. The total height of the panel shall be 2250 mm. The depth of the panel shall be 600 mm. The panels shall have suitable width required for mounting of all the equipments on the front panel. 7.9. The panels shall match with the existing panels in APDCL substations, the details of which will be furnished to the successful bidder. Matching includes height , depth of the panels, colour matching and mimic matching' and arrangement of equipment on the front.

8.0 Mounting 8.1. All equipment on and in panels shall be mounted and completely wired to the terminal blocks ready for external connection. The equipment on front of panel shall be mounted flush.

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8.2. Equipment shall be mounted such that removal and replacement can be accomplished individually without interruption of service to adjacent devices and are readily accessible without use of special tools. Terminal marking shall be clearly visible. 8.3. The contractor shall carry out cutouts, mounting and wiring of the free issue items supplied by others, if any which are to be mounted in this panel in accordance with the corresponding equipment manufacturer's drawings. Cutouts if any, provided for future mounting of equipment shall be properly blanked off. 8.4. The center lines of switches, push buttons and indicating lamps shall be not less than 750 mm from the bottom of the panel. The center lines of relays, meters and recorders shall be not less than 450 mm from the bottom of the panel. 8.5. The center lines of switches, push buttons and indicating lamps shall be matched to give a neat and uniform appearance. Likewise the top lines of all meters, relays and recorders etc., shall be matched. 8.6. No equipment shall be mounted on the doors. 8.7. All the equipment connections and cabling shall be designed and arranged to minimize the risk of fire and damage which may be caused by fire. 9.0 Panel Internal Wiring and Other Accessory Equipment 9.1. Panels shall be supplied completely. with interconnecting wiring provided between all electrical devices mounted and wired in the panels and between the devices and terminal blocks for the devices to be connected to equipment outside the panels. When panels are arranged to be located adjacent to each other all inter panel wiring and connections between the panels shall be furnished and the wiring shall be carried out internally. These adjacent inter panel wiring shall be clearly indicated in the drawing furnished by the contractor. 9.2. All wiring shall be carried out with 1100 V grade, single core, stranded copper conductor wires with PVC insulation and shall be heat resistant grade and vermin and rodent proof. The minimum size of the stranded copper conductor used for internal wiring shall be as follows: i) All circuits except current transformer and potential transformer circuits one multi strand 2.5 Sq. mm per lead ii) Current transformer circuit : one 4.0 Sq. mm per lead. The minimum number of strands per conductor shall be three. 9.3. All internal wiring shall be securely supported, neatly arranged, readily accessible and connected to equipment terminals and terminal blocks. Wiring gutters and troughs shall be used for this purpose. 9.4. Auxiliary bus wiring for AC and DC supplies, voltage transformer circuits, annunciation circuits and other common services shall be provided near the top of the panels running throughout the entire length of the panels. 9.5. Wire termination shall be made with solder less crimping type and tinned copper ring type lugs which firmly grip the conductor and insulation. Insulted sleeves shall be provided at all the wire terminations. Engraved core identification plastic ferrules marked to correspond with panel wiring diagram shall be fitted at both ends of each wire. Ferrules shall fit tightly on the wire and shall not fall off when the wire is disconnected from terminal blocks 9.6. All wires directly connected to trip circuit of breaker or device shall be distinguished by the addition or red coloured unlettered ferrule. Number 6 and 9 shall not be included for ferrule purposes. 9.7. Longitudinal troughs extending throughout the full length of the panel shall be preferred for inter panel wiring. Interconnections to adjacent panel shall be brought out to a separate set of terminal blocks located near the slots or holes meant for taking the inter connecting wires. Arrangements shall permit easy inter connections to adjacent panels at site and wires for this purposes shall be provided by contractor looped and bunched properly inside the panel. 9.8. The Successful bidder shall be solely responsible for the completeness and correctness of the internal wiring and for the proper functioning of the connected equipment. 10.0 Terminal Blocks 10.1. All internal wiring to be connected to the external equipment shall terminate on terminal blocks preferably vertically mounted on the side of each panel. Terminal blocks shall be 1100 V grade and 85

have 10 amps continuous rating ,complete with insulated barriers, stud type terminals, washers, nuts and lock nuts. Terminal block design shall include a white fibre markings strip with clear plastic slip-on terminal covers. Markings on the terminal strips shall correspond to wire number and terminal numbers on the wiring diagrams. 10.2. Terminal blocks for current transformer and voltage transformer secondary leads shall be provided with test links and isolating facilities. Also current transformer secondary leads shall be provided with short-circuiting and earthing facilities. 10.3. At- least 20 % spare terminals shall be provided on each panel and these spare terminals shall be uniformly distributed on all terminal blocks. 10.4. Unless otherwise specified. terminal blocks shall be suitable for connecting the following conductors of purchasers cable on each side i. ii. All circuits except current and potential transformer circuits : minimum of one of 2.5 sq.mm copper. All CT and PT circuits: minimum of two of 4.0 mm square copper.

10.5. There shall be a minimum clearance of 250 mm between the first row of terminal blocks and associated cable gland plate. Also the clearance between two rows of terminal blocks shall be minimum, of 150 mm. 10.6. Arrangement of the terminal block assembles and the wiring channel within the enclosure shall be such that a row of terminal blocks is run parallel and in close proximity along each side of wiring duct to provide for convenient attachment of internal panel wiring. The side of the terminal block opposite the wiring duct shall be reserved for purchaser's external cable connection. An adjacent terminal block shall also share this fired wiring corridor. A steel strip shall be connected between adjacent terminal block rows at 450 mm intervals for support of incoming cables. 10.7. The number and sizes of the Purchaser's multi-core incoming cable will be furnished to the Contractor after placement of the order. All necessary cable terminating accessories such as gland plates, packing glands, crimp type tinned copper lugs supporting clamps .and brackets, wiring troughs and gutters etc., for purchaser's cable shall be included in contractor's scope of supply. 11.0 Painting 11.1. All sheet steel work shall be phosphated, in accordance with the 18:6005 "Code of Practice for phosphating iron and steel". Oil, grease, dirt and sweat shall be thoroughly removed by emulsion cleaning. Rust and scale shall be removed by picking with dilute acid followed by washing with running water rinsing with a slightly alkaline hot water and drying. 11.2. After phosphating thorough rinsing shall be carried out with clear water followed by final rinsing with dilute dichromate solution and oven drying. The phosphate coating shall be sealed with application of two coats of ready mixed, stoved type zinc chromate primer. The first coat may be "flash dried" while the second coat shall be stoved . 11.3. After application of the primer, two coats of finishing synthetic enamel paint shall be applied, each coat followed by stoving. The second finishing coat shall be applied after completion of tests. The exterior Colour of the paint shall be selected by the purchaser at a later date. 11.4. Each coat of primer and finished paint shall be of a slightly different shade to enable inspection of the painting. The powder coat paint shade should Air Craft Grey (IS : 5) and thickness of 50-60 microns. A small quantity of finished paint shall be supplied for minor touching up required at site after installation of the panels. 11.5. In case the bidder proposes to follow any other established painting procedure like electrostatic painting, the procedure shall be submitted along with offer/bid for purchaser's review and approval. 12.0 Mimic Diagram 12.1. 12.2. Coloured mimic diagram and symbols showing the exact representation of the system shall be provided in the front of control panels. Mimic diagram shall be made preferably of anodized aluminum or plastic of approved fast Colour material which shall be screwed on to the panel and can be easily cleaned. Painted overlaid mimic

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is also acceptable. The mimic bus shall be 2 mm thick. The width of the mimic bus shall be 10 mm for bus bars and 7 mm for other connections. 12.3. 12.4. 12.5. 13.0 Mimic bus Colour will be decided by the Purchaser and shall be obtained from the Purchaser by the successful Bidder. When semaphore indicators are used for isolator position they shall be so mounted in the mimic that the isolator closed position shall complete the continuity of mimic. Indicating lamp, one for each phase for each bus shall be provided on the mimic to indicate bus charged condition.

Name Plates and Markings 13.1. All equipment mounted on front and rear side as well as equipment mounted inside the panels shall be provided with individual nameplates with equipment designation engraved. Also on the top of each panel, on front as well as rear side, large and bold nameplates shall be provided for circuit/feeder designation. AlI front mounted equipment shall be also provided at the rear with individual name plates engraved with tap numbers corresponding to the one shown in the panel internal wiring to facilitate easy tracing of the wiring. The nameplates shall be mounted directly by the side of the respective equipment in a visible manner and shall not be hidden by the equipment wiring. Nameplates shall be made of non-rusting metal or any other suitable material. Nameplates shall be black with white engraving lettering. The nameplates inscription and size of nameplates and letters shall be submitted to the purchaser for approval. Each instrument and meter shall be prominently marked with the quantity measured e.g. kV, A, MW, etc. All relays and other devices shall be clearly marked with manufacturer's name, manufacturer's type, serial number and electrical rating data. Each switch shall bear clear inscription, identifying its function e.g. "BREAKER" ,"52 A, "AMMETER" etc. Similar inscriptions shall also be provided on each device whose function is not otherwise identified. If any switch device does not bear this inscription separate name plate giving its function shall be provided for it. Switch shall also have clear inscription for each position indicating e.g. "TRIP-NEUTRAL-CLOSE", "ON-OFF", "R-Y-B-N:-OFF", etc.

13.2.

13.3.

13.4.

13.5.

14.0

Miscellaneous Accessories and Supporting Steel 14.1. 14.2. Plug point- An AC 240 Volts, single phase, 5A, 50 HZ AC plug point shall be provided in the interior of each cubicle with "ON-OFF" Switch for connection of hand lamps. Interior lighting: Each panel shall be provided with a CFL lighting fixture rated for 240 volts, single phase, 50 HZ supply for the interior illumination of the panel during maintenance. The fittings shall be complete with switch fuse unit and switching of the lighting shall be controlled by the respective panel door switch. One DC emergency lamp is to be fitted and should be complete with switch fuse unit. Each control panel shall be provided with necessary arrangements for receiving, distributing, isolating and fusing of DC and AC supplies for various control signaling, lighting and space heater circuits. MCBs for the incoming circuits and fuses for sub-circuits shall be provided. Selection of the main and sub-circuit fuse rating shall be such as to ensure selective clearance of sub-circuit faults. Potential circuit for relaying and metering shall be protected by fuses. All fuses shall be HRC cartridge type conforming to IS : 2208 mounted on plug-in type fuse bases. All accessible live connection to fuse bases shall be adequately shrouded. Fuses shall have operation indicators for indicating blown fuse condition. Fuse carrier base shall have imprints of the fuse rating and voltage. Supporting Steel: All necessary foundation anchor bolts and other parts of supporting and fastenings, of the panels shall be supplied by the contractor.

14.3. 14.4.

14.5. 15.0

Earthing 15.1. All panels shall be equipped with an earth bus securely screwed. Location of earth bus shall ensure no radiation interference for earth systems under various switching conditions of isolators and breakers. The material and the sizes of the bus bar shall be at least 25 x 6 mm copper flat.

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15.2. When several panels are mounted adjoining each other, the earth bus shall be made continuous and necessary connectors and clamps for this purpose shall be included in the scope of supply of contractor. Provision shall be made for extending the earth bus bars to future adjoining panels on either side. 15.3. Provision shall be made on each earth bus bars of the end panels for connecting purchaser's earthing grid. Necessary terminal clamps and connectors for this purpose shall be included in the scope of supply of contractor. The wire or screens should be clearly bonded and earthed at the gland plate. 15.4. All metallic cases of relays, instruments and panel mounted equipment shall be connected to the earth bus preferably by independent copper wires of size not less than 2.5 Sq.mm. The colour code of earthing wires shall be green. Earthing wire shall be connected on terminals with suitable clamp connectors and soldering shall not be permitted. 15.5. Looping of earth connections which would result in loss of earth connection to other devices where the loop is broken shall not be permitted. However, looping of earth connections between equipment to provide alternative paths to earth bus shall be provided. 15.6. VT and CT secondary neutral or common lead shall be earthed at one place only at the terminal blocks where they enter the panel. Such earthing shall be made through links so that earthing may be removed from one group without disturbing continuity of earthing system for other groups. 16.0 Metering Instruments: Instruments and Meters 16.1. All instruments, meters, recorders and transducers shall be enclosed in dust proof, moisture resistant, black finished cases and shall be suitable for tropical use. They shall be calibrated to read directly the primary quantities. They shall be accurately adjusted and calibrated at works and shall have means of calibration, check and adjustment at site. All accessories including test switches and test plugs, where applicable shall be furnished. Their elements shall be shock resistant and shielded from external magnetic fields. 16.2. . Ammeters:

16.2.1. All ammeters shall be of digital type and provided with direct reading triple range scale. Scale value of ammeters shall be equal to 1 to 1.3 times the rated primary current of the associated current transformer feeding it. The rated current shall be 5.0 Amp. Accurate reading of ammeter shall be possible at the lowest limit of 5 % of the rated current. Accuracy class 1.0 or better as per IS: 1248 16.3. Voltmeter:

16.3.1. All voltmeters shall be of digital type direct reading scale. The maximum scale value of voltmeters shall be 50% in excess of the primary voltage of the associated PTs. The rated voltage of the voltmeter shall be 110 volts A.C., accuracy class 1.0 or better as per IS: 1248. 16.4. Watt meters

16.4.1. Digital watt meters wherever specified shall be 3 phase, 4 wire three element type provided with direct reading scales. The scale values of wattmeter shall be as per ratio of the measuring cores of respective CTs and PTs. The current coils shall be rated for 5/1 ampere and voltage coils for 110 volt continuous. The wattmeters shall be suitable for circuits with unbalanced loads to be usually met with in commercial service. Accuracy class will be 1.0 or better as per IS: 1248. 16.5. Energy Meters : 16.5.1. Energy meters shall be static type conforming to IEC 687 and suitable for bi-directional power flow. The static meter shall measure active and reactive energy both import and export, by 3 phases 4 wire principle suitable for ba1anced / unbalanced 3 phase load. Accuracy of meter shall. be 0.5for active energy and 0.5 for reactive energy. The active and reactive energy shall be directly computed in CT & VT primary values and stored in four different registers as MWH (E), MWH(I), MVARH (E) and MVARH (I) along with a plus sign for export and minus sign for import. CT secondary is 5 A the appropriate ratios of meters shall compute the energy sent out/received, from/to the station bus bar during each successive 15 minute block and store in the respective registers. Meter shall display on demand the energy sent out! received during the previous 15 minute block. Further the meter shall continuously integrate the energy readings of each register upto that time. All these readings shall be displayed on demand. Cumulative reading of each register shall be stored in non-volatile memory at the end of each hour of day starting from 01 hours. These readings shall be stored for a period of 40 days before being erased. The static meter shall have built in clock and calendar having an accuracy of 1 minute per month or better. Date / time shall be displayed on demand. 88

16.5.2. Each meter shall have a unique identification code provided by purchaser and shall be marked permanently on the front and also on the non-volatile memory. The voltage monitoring of all the three voltages shall be provided. 16.5.3. The meter shall normally operate with power drawn from VT supplies. Power supply to the meter shall be healthy even with a single phase VT supply. An automatic back up shall be provided by a built in life time battery and shall not need replacement for at least ten years with a continuous VT interruption of even two years. Date and time of VT interruption and restoration shall be automatically stored in non-volatile memory. 16.5.4. The meter shall have an optical port at the front of the meter for data collection by a hand held device. The meter shall have means to test MWH accuracy and for connecting it to time of day tariff equipment. 16.5.5. The meter should have optical port for local communication. RS 232 and RS 485 port should be incorporated along with Ethernet port. 16.5.6. The bidder is to provide the software for meter for downloading and up loading to base computer along with one hand held common meter reading instrument along with software. 16.5.7. The meter should preferably be either Secure or L & T make as per APDCLs specification. 17.0 Relays: 17.1. All relays shall conform to the requirements of IS:3231 or other applicable approved standards. Relays shall be suitable for flush or semi flush mounting on the front with connections from the rear. Relays shall be rectangular in shape and shall have dust tight, dull' black or egg shall black enamel painted cases with transparent cover removable from the front. 17.2. All protective relays shall be in draw out or plug-in type / modular cases with proper testing facilities. The testing facilities provided on the relays shall be specifically stated in the bid. Necessary test plugs shall be supplied loose and shall be included in Contractor's scope of supply. Test block and switches shall be located immediately below each relay for testing. As an alternative to test block and test plug arrangements the Bidder shall also quote alternative testing facility of protective relays by providing a push button which when pressed connects the testing equipment to the relay coils and injects current in the coil and automatically disconnects the trip circuits and on operation of relay gives a signal that the equipment and the circuits are correct. 17.3. The purchaser reserves the right for accepting anyone of the above two testing facilities. Unless otherwise specified all auxiliary relays and timers shall be supplied in non-draw out cases/plug in type modular cases. 17.4. All AC relays shall be suitable for operation at 50 Hz AC Voltage operated relays shall be suitable for 110 Volts VT secondaries and current operated relays for 5 Amp CT secondaries as specified in this specification. DC auxiliary relays and timers shall be designed for 110 V DC voltage and shall operate satisfactorily between 70 % and 110% of rated voltage. Voltage operated relays shall have adequate thermal capacity for continuous operation. 17.5. The protective relays shall be suitable for efficient and reliable operation of the protection scheme described in the specification. Necessary auxiliary relays and timers required for interlocking schemes for multiplying of contacts/suiting contact duties of protective relays and monitoring of control supplies and circuits, lockout relay monitoring of circuits etc., and also required for the complete protection schemes described in the specification shall be provided. 17.6. All protective relays shall be provided with at least two pairs of potential free isolated output contacts. Auxiliary relays and timers shall have pairs of contacts as required to complete the scheme. Contacts shall be silver faced with spring action. Relay cases shall have adequate number of terminals for making potential free external connections to the relay coils and contacts including spare contacts. Relay case size shall be so chosen as not to introduce any limitations on the use of available contacts on the relay due to in-adequacy of terminals. Paralleling of contacts, if any, shall be done at the terminals on the casing of the relay. 17.7. All protective relays, auxiliary relays and timers except the lock out relays and interlocking relays specified shall be provided with self-reset type contacts. All protective relays and timers shall be provided with externally hand reset positive action operation indicators, provided with inscription, subject to purchaser's approval. All protective relays which do not have built in hand reset operation indicators shall have additional auxiliary relays with operating indicators for this purpose. Similar

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separate operating indicator (auxiliary relays) shall also be provided in the trip circuits of protections located outside the board such as bucholz relays, temperature protection, fire protection. etc., 17.8. Timers shall be done of the electromagnetic or solid state type. Pneumatic timers are not acceptable. Short time delays in terms of milliseconds may be obtained by using copper slugs on auxiliary relays. In such case it shall be ensured that the continuous rating of the relay is not affected. Time delay in terms of milliseconds obtained by the external capacitor resistor combination is not acceptable. 17.9. No control relay which shall trip the power circuit breaker when the relay is de-energized shall be employed in the circuits. 17.10. Provision shall be made for easy isolation of trip circuits of each relay for the purpose of testing and maintenance. 17.11. All relays shall withstand a test voltage 2.5 kVrms voltage,50Hz for one second.

17.12. Auxiliary seal-in-units provided on the protective relays shall preferably be of shunt reinforcement type. If series relays are used the following, shall be strictly ensured: i. The operating time of the series seal-in-unit shall be sufficiently shorter than that of the trip coil or trip relay in series with which it operates to ensure definite operation of the flag indicator of the relay.

ii. Seal-in-unit shall obtain adequate current for operation when one or more relays operate simultaneously. iii. Impedance of the seal-in-unit shall be small enough to permit satisfactory operation of the trip coil on trip relays when the DC supply voltage is minimum. 17.13. All protective relays and alarm relays shall be provided with one extra isolated pair of contacts wired to terminals exclusively for purchaser's use. 17.14. For numeric relays the following requirements shall be met with :

17.14.1. Numerical relay shall have both RS 485 and RS 232 communication ports. And ten numbers digital IO. Relay software is required. 17.14.2. The numerical relays shall be completely numerical with protection elements realized using software algorithm. 17.14.3. The relay should have high immunity to electrical and electromagnetic interference. Relay should confirm to following mandatory type test for safe operation of relay : a. b. c. d. e. High frequency disturbance test as per IEC 610 4-1 Fast transient disturbance test as per IEC 61000 4-4 Electrostatic discharge as per IEC 61000 4-2 Radio frequency interference as per ANSI C 37.90.2 Impulse test as per IEC 6100 4-3

18.0 Annunciation System: 18.1. Alarm annunciation system shall be provided for the control board by means of visual and audible alarm in order to draw the attention of the operator to the abnormal operating conditions or the operation of some protective devices. The annunciation equipment shall be suitable for operation with 110 V DC voltage. 18.2. The visual annunciation shall be provided by annunciation facia, mounted flush on the top of the panels. The audible alarm shall be provided by alarm buzzer and bell for trip and non-trip alarm respectively. 18.3. The annunciator fascia shall be provided with translucent plastic window for alarm point with minimum size of 35 mm x 50 mm. The facia plates shall be engraved in black lettering with respective inscriptions which will be furnished to the Bidder by the purchaser. Alarm inscriptions shall be engraved on each window in not more than three lines and size of the let6tering shall not be less than 5 mm.

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18.4. Each annunciation window shall be provided with two white lamps in parallel to provide safety against lamp failure. Long life lamps shall be used. The lamp circuit shall include series resistor of adequate rating. The cover plate of the facia windows shall be flush with the panel and shall be capable of easy removal to facilitate replacement of lamps. The transparency of cover plates and wattage of the lamps provided in the facia windows shall be adequate to ensure clears visibility of the inscriptions in the control room having high illumination intensity (500 lux) from the location of the operator's desk. 18.5. TRIP AND NONTRIP facia shall be differentiated. All TRIP facia shall have red colour and all NONTRIP facia shall have white colour. Sl. No. 1 2 3 4 5 Alarm condition Normal Abnormal Acknowledge push button is pressed Reset push button is pressed Lamp test push button pressed Fault contact Open Close Close open Close Open Visual Annunciation Off Flashing Steady on Steady on On Steady on Audible Annunciation Off on Off Off Off Off

18.6. Visual and audible annunciation for the failure of DC supply to the annunciation system shall also be provided and this annunciation shall operate on 240 volts AC supply with separate fuses. On failure of the power supply to the annunciation system for more than 3 seconds (adjustable setting) an indicating lamp shall light up and a bell shall sound. A separate push button shall be provided for cancellation of this audible alarm alone but the indicating lamp shall remain steadily lighted till the supply to the annunciation system is restored. The sound of the audible alarm (bell) provided for this annunciation shall be different from the audible alarm provided for this annunciation system. 18.7. A separate voltage check relay shall be provided to monitor the failure of supply (240 V AC) to the scheme mentioned above. If the failure of supply exists for more than 2 to 3 seconds, this relay shall initiate visual and audible annunciation. The annunciation system described above shall meet the following additional requirements. 18.8. The annunciation system shall be capable of catering to all simultaneous signals at a time. i) One self resetting push button shall be provided on each panel for testing in fascia window lamps. Push buttons for testing flasher and audible alarm circuit of annunciation supply failure monitoring shall also be provided. These testing circuits shall be so connected that while test is being done it shall not prevent the registering of any new annunciation that may land during the test.

iii) One set each of the following push buttons shall be provided on each panel. a) Reset push button for annunciation system; b) Accept push button for annunciation system. iv) The annunciation shall be repetitive type and shall be capable of registering the fleeting signal. For fault contacts which open on a fault, it shall be possible at site to change annunciators from "close to fault" and vice versa. v) The annunciator shall be suitable for operation with normally open fault contacts which close on a fault. For fault contacts which open a fault, it shall be possible at site to change annunciators from "close to fault" and vice versa. vi) Only electro-magnetic relay type alarm and annunciation relay schemes are acceptable and static type annunciation schemes are not acceptable. Contactors are not acceptable for annunciation system. 19.0 Switches 19.1. Control and Instrument switches shall be rotary operated type with escutcheon plates clearly marked to show operating position and circuit designation plates and suitable for flush mounting with only switch front plate and operating handle projecting out. Handles of different shapes and suitable inscriptions on switches aS per clause 6.8 shall be provided as on aid switch identification.

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19.2. The selection of operation handles for the different types of switches shall be as follows: 1 2 3 4 19.3. Breaker & isolator switches Selector switches Instrument switches Protection transfer switch Pistol grip, black Oval or knob, black Round, knurled, black Pistol grip, lockable & black

The control switch of breaker and isolator shall be of spring return to neutral type. The spring return type shall be provided with target which shall indicate the last operation of the switch. The control springs shall be strong and robust enough to prevent inadvertent operation due to light touch. The spring return type switch shall have spring return from close and trip positions to "after close" and "after trip" positions respectively. Instrument selection switches shall be of maintained contact (stay put) type. Ammeter selection switches shall make-before-break type contacts so as to prevent open circuiting of CT secondaries when changing the position of the switch. They shall be of 5 position type viz R-Y-B-N-Off. Voltmeter transfer switches for AC shall be suitable for reading all line-to-line and line-to neutral voltages for non-effectively earthed systems and for reading all line to line voltages for effectively earthed systems . Lockable type of switches which can be locked in particular positions shall be provided when specified. The key locks shall be fitted on the operating handles. The contacts of all switches shall preferably open and close with snap action to minimize arcing. Contacts of switches shall be spring assisted and contact faces shall be with rivets of pure silver. Springs shall be used as current carrying parts. The contact combination and their operation shall be such as to give completeness to the interlock and function of the scheme. The contact rating of the switches shall be as follows: Contact Rating in Amps a) Make and carry continuously b) Make and carry for 0.5 Sec. c) Break i) Resistive load ii) Inductive load with L/R= 40 110 V DC 10 30 3 0.2 240 V AC 10 30 7 7

19.4.

19.5. 19.6.

19.7.

20.0 Indicating Lamps 20.1. Indicating lamps shall be panel mounting type with rear terminal connections. Lamps shall be of LED type. Lamps shall have translucent lamp covers to diffuse light coloured red, green, amber, dear white or blue as specified. The lamp cover shall be of screwed type, un-breakable and moulded from heat resisting material. 20% of lamps actually used on the boards and 10% of the lamp bases of various colour actually used shall be supplied in excess to serve as spares. The wattage and resistance of the lamps shall be as follows: 110 V -5 to 7 W - 1000 to 2000 Ohms Bulbs and lenses shall be interchangeable and easily replaceable from the front of the panel. Tools, if required for replacing the bulbs and lenses shall also be included in the scope of supply. The indicating lamps with resistors shall withstand 120% of rated voltage on a continuous basis.

20.2. 20.3. 20.4. 21.0

Position Indicators 21.1. Position indicators of 'SEMAPHORE' type shall be provided when specified as part of the mimic diagrams on panels for indicating the position of circuit breakers, isolating/earthing switches etc. The indicator shall be suitable for semi-flush mounting with only the front disc projecting out and with terminal connection from the rear. Their strips shall be of the same colour as the associated mimic. 21.2. Position indicator shall be suitable for either AC or DC operation as specified. When the supervised object is in the closed position, the pointer of the indicator shall take up a position in line with the

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mimic bus bars, and at right angles to them when the object is in the open position. When the supply failure to the indicator occur the pointer shall take up an intermediate position to indicate the supply failure. The rating of the indicator shall not exceed 2.5 W. 21.3. The position indicators shall withstand 120% of rated voltage on a continuous basis.

22.0 Trip Circuit Supervision Relays 22.1. Trip circuit shall be supervised by means of relays. The scheme shall continuously monitor each trip coil in both pre-close and post-close of the breaker. The scheme shall detect. i) Failure of DC supply to each trip coil. il) Open circuit of trip circuit wiring and iii) Failure of mechanism to complete the tripping operation. 22.2. Also 2 Nos. indicating lamps to act in conjunction with trip circuit supervision relays for healthy trip indication of 2 sets of trip coils shall be supplied. 22.3. Necessary external resistors for trip circuit supervision relays shall be supplied. 23.0 Flag Relays Shall Have i) ii) iii) Hand reset flag indication Two elements Have necessary NO/NC contacts for each element/coil to meet scheme requirements.

24.0

Detailed Description of Protections The protection, auxiliary relay and timers and other equipment that are required to be provided are included in the detailed equipment schedule of panels vide Annexure.-I of this specification The detailed description of Back up protection and the associated equipment is described below: The setting ranges of relays given in specification are indicative. The setting ranges of the equipment offered, if different from the ones specified, shall also be acceptable if they met the functional requirements. The bidder shall quote the protection equipment, meeting the following requirements. 33/11 KV, TRANSFORMER a) Differential Protection : It shall have i) Triple pole high speed percentage biased differential type. ii) An operating time not more than 30 milli Secs. At 5 times operating current setting of 20%. iii) Three instantaneous high set over current units iv) Second harmonic restraint feature and fifth harmonic by pass/restraint feature and also be stable under normal over fluxing conditions. v) an operating current setting of 20% or less, vi) Suitable for rated current of 5A and 1 Ampere vii) Adjustable bias setting range of 20% to 50% viii) Two bias windings per phase ix) Stable on heavy through faults x) Include necessary separate interposing CTs for angle and ratio correction or have internal features in the relay to take care of angle and ratio correction. xi) Shall be of numerical type. b) Over current and earth fault protection for transformer

The relay should be triple pole non-directional with IDMT characteristics. It should either be numeric or electromagnet type, however offer for Areva make Micom series of relay will be preferred. c) Auxiliary relays for transformer protection devices

93

Auxiliary relay required for bucholtz trip and alarm, HV winding temperature trip & alarm, LV winding temperature trip & alarm, oil temperature alarm & trip and low oil level alarm, PRV trip, shall be provided. Each auxiliary relay shall have 2 pairs of contacts and one hand reset flag indicators. The auxiliary relays may be of non-draw out type d) Inter Tripping Relays

1 No. inter trip relay to trip HV and LV breakers of the transformer and to isolate the transformer from supply shall be supplied. The inter trip relay shall be of high speed and shall be provided with hand reset operation indicator and 4 NO + 2 N/C hand reset contacts for 33 KV breaker and 13 NO + 3 N/C hand reset contacts for 11 KV breaker. The protection scheme shall function as follows: a) Differential relays operated: both HV, and LV breakers trip. b) OIC & E/F on HV operated: both H.V and LV breakers trip. c) Buchholz Relay Operated: both HV & L.V. breakers trip. d) Winding temperature trip contact closed: both HV & LV. breakers trip. e) Oil temperature - alarm only. f) PRV Operated: both HV & L.V. breakers trip. 24.1. Relay and Control Panels for 33 kV Feeders Following meters, relays etc shall be provided in the feeder panel, However. any other items which are not specifically mentioned in this specification but are required to complete the scheme and for satisfactory operation of scheme shall also be deemed to be included in this specification. 1) PROTECTIVE RELAYS: Over current relay 2 Nos Earth fault relay 1 No Relays for OIC and E/F protection shall I. be of numeric non-directional type II. be of triple pole type with two outer elements for O/C and the other for-E/F protection. III. be with IDMT characteristics with a definite minimum time of 3 sec at 10 times settings. IV. have a variable setting range of 50-200% for over current and 20-80% for earch fault. V. be rated for 5/1 ampere VI. include hand reset flag indicator

2)

INSTRUMENTS AND METERS Following meters and instruments shall be provided in the panel: One no. Ammeter Digital Type One no. Voltmeter Digital Type One no Watt meter of digital type Electronic Trivector meter ( as per specification) CONTROLS Following control switches shall be provided in the panel: One no., three position (i.e. trip-neutral-close) breaker control switch. One no. Ammeter- selector switch. Push button for trip circuit healthy indication. Selector switch for voltmeter INDICATION AND ALARMS Following indicating arrangement shall be provided in the feeder panel: Indicating lamps for CB ON/OFF positions 2 nos. Indicating lamp for TRIP CIRCUIT HEALTHY CONDITION 2 No Indicating lamp labeling Breaker Spring changed 1 No Indicating lamp for Auto-trip indication 1 No.

a) b) c) d) 3)

a) b) c) d) 4) a) b) c) d)

94

e)

Mimic diagram indicating the relevant position of the single Line diagram of the sub-station incorporating the Semaphore Indicators for circuit breakers Semaphore indicator for Isolators And for Earth switch

1 No. 2 Nos. 1 No.

25.0 AUXILIARY SUPPLY Auxiliary supplies which shall be made available in substation are as follows: a) A.C. supply 415 V/240 volts, 50Hz three/single phase b) D.C. supply: 110 Volts 26.0 INSPECTION Inspection may be carried out by the purchaser or third party nominee at any stage of manufacture. The supplier shall grant free access to the purchaser's representative or third party nominee at a reasonable time when the work is in progress. Inspection and acceptance of any equipment under this specification by the purchaser shall not relieve the supplier of his obligation of furnishing equipment in accordance with the specification and shall not prevent subsequent rejection if the equipment is found defective.

95

3.5

TECHNICAL SPECIFICATION FOR 11kV INDOOR VACUUM SWITCHGEAR

1.0 SCOPE 1.1. This specification covers the manufacture, testing at manufactures works, transport to site, insurance, storage, erection and commissioning of indoor 11 KV ,9 unit Panel switch boards which includes 11KV circuit breakers with current transformers, voltage transformers, protective devices, protective relays measuring instruments and meters etc. and wired complete with all accessories as specified. 1.2. It may be noted that the 11 KV Indoor Vacuum Switchgear must meet the following minimum criteria. Failure to comply with the requirements may results in rejection of the BID as non-responsive: 1.2.1. The Manufacturer must have designed, manufactured, type tested and supplied 11 KV Indoor Vacuum Switchgear in at least two power utilities of similar rating which are in successful operation for at least 5 (Five) years as on the date of bid opening. Which should be substantiated by furnishing performance report by the official of the rank of minimum DGM/SE 2.0 STANDARD 2.1. Latest issues of the following standards shall be applicable. I.S. 13118 I.S. 2705 I.S. 3156 I.S. 2099 I.S. 335 I.S. 1554 I.S. 3231 I.S. 1248 Circuit Breakers Current transformers Voltage transformers Porcelain Bushing, High Voltage Insulating oil Cables Electrical relays for power system protection Electrical indicating instruments.

3.0 DRAWINGS, MANUALS, LITERATURES ETC. 3.1. The successful tenderer shall be required to submit to the purchaser for his approval five copies of drawings and other details which include bue not limited to the following:a) General out line drawings with full dimensions. b) Detailed drawings showing the mounting arrangement of the switchboards, provisions for cable entries etc. c) Detailed drawings showing the provisions kept for extension of the switchboards. d) List of all component parts, fittings and accessories of the switchboards with makers name, type, ratings etc. e) A.C. and D.C. schematic and wiring diagrams. 3.2. After approval of drawings the tender shall submit to the purchaser for the reference and record five copies of the above drawings including the following leaflets / manuals (in sic copies): a) Instruction books / operation and maintenance manuals for circuit breaker and other component parts. b) Descriptive literature/leaflets on construction and other details of circuit breakers and other component parts. 3.3. In addition to the above successful tenderer shall supply three sets of all the above final drawings, literatures, manuals etc under a common cover with each and every sets of switchboard. All the above drawings, literatures, manuals etc. shall from a part of the contract. 4.0 TECHNICAL SPECIFICATION: 4.1. The switchboard shall be metal enclosed, floor mounting, single front self supporting cubical type suitable for indoor. The switchgear shall be easily extendable in future. 4.2. The switchgear assembly shall be designed for the power system having the following parameters. a). Nominal system voltage: 11KV b). Highest system voltage: 12KV c). Frequency: 50 Hz. d). System earthing: Solidly earthed neutral e). System fault level: 250 MVA f). Degree of protection of switchgear assembly: 1PH3 as per IS: 3427 96

5.0 CONSTRUCTIONAL FEATURES: 5.1. The 11 KV switchgear panels shall be made of stretched leveled steel plates of thickness not less than 3 mm and structural steel having light sections. 5.2. The steel panel and frame work shall have rigorous surface treatment before application of suitable primer and two coats of paints, painting shall be a anti-corrosive and anti-condensive type. 5.3. Each panel shall be divided into independent compartment completely isolated from one another to house the circuit breaker, instruments, relay, bus bar, cable boxes etc. The front compartment housing the breaker shall be such that the breaker can be taken out only when it is in open condition. 5.4. The switchgear boards shall have a single front, single tier, fully compartmentalized, metal enclosed construction, comprising of row of freestanding floor mounted panels. Each circuit shall have a separate vertical panel with distinct compartments for circuit breaker ,cable termination, main busbar and auxiliary control devices. The adjacent panels shall be completely separated by steel sheets except in busbar compartments where insulated barriers shall be provided to segregate adjacent panels. However, manufacturers standard switchgear design without internal barriers in busbar compartment may also be considered. 5.5. The circuit breakers and bus PTs shall be mounted on withdrawable trucks, which shall roll out horizontally from service position to isolated position. The breaker truck shall be floor mounted so that it can easily be pulled out on the control room floor and the help of trolly etc. are not to be utilized. 5.6. The switchgear assembly shall be dust, moisture, rodent and vermin proof, with the truck in any position SERVICE, ISOLATED, TEST or removed, and all doors and covers closed. All doors, removable covers and glass windows shall be gasketted all round with synthetic rubber or neoprene gaskets. 5.7. The bus VT/relay compartments shall have degree of protection not less than IP : 52 in accordance with IS:2147. However, remaining compartments can have a degree of protection of IP:42. All louvers if provided shall have very fine brass or GI mesh screen, IPH-2 degree of protection as per IS: 3427 to all live parts shall (whether isolated or removed from panel) even when the breaker compartment door is open. Tight fitting garments / gaskets are to be provided at all openings in rely compartment. 5.8. Circuit breaker shall be vacuum; draw out type housed in a separate cubicle of the switchboard and shall be enclosed from all sides. A sheet steel hinged lockable door shall be at the front. It shall be possible to withdraw the circuit breaker to Test and Isolated position with the door closed. Door interlock shall be provided such that the door can only be opened after withdrawing the breaker to Isolated position and the breaker cannot be racked into the Service position unless the door is closed. A visual indication as to show when the breaker is in Service, Test of Isolated position shall be provided in front of the door. 5.9. The switchgear shall be cooled by natural airflow and cooling by any other method shall not be accepted. 5.10. Total height of the switchgear panels shall not exceed 2600 mm. The height of switches, pushbuttons and other hand-operated devices shall not exceed 1800 mm and shall not be less than 700mm. 5.11. Switchgear construction shall have a bushing or other sealing arrangement between the circuit breaker compartment and the busbar / cable compartments, so that there is no air communication around the isolating contacts in the shutter area with the truck in service position. 5.12. The breaker and the auxiliary compartments provided on the front side shall have strong hinged doors, busbar and cabling compartments provided on the rear side have bolted compartment covers with self retaining bolts. Breaker compartment doors shall have locking facility. 5.13. In the service position, the truck shall be so secured that it is not displaced by short circuit. Busbars, jumpers and other components of the switchgear shall also be properly supported to withstand all possible short circuit forces corresponding to the short circuit rating specified. 5.14. Suitable base frames made out of steel channels shall be supplied along with necessary anchor bolts and other hardware, for mounting of the switchgear panels. These shall be dispatched in advance so that they may be installed and leveled when the flooring is being done, welding of base frame to the insert plates as per approval installation drawings. 5.15. The switchboard shall have the facility of extension on the both sides Adopter panels and dummy panels required to meet the various busbar 6.0 CIRCUIT BREAKER RATING 6.1. FOR INCOMER 6.2. FOR BUS COUPLER 6.3. FOR OUTGOING FEEDER

97

7.0

CURRENT TRANSFORMER RATING 7.1. FOR TRANSFORMER INCOMING (i) Accuracy class : a) Core -I b) Core II c) Core III (ii) Rated Burden a) Core I b) Core II (iii) Knee point voltage : (v) Ratio:

: 0.5 with ISF less than 5 : 5 P with ALF 10 : PS (for 3 core CT only) : 30 VA : 15 VA 100 volts (for core III ) : 600-300-150/5-5-2.89

7.2. Current Transformers for outgoing (feeders) (i) Ratio : 400-200/5-5 (ii) Accuracy class : a) Core -I : 0.5 with ISF less than 5 b) Core II : 5 P with ALF 10 (iii) Rated Burden : a) Core I :30 VA b) Core I : 15 VA 7.3. Current Transformers for Bus Section (i) Ratio : a) 600-300/5-5 (ii) Accuracy class : a) Core -I : 0.5 with ISF less than 5 b) Core II : 5 P with ALF 10 (iii) Rated Burden : a) Core I b) Core I : 15 VA : 15 VA

8.0

POTENTIAL TRANSFORMERS 8.1. . The tenderer shall quote for oil immersed or cast-resin type having the following particulars for the purpose of metering: 1. Rated voltage ratio : 11000/110 2. No. of phases : 3 Phases / star - star connected 3. Rated Burden : 100 VA per phase 4. Class of accuracy : 0.5 5 Primary wiring of the PTs shall be protected by suitable H.R.C. fuse. 8.2. Two sets of 11 KV/110 V PTs shall be provided PROTECTIVE RELAYS: 9.1. All the incoming and outgoing switchgear units shall be provided protective relays to disconnect the faulty circuits with speed and certainty without interfering with healthy circuits. 9.2. The protective relays mounted on the panels shall be of the draw out type. The relavs must be capable of resetting without necessity of opening the case. The relays shall be provided with flag indicates to enable the type of fault conditions to be identified. 9.3. Incoming and outing feeders units and the bus coupler panel shall be provided with combined over current and earth fault relay with current range of 50-200% for O/C with inverse characteristics and 2080% for E/F relay of time range 0.3 secs at 10 times current.

9.0

10.0 MEASURING INSTRUMENTS 10.1. All instruments shall be switchboard type, back connected, suitable for flush mounting and shall comply with the requirements of latent issues of relevant Indian Standards. The instrument cases shall be dust proof, water tight, vermin proof and specially constructed to adequately protect the instruments against damage or deterioration due to high ambient temperature and humidity. 10.2. All instruments shall be access adjustable and calibrated before dispatch and shall have means for calibration check and adjustment at site. 10.3. All ammeters shall be digital type with direct reading scales. The scale value of ammeters shall be as per the primary current ratings of the associated current transformers. The rated current of ammeter elements shall be 5 ampere and accuracy class 1.0 as per IS: 1248. 10.4. All voltmeters shall be of digital type with direct reading scales. The maximum scale value of voltmeters shall be 50% in access of the primary voltage of associated PT. The rated voltage of the voltmeters shall be 110 volts A.C. and accuracy class shall be 1.0 as per IS: 1248. 10.5. Indicating wattmeters shall be of digital type of accuracy class 1. 10.6. Energy meters shall be digital type of accuracy class 0.5.and of Secure make or L&T make preferably as per APDCL Spec

98

11.0 SMALL WIRING AND TERMINAL BLOCKS 11.1. All panels shall be furnished completely factory wired up to terminal blocks ready for external connections. All wiring shall be switchboards type, with annealed copper wires with PVC insulation for 1100 volts complying with requirements of latest issue of IS: 1554 (Part-I). The sizes of the wiring for different circuits shall be go chosen as to provide ample margin for the purposes intended and shall be subjected to approval of the purchaser. However minimum cross section of wires t be used shall not be less than 1.5. sq.m. All the operating coils and small wires shall withstand a power frequency ten voltage of 2 KV for one minute. 12.0 SAFETY EARTHING 12.1. Earthing of current free metallic parts of metallic bodies of the equipment on the panel and the switchboards shall be done with soft drawn single conductor bare cooper. A copper ground bus extending the entire length of the panels shall be provided. Suitable clamp type terminals shall be provided for connecting both ends of the bus to the station earth system. The earth connection of instrument transformers wherever necessary shall be connected with the main earth wire of the panel earthing system. Multilpe earthing of any instrument transformer circuit shall be avoided. 13.0 CABLE BOXES AND CABLE GLANDS: 13.1. Cable boxes with cable glands shall be supplied with each of the panel. It should be of adequate dimension for terminals of 11 KV cables of sizes 300 and 185 sqmm and 180 sq.mm. 13.2. The 11 KV cable boxes shall preferably be located at the back of the switchboards and shall be suitably mounted for cables rising from cable trenches running at floor of the control room. The cable glands provided at the entrance shall facility for earthing of amounting. 13.3. All control/Wire entries should be by means of suitable cable glands such glands should be of brass and tinned. 14.0 DETAILS OF FITTING AND ACCESSORIES 14.1. The 11 KV switchboards shall consist of the following equipments for each incoming outgoing and buscoupler panels as per single line diagram enclosed. 14.2. Incoming panel (Transformer panel) I. Circuit Breaker: No. : - Triple pole circuit breaker. With continuous current rating of 800A. :Manually, charged independent spring closing, mechanism fitted with mechanical ON and OFF indications. 1 No. 1 No. : Hand trip device. : Shunt trip coil suitable for 110 D.C.

II. Meters and Instrument: 1 No. : Ammeter with selector switch. 1 No. : Voltmeter with selector switch. 1 No. : Electronic Tri-vector Meter 1 No. : Test terminal block for meters. III. Relays: 1 Set : Over current and earth fault relay. 1 Set : Testing links and terminals for relays. Indication 2 No. : Indicating lamps for indication of ON and OFF position of breaker. 1 No. : Indicating lamp labeled trip Circuit healthy with push button. IV. Annunciation: Annunciation: No annunciation facia shall be provided for Outgoing panel V. Other Equipments and fitting: Same as for incoming panel but cable box shall be suitable for following size of cable: 1 No. : 3 core 11 KV cable of size up to 630 sq.mm. 14.3. BUS SECTION PANEL: Same as detailed for incoming panel in clause 7.16.1 but with following modifications/additions/deletions: I. Circuit Breaker: 800 A II. Current and potential transformer 99

NO Potential transformer required, CT ratio as specified for bus section panel. Meters and Instruments: All meters except the ammeter with selection switch shall be deleted. IV. Relays: Only 1set O/C & E/F relay shall be provided. V. Indication: Indicating lamp labeled Auto trip with accept push button associated with Auto trip alarm shall be added. VI. Annunciation: No annunciation facia shall be provided for bus section panel. VII. Other Equipments and Fittings: Cable box shall be deleted. III. 14.4. COMMON ALARM AND ANNUNCIATION: I. Each switchboard shall be provided with a suitable common alam system for: a). D.C. Power supply failure. b). A.C. Power supply failure. c). Auto trip alarm. II. An AC operated relay with AC buzzer and AC indicating lamp shall be provided for annunciation of DC failure. III. A DC operated relay with DC buzzer and DC lamp shall be provided for AC failure. IV. Alarm and annunciation scheme shall be provided completed with horns, buzzers, relays, alarm connection push buttons, alarm test push buttons etc.

15.0

CIRCUIT LABELING: 15.1. Each switchgear shall be appropriately such as INCOMING TRANSFORMER, OUTGOING FEEDER and BUS SECTION, Associated Circuit breaker ratings, CT & PT ratio and any other information, manufacturer feels necessary shall also be included in the label. PERFORMANCE GUARANTEE 16.1. The bidder shall offer equipment performance guarantee for a minimum period of 1 year from the date of commissioning. SPECIAL TECHNICAL SPECIFICATIONS OF SWITCHGEAR: 17.1. Switchgear shall be installed on finished surfaces, concrete or steel sills. Contractor shall be required to install and align any channels sills, which form part of foundations. Circuit breaker trolley wheels shall move on channels, which shall form part of floor. The channel length shall be minimum of 1-meter form the door of switchgear panel. Power bus enclosure, ground and control splices of conventional nature shall be cleaned and bolted together with torque wrench of proper size or by other approved means. Tape or compound shall be spilled where called for in drawing Contractor shall take utmost care in handling instruments, relays and other delicate mechanism. Wherever the instruments and relays are supplied loose along with switchgear, they shall be mounted only after the associated switchgear panels have been erected and aligned. The blocking materials, employed for safe transit of instrument and relays shall be removed after ensuring that panels have been completely installed and no further movement of the same would be necessary. Any damage shall be immediately reported to Engineer. 17.2. Foundation work for all switchgear panels will be carried out by contractor. For R&M of existing substation foundation work shall be done wherever required as per site condition. 17.3. Circuit breaker may be provided with inter pole barriers of insulting materials, if the same is standard design of the manufacture. But use of inflammable materials like Hylam shall not be acceptable. 17.4. The control switch located on the switchgear would normally be used for operation of circuit breaker in service/isolated position, and for tripping it in an emergency. 17.5. Facilities shall be provided for mechanical tripping of the breaker. 17.6. Auxiliary contacts of breaker may be mounted in the fixed portion or in withdraw able truck as per the standard practice of the manufacture, and shall be directly operated by the breaker operating mechanism.

16.0

17.0 .

100

17.7.

Auxiliary contacts mounted in the portion shall not be operable by the operating mechanism, once the truck is withdrawn from the service position, but remain in the position corresponding to breaker open position. Auxiliary contacts mounted on the truck portion and dedicated for use shall be wired out in series with a contact denoting breakers service position. With truck withdrawn, the auxiliary contacts shall be operable by hand for testing. For Employers use six (6) normally opened (NO) and six (6) normally closed (NC) auxiliary contacts shall be wired out to the terminal blocks. Contact multiplication, if necessary to meet the above contact requirement, shall be done through suitable latch relay of English Electric type VAJC-11 or equivalent.

17.8.

17.9. It shall be possible to easily insert breaker contractor of one feeder into any one of the panel meant for same rating but at the same time shall be prevented from inserting it into panels meant for a different type of rating. 17.10. All bus bar and jumper corrections shall be of high conductivity copper or aluminium alloy. They shall be adequately supported on insulators to withstand electrical and mechanical stresses due to specified short circuit currents. Busbar joints shall be bolted type. Busbar cross-section shall be uniform throughout the length of switchgear. Busbar and other high voltage connection shall be sufficiently corona free at maximum working voltage. Contact surfaces at all joints shall be silver plated or properly cleaned and no oxide grease applied to ensure an efficient and trouble free connection. All bolted joints shall have necessary plain and spring washers. All connection hardware shall have high corrosion resistance. Suitable bimetallic connectors shall be used for aluminium to copper connections. Busbar insulators shall be of arc and track resistant high strength, non-hygroscopic, noncombustible type and shall be suitable to withstand stresses due to over-voltages, and short circuit current. Busbar shall be supported on the insulators such that the conductor expansion and contraction are allowed without straining the insulators. In case of organic insulator partial discharge shall be limited to 100 pico coulomb at rated voltage x1.1/ 3. Use of insulators and barriers of inflammable material such as Hylem shall not be accepted. All busbur shall be colour coded. The temperature of the busbars and all other equipment, when carrying the rated current continuously shall be limited as per the stipulations of relevant India Standards, duly considering the specified ambient temperature (50 deg. C). The temperature rise of the horizontal and vertical busbars when carrying the rated current shall be in no case exceed 55 deg.C for silver plated joints and 35 deg.C for all other type of joints. The temperature rise at the switchgear terminals intended for external cable termination shall not exceed 35 deg.C. Further the switchgear parts handled by the operator shall not exceed a rise of 5deg.C. PAINTING: Al sheet steel work shall be pretreated in tanks in accordance with IS: 6005. Degreasing shall be done by alkaline cleaning. Rust and scale shall be removed by pickling with acid. After pickling, the parts shall be washed in running water. Then these shall be rinsed in slightly alkaline hot water and dried. The phosphated coating shall be Class C as specified in IS: 6008. The phosphated surface shall the rinsed and passivated prior to application of stoved lead oxide primer coating. After primer application, two coats of finishing synthetic enamel paint on panels shall be applied. Finishing paint on panels shall be shade 692 (smoke grey) of IS: 5 unless specified otherwise by the Owner. The inside of the panels shall preferably be glossily white. Each coat finishing shall be properly stoved. The paint thickness shall not be less than 50 microns. Finished surfaces from scratches, grease dirts and oily spots during testing, transporation, handling and erection.

17.11. 17.12. 17.13.

17.14.

17.15. 17.16.

18.0 18.1.

19.0

SWITCHGEAR WIRING 19.1. All switchgear panels shall be supplied completely wired internally upto the terminal block ready to receive external cabing. All inter cubicle wiring and connections between panels of same switchboard including all bus wiring for AC and DC supplies shall be provided by the Contractor. All internal wiring shall be carried out 650 grade, single core, 1.5 sq.mm, stranded copper wires having minimum of seven strands per conductor and colour coded, PVC insulation. CT circuits shall be wired with 2.5 sq.mm. wires which otherwise are similar to the above. Extra flexible wires shall be used for wiring between fixed and moving parts such as hinged doors. All wiring shall be properly supported neatly, readily accessible and securely connected to equipment, terminals and termenal blocks. Wiring troughs or gutters be used for this purpose. 101

19.2.

Internal wire terminals shall be made with solder less crimping type tinned copper lugs, which shall firmly grip the conductor. Insulation sleeves shall be provided over the exposed parts of lugs. The lugs related to CT secondary circuit wiring shall be hole type. 19.3. Engraved core identification plastic ferrules marked to correspond with panel wiring diagrams be fitted at both ends of each wire number 6 and 9 shall not be used for wire identification. Ferrules shall fit tightly on wires and shall not fall off when wire is, disconnected from terminal. All wires directly connected to trip the circuit breaker shall be distinguished by the addition of a red coloured unlettered ferrule. 19.4. Inter connection to adjacent panels shall be brought out to a separate set of terminal blocks located near the slots or holes, meant for the interconnecting wires. Arrangement shall permit neat layout and easy inter connections to adjacent panels at site and wires for this purpose shall be provided by Contractor looped and bunched properly inside the panels. The inter panel wires shall be cross ferruled i.e. it shall have details of emanating terminal and also where it is terminated. 19.5. Manufacturer shall be fully responsible for the completeness and correctness of the internal wiring and for the proper functioning of the connected equipment. 19.6. The Manufacturer shall provided the necessary clamps wiring troughs etc. for all wiring in side the switchgear enclosed including the power and control cables. 20.0 POWER CABLE TERMINATION: 20.1. The cable termination compartment shall received the stranded aluminium conductor, XLPE insulated, shielded, armoured / unarmoured, PVC jacketed, single core / three core unearthed / earthed grade power cable (s). 20.2. A minimum clearance of about 600 mm shall be kept between the cable lug bottom ends and gland plates for stress cone formation for XLPE Cable. Interphase clearance in the cable termination compartment shall be adequate to meet electrical and mechanical requirement besides facilitating easy connections and disconnections of cables. Dimensional drawing of cable connected compartment showing the location of lug, glands, CTS, gland plates etc. and the electrical clearances available shall be submitted Employer approval during detailed engineering. 20.3. Cable termination compartment shall be complete with power terminals, power lugs and associated hardware and removable undrilled gland plates. Fopr all single core cables grand plates shall be of nonmagnetic material. 20.4. Supply of the cable termination kit and cable termination shall be in scope of contractor.

21.0

TESTS: 21.1. The Contractor shall submit the type test reports of following type tests for approval of the Employer for circuit breaker, circuit breaker panels, of each voltage class and current rating: i). Short circuit duty test on circuit breaker, mounted inside the panel offered along with CTs, bushing and separator. ii). Short time withstand test on circuit breaker, mount inside panel offered together with CTs, bushing and separator. iii). Power frequency withstand test on breaker and panel. iv). Lighting impulse withstand test on breaker and panel. v)The indoor VCB switchgear should have internal arc test conducted at CPRI 21.2. Temperature rise test on breaker and panel together. For this test, the test set up shall include three panels with breakers, the test breaker and panel being placed in the center. The adjacent panels shall also be loaded to their current capacity. Alternatively the test panel may be suitably insulated at the sides, which will be adjoining to other panels in actual site configuration. .. 21.3. . Switching over-voltage test as per clause 3.2(b) on each rating of breaker. a. Measurement of resistance of main circuit. b. Mechanical eduranc4e test on breaker. c. Mechanical operation test. Viii). Short circuit withstand test of earthing device (Truck / Switch). 21.4. For all the important components like instrument transformers, relays, instruments, switches, bushing, wires, insulators, timers, annunciation, terminal blocks and fuses etc. the contractor shall furnish satisfactory type test reports for Employers approval. Such reports cover all applicable type test listed in relevant Indian Standards, for all components of type and rating being supplied.

22.0 COMMISSIONING CHECKS / TESTS 22.1. After installation of panels, power and control wiring and connect contractor shall perform commissioning checks as listed below to proper operation of switchgear / panels and correctness of all respects. 102

22.2. GENERAL a). Check name plate details according to specification. b). Check for physical damage. c). Check tightens of all bolts, clamps and connecting terminal. d). Check earth connections. e). Check cleanliness of insulators and bushings. f). Check heaters are provided. g). H.V. test on complete switchboard with CT & breaker / contractor lubricated in position. h). Check all moving parts are properly lubricated. i). Check all alignment of bus bars with the insulators to ensure alignment and fitness of insulators. j). Check for inter changeability of breakers. k). Check continuity and IR value of space heater. l). Check earth continuity of the complete switchgear board. 22.3. CIRCUIT BREAKER a). Check alignment of trucks for free movement . b). Check correct operation of shutters. c). Check show closing operation (if provided). d). Check control wiring for correctness of corrections, continuity and IR values. e). Manual operation of breakers completely assembled. f). Power closing / opening operation manually and electrically at extreme condition of control supply voltage. g). Closing and tripping time. h). Trip free and anti-pumping operation. i). IR values, resistance and minimum pick up voltage of coils. j). Simultaneous closing of all the three phases. k). Check electrical and mechanical inter locks provided. l). Checks on spring charging motor, correct operation of limit switches and time of charging. m). Check vacuum (as applicable). n). All functional checks

103

3.6

TECHNICAL SPECIFICATION FOR 33KV & 11 KV ISOLATORS

7.1.0. SCOPE 7.1.1. This section of the specification is intended to cover design specifications for manufacture and testing of 33
KV and 11 KV gang operated switch (Isolators) with all fittings and accessories.

7.1.2. The Isolators are for outdoor installation suitable for horizontal/vertical mounting on mounting structures and
for use at sub-stations.

7.1.3. Isolators shall be supplied with Earth Switch as and where specified. 7.2.0. GENERAL 7.2.1. The Isolators and accessories shall conform in general to IS 9921 (or IEC: 62271-102) except to the extent
explicitly modified in specification.

7.2.2. All isolating switches and earthing switches shall have rotating blades and pressure releasing contacts. All
isolating and earth switches shall operate through 90 angle from closed position to fully open position.

7.2.3. Complete isolator with all the necessary items for successful operation shall be supplied including but not
limited to the following: (i). Isolator assembled with complete base frame, linkages, operating mechanism, control cabinet, interlocks etc. (ii). All necessary parts to provide a complete and operable isolator installation, control parts and other devices whether specifically called for herein or not. (iii). The isolator shall be designed for use in the geographic and meteorological conditions as given in Section 1.

7.3.0. DUTY REQUIREMENTS 7.3.1. Isolators and earth switches shall be capable of withstanding the dynamic and thermal effects of the
maximum possible short circuit current of the systems in their closed position. They shall be constructed such that they do not open under influence of short circuit current.

7.3.2. The earth switches, wherever provided, shall be constructionally interlocked so that the earth switches can
be operated only when the isolator is open and vice versa. The constructional interlocks shall be built in construction of isolator and shall be in addition to the electrical and mechanical interlocks provided in the operating mechanism.

7.3.3. In addition to the constructional interlock, isolator and earth switches shall have provision to prevent their
electrical and manual operation unless the associated and other interlocking conditions are met. All these interlocks shall be of failsafe type. Suitable individual interlocking coil arrangements shall be provided. The interlocking coil shall be suitable for continuous operation from DC supply and within a variation range as stipulated elsewhere in this specification.

7.3.4. The earthing switches shall be capable of discharging trapped charges of the associated lines. 7.3.5. The isolator shall be capable of making/breaking normal currents when no significant change in voltage
occurs across the terminals of each pole of isolator on account of make/break operation.

7.3.6. The isolator shall be capable of making/breaking magnetising current of 0.7A at 0.15 power factor and
capacitive current of 0.7A at 0.15 power factor at rated voltage.

7.4.0. CONSTRUCTIONAL DETAILS 7.4.1. All isolating switches and earthing switches shall have rotating blades and pressure releasing contacts. All
isolating and earth switches shall operate through 90 angle from closed position to fully open position.

7.4.2. Contacts:
a) The contacts shall be self-aligning and self-cleaning and so designed that binding cannot occur after remaining closed for prolonged periods of time in a heavily polluted atmosphere.

104

b)

c) d)

No undue wear or scuffing shall be evident during the mechanical endurance tests. Contacts and spring shall be designed so that readjustments in contact pressure shall not be necessary throughout the life of the isolator or earthing switch. Each contact or pair of contacts shall be independently sprung so that full pressure is maintained on all contacts at all time. Contact springs shall not carry any current and shall not lose their characteristics due to heating effects. The moving contact of double break isolator shall have turn-and -twist type or other suitable type of locking arrangement to ensure adequate contact pressure. All metal parts shall be of non-rusting and non-corroding material. All current carrying parts shall be made from high conductivity electrolytic copper/aluminium. Bolts, screws and pins shall be provided with lock washers. Keys or equivalent locking facilities if provided on current carrying parts, shall be made of copper silicon alloy or stainless steel or equivalent. The bolts or pins used in current carrying parts shall be made of non-corroding material. All ferrous castings except current carrying parts shall be made of malleable cast iron or cast-steel. No grey iron shall be used in the manufacture of any part of the isolator. The live parts shall be designed to eliminate sharp joints, edges and other corona producing surfaces, where this is impracticable adequate corona shield shall be provided.. Isolators and earthing switches including their operating parts shall be such that they cannot be dislodged from their open or closed positions by short circuit forces, gravity, wind pressure, vibrations, shocks, or accidental touching of the connecting rods of the operating mechanism. The switch shall be designed such that no lubrication of any part is required except at very infrequent intervals i.e. after every 1000 operations or after 5 years whichever is earlier. The insulator shall conform to IS: 2544 and/or IEC-60168. The insulators shall have a minimum cantilever strength of 400 Kgs. for 33/11 kV insulators respectively. Pressure due to the contact shall not be transferred to the insulators after the main blades are fully closed.

7.4.3. Blades:
a)

b) c)

d)

7.4.4. Insulators:
a) b)

7.4.5. Base:
Each isolator shall be provided with a complete galvanised steel base provided with holes and designed for mounting on a supporting structure.

7.5.0. EARTHING SWITCHES 7.5.1. Where earthing switches are specified these shall include the complete operating mechanism and auxiliary
contacts.

7.5.2. The earthing switches shall form an integral part of the isolator and shall be mounted on the base frame of
the isolator.

7.5.3. The earthing switches shall be constructionally interlocked with the isolator so that the earthing switches
can be operated only when the isolator is open and vice versa. The constructional interlocks shall be built in construction of isolator and shall be in addition to the electrical interlocks. Suitable mechanical arrangement shall be provided for de-linking electrical drive for mechanical operation.

7.5.4. Each earth switch shall be provided with flexible copper/aluminum braids for connection to earth terminal.
These braids shall have the same short time current carrying capacity as the earth blade. The transfer of fault current through swivel connection will not be accepted.

7.5.5. The frame of each isolator and earthing switches shall be provided with two reliable earth terminals for
connection to the earth mat.

7.5.6. Isolator design shall be such as to permit addition of earth switches at a future date. It should be possible to
interchange position of earth switch to either side.

7.5.7. The earth switch should be able to carry the same fault current as the main blades of the Isolators and shall
withstand dynamic stresses.

7.6.0. OPERATING MECHANISM 7.6.1. The bidder shall offer manual operated Isolators and earth switches..
105

7.6.2. Control cabinet/operating mechanism box shall be made of aluminum sheet of adequate thickness
(minimum 3 mm).

7.6.3. Gear should be of forged material suitably chosen to avoid bending/jamming on operation after a prolonged
period of non-operation. Also all gear and connected material should be so chosen/surface treated to avoid rusting.

7.7.0. OPERATION 7.7.1. The main Isolator and earth switches shall be gang operated. 7.7.2. The design shall be such as to provide maximum reliability under all service conditions. All operating
linkages carrying mechanical loads shall be designed for negligible deflection. The length of inter insulator and interpole operating rods shall be capable of adjustments, by means of screw thread which can be locked with a lock nut after an adjustment has been made. The isolator and earth switches shall be provided with over center device in the operating mechanism to prevent accidental opening by wind, vibration, short circuit forces or movement of the support structures.

7.7.3. Each isolator and earth switch shall be provided with a manual operating handle enabling one man to open
or close the isolator with ease in one movement while standing at ground level. Detachable type manual operating handle shall be provided. Suitable provision shall be made inside the operating mechanism box for parking the detached handles. The provision of manual operation shall be located at a height of 1000 mm from the base of isolator support structure.

7.7.4. The isolator shall be provided with positive continuous control throughout the entire cycle of operation. The
operating pipes and rods shall be sufficiently rigid to maintain positive control under the most adverse conditions and when operated in tension or compression for isolator closing. They shall also be capable of withstanding all torsional and bending stresses due to operation of the isolator. Wherever supported the operating rods shall be provided with bearings on either ends. The operating rods/ pipes shall be provided with suitable universal couplings to account for any angular misalignment.

7.7.5. All rotating parts shall be provided with grease packed roller or ball bearings in sealed housings designed to
prevent the ingress of moisture, dirt or other foreign matter. Bearings pressure shall be kept low to ensure long life and ease of operation. Locking pins wherever used shall be rustproof.

7.7.6. Signaling of closed position shall not take place unless it is certain that the movable contacts, have reached
a position in which rated normal current, peak withstand current and short time withstand current can be carried safely. Signaling of open position shall not take place unless movable contacts have reached a position such that clearance between contacts is atleast 80% of the isolating distance.

7.7.7. The position of movable contact system (main blades) of each of the Isolators and earthing switches shall
be indicated by a mechanical indicator at the lower end of the vertical rod of shaft for the Isolators and earthing switch. The indicator shall be of metal and shall be visible from operating level.

7.7.8. The contractor shall furnish the following details along with quality norms, during detailed engineering stage.
(i) (ii) Current transfer arrangement from main blades of isolator along with millivolt drop immediately across transfer point. Details to demonstrate smooth transfer of rotary motion from motor shaft to the insulator along with stoppers to prevent over travel.

7.8.0. TEST AND INSPECTION 7.8.1. The switches shall be subjected to the following type test in accordance to with IS: 9920.
I) II) III) IV) V) VI) VII) VIII) I) II) III) Dielectric test (impulse and one minute) power frequency withstands voltage. Temperature rise test Rated off load breaking current capacity Rated active load breaking capacity Rated line charging breaking capacity Rated short time current Rated peak withstand current Mechanical and Electrical Endurance Power frequency voltage dry test Measurement of resistance of the main circuit Operating test.

7.8.2. The equipment shall be subjected to the following routine test.

7.8.3. The porcelain will have pull out test for embedded component and beam strength of porcelain base.
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7.9.0. CONNECTORS 7.9.1. Each isolator shall be provided with appropriate number of bimetallic clamping type connectors as detailed
in the schedule of requirement. The maximum length of jumper that may be safely connected or any special instruction considered necessary to avoid under loads on the post isolators should be stated by the tenderer.

7.10.0. SUPPORTING STRUCTURES 7.10.1. All isolators and earthing switches shall be rigidly mounted in an upright position on their own supporting
structures. Details of the supporting structures shall be furnished by the successful tenderer. The isolators should have requisite fixing details ready for mounting them on switch structures.

7.11.0. PRE-COMMISSIONING TESTS 7.11.1. Contractor shall carry out following tests as pre-commissioning tests. Contractor shall also perform any
additional test based on specialties of the items as per the field instructions of the equipment Supplier or Employer without any extra cost to the Employer. The Contractor shall arrange all instruments required for conducting these tests along with calibration certificates and shall furnish the list of instruments to the Employer for approval. (a) Insulation resistance of each pole. (b) Manual operation and interlocks. (c) Insulation resistance of control circuits and motors. (d) Ground connections. (e) Contact resistance. (f) Proper alignment so as to minimise to the extreme possible the vibration during operation. (g) Measurement of operating Torque for isolator and Earth switch. (h) Resistance of operating and interlocks coils. (i) Functional check of the control schematic and electrical & mechanical interlocks. (j) 50 operations test on isolator and earth switch.

7.12.0. TECHNICAL DATA SHEET FOR ISOLATORS


SL No. Technical Particulars 33 kV 1 2 3 4. 5 6 7 8 Nominal system voltage, kV Highest system voltage, kV Rated frequency, Hz. Type of Isolator Rated continuous current, A Rated short time current, kA for 3sec Rated duration of short time current, Second Rated lightning impulse withstand voltage, kV (peak) i) To earth & between poles ii) Across isolating distance Rated 1 minute power frequency withstand voltage, kV (rms) i) To earth & between poles ii) Across isolating distance Minimum creepage distance of insulators, mm Temperature rise 33 36 50 Double Break, center pole rotating 630 25 3 Isolators class 11kV 11 12 50 Double Break, center pole rotating 630/400 A 16 3

170 170

95 95

70 80

28 40

10

900

400 As per relevant IS 107

11

3.7
5.1.0.

TECHNICAL SPECIFICATION OF OUTDOOR CURRENT AND POTENTIAL TRANSFORMERS

SCOPE OF CONTRACT

5.1.1. This Section of the Specification covers general requirements for design, engineering, manufacture, assembly and testing at manufacturers works of 33kV and 11 kV outdoor Current and Potential Transformers. 5.2.0. STANDARDS

5.2.1. The equipment covered by this specification shall, unless otherwise stated be designed, constructed and tested in accordance with the latest revisions of relevant Indian Standards and shall conform to the regulations of local statutory authorities. 5.2.2. 5.2.3. In case of any conflict between the Standards and this specification, this specification shall govern. The current transformer shall comply also with the latest issue of the following Indian standard.
(i) (ii) (iii) (iv) (v) (vi) (vii)

IS: 2705(Part-I) IS: 2705(Part-II) IS: 2705(Part-III) IS: 2705(Part-IV) IS: 3156(Part-I) IS: 3156 (Part-II) IS: 3156 (Part-III)

Current transformers: General requirement. Current transformers : Measuring Current transformers Current transformers : Protective Current transformers Current transformers: Protective Current transformers for special purpose application. Potential transformers: General requirement. Potential transformers : Measuring Potential transformers Potential transformers : Protective Potential transformers

5.3.0.

GENERAL REQUIREMENTS

5.3.1. The cores of the instrument transformers shall be of high grade, non-aging CRGO steel of low hysteresis loss and high permeability. 5.3.2. 5.3.3. 5.3.4. Instrument transformers shall be of Dead Tank design or Live Tank design. The instrument transformers shall be truly hermetically sealed POLYCRETE Type A complete leak proof secondary terminal arrangement shall be provided with each instrument transformers, secondary terminal shall be brought into weather, dust and vermin proof terminal box. Secondary terminal boxes shall be provided with facilities for easy earthing, shorting, insulating and testing of secondary circuits. The terminal boxes shall be suitable for connection of control cable gland. All instrument transformers shall be of single phase unit. The instrument transformers shall be so designed to withstand the effects of temperature, wind load, short circuit conditions and other adverse conditions. All similar parts, particularly removable ones, shall be interchangeable with one another. All cable ferrules, lugs, tags, etc. required for identification and cabling shall be supplied complete for speedy erection and commissioning as per approved schematics.

5.3.5. 5.3.6. 5.3.7. 5.3.8.

5.3.9. The instrument transformers shall be designed to ensure that condensation of moisture is controlled by proper selection of organic insulating materials having low moisture absorbing characteristics. 5.3.10. All steel work shall be degreased, pickled and phosphated and then applied with two coats of Zinc Chromate primer and two coats of finishing synthetic enamel paint.

108

5.4.0. COMMON MARSHALLING BOXES 5.4.1. The outdoor type common marshalling boxes shall conform to the latest edition of IS 5039 and other general requirements specified hereunder. 5.4.2. The common marshalling boxes shall be suitable for mounting on the steel mounting structures of the instrument transformers. 5.4.3. One common marshalling box shall be supplied with each set of instrument transformers. The marshalling box shall be made of sheet steel and weather proof. The thickness of sheet steel used shall be not less than 3.0 mm. It is intended to bring all the secondary terminals to the common marshalling. 5.4.4. The enclosures of the common marshalling boxes shall provide a degree of protection of not less than IP 55 (As per IS 2147). 5.4.5. The common marshalling boxes shall be provided with double hinged front doors with pad locking arrangement. All doors and removable covers and plates shall be sealed all around with neoprene gaskets or similar arrangement. 5.4.6. Each marshalling box shall be fitted with terminal blocks made out of moulded non-inflammable plastic materials and having adequate number of terminals with binding screws washers etc. Secondary terminals of the instrument transformers shall be connected to the respective common marshalling boxes. All out going terminals of each instrument transformer shall terminate on the terminal blocks of the common marshalling boxes. The terminal blocks shall be arranged to provide maximum accessibility to all conductor terminals. 5.4.7. Each terminal shall be suitably marked with identification numbers. Not more than two wires shall be connected to any one terminal. At least 20 % spare terminals shall be provided over and above the required number. 5.4.8. All terminal strips shall be of isolating type terminals and they will be of minimum 10 A continuous current rating. 5.4.9. All cable entries shall be from bottom. Suitable removable gland plate shall be provided on the box for this purpose. Necessary number of cable glands shall be supplied fitted on to this gland plate. Cable glands shall be screw on type and made of brass. 5.4.10. Each common marshalling box shall be provided with two numbers of earthing terminals of galvanised bolt and nut type. 5.4.11. All steel, inside and outside work shall be degreased, pickled and phosphated and then applied with two coats of Zinc Chromate primer and two coats of finishing synthetic enamel paint. The colour of finishing paint shall be as follows: 5.4.12. 5.4.13. i) Inside: ii) Outside: Glossy White Light Grey (Shade No. 697 of IS: 5)

5.5.0. TESTS 5.5.1. Routine/Acceptance Tests (all units) 5.5.2. All routine tests shall be carried out in accordance with relevant Standards. All routine/acceptance tests shall be witnessed by the Employer/his authorised representative. 5.5.3. Type Tests: The bidder shall furnish type test certificates and results for the all tests as per relevant Standards along with the bid for current and potential transformers of identical design. 5.5.4. Type test certificates so furnished shall not be older than 5 (five) years as on date of Bid opening.

5.6.0.

NAME PLATES

5.6.1. All equipment shall have non-corrosive name plates fix at a suitable position indelibly mark with full particular there on in accordance with the standard adapted.

109

5.7.0.

MOUNTING STRUCTURES

5.7.1. All the equipment covered under this specification shall be suitable for mounting on steel structures. Supply of mounting structures is also in the scope of this tender. 5.7.2. Each equipment shall be furnished complete with base plates, clamps, and washers etc. and other hardware ready for mounting on existing steel structures. 5.8.0. SAFETY EARTHING 5.8.1. The non-current carrying metallic parts and equipment shall be connected to station earthing grid. For this two terminals suitable for 40mm X 10mm GI strip shall be provided on each equipment. 5.9.0. TERMINAL CONNECTORS 5.9.1. The equipment shall be supplied with required number of terminal connectors of approved type suitable for ACSR/XLPE cable. The type of terminal connector, size of connector, material, and type of installation shall be approved by the Employer, as per installation requirement while approving the equipment drawings. 5.10.0. PRE-COMMISSIONING TESTS 5.10.1. Contractor shall carry out following tests as pre-commissioning tests. Contractor shall also perform any additional test based on specialties of the items as per the field instructions of the equipment Supplier or Employer without any extra cost to the Employer. The Contractor shall arrange all instruments required for conducting these tests along with calibration certificates and shall furnish the list of instruments to the Employer for approval. 5.10.2. Current Transformers (i) (ii) (iii) (iv) (v) (vi) (vii) (viii) Insulation Resistance Test for primary and secondary. Polarity test. Ratio identification test - checking of all ratios on all cores by primary injection of current. Dielectric test of oil (wherever applicable). Magnetising characteristics test. Tan delta and capacitance measurement Secondary winding resistance measurement Contact resistance measurement (wherever possible/accessible).

5.10.3.

Potential Transformers (i) (ii) (iii) (iv) (v) (vi) Insulation Resistance test for primary (if applicable) and secondary winding. Polarity test. Ratio test Dielectric test of oil (wherever applicable). Tan delta and capacitance measurement of individual capacitor stacks. Secondary winding resistance measurement.

5.11.0. TECHNICAL DATA SHEET FOR CURRENT AND POTENTIALTRANSFORMERS 5.11.1. For 33 kV/11kV CTs the instrument security factor at all ratios shall be less than 2.5 for metering core.

5.11.2.

TYPE AND RATING:

All instrument transformer shall be outdoor type, single phase, polycrete type suitable for mounting on steel structure. The instrument transformer shall have the following ratings and particulars. 110

S L N o . A B C D E a ) b ) F G H J

Item

Ratings and Particulars 33 KV 11 KV

Nominal system voltage Highest system voltage, kV Rated frequency ,HZ System earthing Insulation level Impulse withstand voltage: kVp One minute p.f. Withstand voltage, kV (r.m.s.) Short time current for one second, kA Minimum creepage distance, mm Temperature rise TRANFORMER C.T. (i) No. of Cores (ii) Transformation ratio (iii) Rated out put (a) Core-1 (b) Core-2 (C) Core-3 (iv) Accuracy class (a) Core-1 (b) Core-2 (C) Core-3 (v) Accuracy limit factor (a) Core-1 (b) Core-2 (C) Core-3 (v) Instrument security factor (a) Core-1 (b) Core-2 (C) Core-3 (v) Minimum Knee point voltage, Volts (C) Core-3 FEEDER CT (i) No. of Cores (ii) Transformation ratio (iii) Rated out put (a) Core-1 (b) Core-2 (iv) Accuracy class (a) Core-1 (b) Core-2 (v) Accuracy limit factor (a) Core-1 (b) Core-2

33 kV 36 50 Solidly earth 170 70 16 900 As per ISS 3 200-100/5-5-5A 30 VA 15 VA 0.5 5P PS 10 Less than 5 100 Volts 2 400-200/5-5-5 30 VA 15 VA 0.5 5P 10

11 kV 12 50 Solidly earth 70 28 12.5 360 As per ISS 3 600-300/5-5-2.89A 30 VA 15VA 0.5 5P PS 10 Less than 5 100volts 2 400-200/5-5 30 VA 15 VA 0.5 5P 10 111

S L N o .

Item

Ratings and Particulars 33 KV 11 KV

(v) Instrument security factor (a) Core-1 (b) Core-2 POTENTIAL TRANSFORMER (a) Core-1 (b) Core-2 (vi) Accuracy class (v) Rated voltage factor (vi) Accuracy class Note: (i) It is intended to use different ratios of the same CT at the same time for differential protections and metering cores. The CTS should therefore be suitable for the above purpose by secondary tapings only. The ratio change by secondary taps is acceptable as long as the required CT specifications are achieved at all ratios. The knee point voltage specified above shall be at higher ratio/ taps. <=5 33kV/3 /110V/3 100 100 0.5 1.2 0.5 <=5 11kV/3 /110V/3 100 100 05 1.2 0.5

(ii)

112

3.8
8.1.0. 8.2.0.

TECHNICAL SPECIFICATION FOR 33kV & 11kV LIGHTNING ARRESTORS

SCOPE This Section covers the specifications for design, manufacture, shop & laboratory testing before despatch of 33 kV and 11 kV 10 kA, Station class heavy duty, gapless metal (zinc) oxide Surge Arrestors complete with fittings & accessories. STANDARDS 8.3.1. The design, manufacture and performance of Surge Arrestors shall comply with IS: 3070( Part-3 )/1993 unless otherwise specifically specified in this Specification GENERAL REQUIREMENT The surge arrestor shall draw negligible current at operating voltage and at the same time offer least resistance during the flow of surge current. The surge arrestor shall consist of non-linear resistor elements placed in series and housed in electrical grade porcelain housing/silicon polymeric of specified creepage distance. The assembly shall be hermetically sealed with suitable rubber gaskets with effective sealing system arrangement to prevent ingress of moisture. The surge arrestor shall be provided with line and earth terminals of suitable size. The ground side terminal of surge arrestor shall be connected with 25x6 mm galvanized strip, one end connected to the surge arrestor and second end to a separate ground electrode. The bidder shall also recommend the procedure which shall be followed in providing the earthing/system to the Surge Arrestor. The surge arrestor shall not operate under power frequency and temporary over voltage conditions but under surge conditions, the surge arrestor shall change over to the conducting mode. The surge arrestor shall be suitable for circuit breaker performing 0-0.3sec.-CO-3min-CO- duty in the system. Surge arrestors shall have a suitable pressure relief system to avoid damage to the porcelain/ silicon polymeric housing and providing path for flow of rated fault currents in the event of arrestor failure. The reference current of the arrestor shall be high enough to eliminate the influence of grading and stray capacitance on the measured reference voltage. The Surge Arrestor shall be thermally stable and the bidder shall furnish a copy of thermal stability test with the bid. The arrestor shall be capable of handling terminal energy for high surges, external pollution and transient over voltage and have low losses at operating voltages.

8.3.0.

8.4.0. 8.4.1. 8.4.2. 8.4.3. 8.4.4.

8.4.5. 8.4.6. 8.4.7.

8.4.8. 8.4.9. 8.4.10.

8.5.0. ARRESTOR HOUSING 8.5.1. The arrestor housing shall be made up of silicon polymeric housing and shall be homogenous, free from laminations, cavities and other flaws of imperfections that might affect the mechanical and dielectric quality. The housing shall be of uniform brown colour, free from blisters, burrs and other similar defects. Arrestors shall be complete with insulating bases, surge counters with leakage current meters (33 KV LA) and terminal connectors. 8.5.2. The housing shall be so coordinated that external flashover shall not occur due to application of any impulse or switching surge voltage up to the maximum design value for arrestor. The arrestors shall not fail due to contamination. The arrester housings shall be designed for pressure relief class as given in Technical Parameters of the specification. Sealed housings shall exhibit no measurable leakage.

8.5.3. 8.6.0.

FITTINGS & ACCESSORIES 8.6.1. The surge arrestor shall be complete with insulating bases, surge counters with leakage current meters (for 33 KV LA) and terminal connectors.

113

8.6.2. The terminals shall be non-magnetic, corrosion proof, robust and of adequate size and shall be so located that incoming and outgoing connections are made with minimum possible bends. The top metal cap and base of surge arrestor shall be galvanized. The line terminal shall have a built in clamping device which can be adjusted for both horizontal and vertical takeoff. 8.7.0. SURGE MONITOR

8.7.1. A self-contained discharge counter suitably enclosed for outdoor use and requiring no auxiliary or battery supply for operation shall be provided for each single pole unit. Leakage current meter with suitable scale range to measure leakage current of surge arrestor shall also be supplied within the same enclosure. The number of operations performed by the arrestor shall be recorded by a suitable cyclometric counter and surge monitor shall be provided with an inspection window. There shall be a provision for putting ammeter to record the current/alarm contacts in the control room if the leakage current exceeds the permitted value. Similar provision shall be considered for surge counter also. 8.7.2. Surge monitor shall be mounted on the support structure at a suitable height so that the reading can be taken from ground level through the inspection window and length of connecting leads up to grounding point and bends are minimum. 8.7.3. 8.8.0. TESTS 8.8.1. Surge monitor shall have to be provided for 33 KV class only.

Test on Surge Arrestors The Surge Arrestors offered shall be type tested and shall be subjected to routine and acceptance tests in accordance with IS: 3070 (Part-3). In addition, the suitability of the Surge Arrestors shall also be established for the following: Residual voltage test Reference voltage test Leakage current at M.C.O.V P.D. test Sealing test Thermal stability test Aging and Energy capability test Watt loss test

8.8.2. 8.8.3.

Each metal oxide block shall be tested for guaranteed specific energy capability in addition to routine/acceptance test as per IEC/IS. The surge arrestor housing shall also be type tested and shall be subjected to routine and acceptance tests in accordance with IS: 2071. Galvanization Test All Ferrous parts exposed to atmospheric condition shall have passed the type tests and be subjected to routine and acceptance tests in accordance with IS: 2633 & IS 6745.

8.9.0. 8.9.1.

NAME PLATE The name plate attached to the arrestor shall carry the following information: Rated Voltage Continuous Operation Voltage Normal discharge current Pressure relief rated current Manufacturers Trade Mark Name of Sub-station Year of Manufacturer Name of the manufacture Purchase Order Number along with date

8.10.0. 8.10.1.

PRE-COMMISSIONING TESTS Contractor shall carry out following tests as pre-commissioning tests. Contractor shall also perform any additional test based on specialties of the items as per the field instructions of the equipment Supplier or Employer without any extra cost to the Employer. The Contractor 114

8.11.0.

shall arrange all instruments required for conducting these tests along with calibration certificates and shall furnish the list of instruments to the Employer for approval. 1. Operation check of LA counters. 2. Insulation resistance measurement. 3. Capacitance and Tan delta measurement of individual stacks. 4. Third harmonic resistive current measurement (to be conducted after energisation. TYPE AND RATINGS SL No . 1 2 3 4 5 6 7 9 10 Rated voltage of arrester, kV Rated frequency, Hz Nominal discharge current of arrester, kA Maximum residual voltage at nominal discharge current, kV (peak) Maximum steep current impulse residual voltage at kV (kVP) One minute power frequency withstand voltage of arrester insulation, kV (rms) 1.2 / 50 second impulse withstand voltage of arrester insulation, kV (peak) Line discharge class Insulator Housing a) b) c) d) Power frequency withstand test voltage (wet) (kV rms) Lightning impulse withstand tests voltage(KVp) Pressure Relief Class Creepage distance not less than (mm) 70 170 40 900 28 95 40 400 Particulars Voltage class 33 kV 11 kV 30 50 10 108 130 70 170 2 9 50 10 40 50 28 95 2

115

3.9
1.0 1.1. SCOPE

TECHNICAL SPECIFICATION OF 33 KV AND 11 KV GANG OPERATED SWITCH

This specification is intended to cover design manufacture, testing at manufacturers works, transport to site, insurance, storage, erection and commissioning of 33 KV and11 KV gang operated switch (Isolators) with all fittings and accessories. 1.2. The Isolators are for outdoor installation suitable for both vertically and horizontally mounting on mounting structures or M.S. Channel and for use at sectionalizing/tapping points of 33 KV lines and at 33/11 KV sub-stations. 1.3. 33 KV isolators shall be supplied with Earth Switch as and where specified 1.4. The successful bidders shall supply the necessary drawings and instructions for installation and commission of the Isolators.

2.0

CONSTRUCTIONAL DETAILS 2.1. The vertically mounted gang switches shall be manually operated triple pole type with single break operation. The operation of the equipment shall be through forward and backward motion of the mid-pole post insulator. The contacts shall be made of silver faced hard drawn copper. 2.2. The horizontally mounted switches, with or without earth switches shall have rotating blade features and pressure reliving features. Such isolators are required to be double break; three posts per phase, single 0 through, gang operated three phase type. All isolators with/without earth switch shall operate through 90 from their fully closed position to fully open position 2.3. The switch shall be fitted with arcing horns and the horns shall be easily replaceable. All isolators shall be provided with suitably rated terminal connectors to directly receive ACSR conductor of required size. The termination shall have at least 3 pairs of holes to hold the conductor tight with nuts & bolts The terminals shall conform to all the test requirements of IS: 5561 and shall be designed as to avoid bimetallic corrosion. 2.4. The operating rod shall comprise of not less than 40 mm (nominal bore) Galvanised steel pipe as per IS 1161-1979. The length of the operating rod shall be suitable for operation as per installation methods. The rod shall be so threaded that the length can be adjusted. 2.5. The horizontal operation shaft shall be of solid Galvanised steel of square section suitable for fitting the insulator base of the switch. Length of the rod shall be such as to maintain the phase clearance as per I.S. 2.6. The operating handle shall have OFF/ON locking arrangement and provision for earthing the equipment. 2.7. The gang operating switch shall be provided with three post insulators per phase conforming to IS 5350 (Pt-III)-1971. The cast iron post shall be embedded in the insulators with sulphur cement. For embedded components, pull out strength should be such as to result in breakings of the porcelain insulators, the beam strength shall be as per relevant T.S. Creepage distance shall not be less than 900 mm and 300 mm for 33KV and 11 KV isolators respectively. 2.8. All similar materials and removable parts of similar equipments shall be interchangeable with each other.

3.0

APPLICABLE STANDARD 3.1. Unless otherwise stipulated in this specification, the Gang operated switch shall conform to IS. 9920 (Pt-I to Pt-IV). Failure to meet guarantees and requirement of specification 4.1. If after installation, the operation of the switch proven to be unsatisfactory, to the purchaser, the tenderer shall have to take back or replace. TEST AND INSPECTION 5.1. The switches shall be subjected to the following type test in accordance to with IS: 9920. I) Dielectric test (impulse and one minute) power frequency withstands voltage. II) Temperature rise test III) Rated off load breaking current capacity IV) Rated active load breaking capacity V) Rated line charging breaking capacity VI) Rated short time current VII) Rated peak withstand current VIII) Mechanical and Electrical Endurance

4.0

5.0

116

5.2. The equipment shall be subjected to the following routine test. IV) Power frequency voltage dry test V) Measurement of resistance of the main circuit VI) Operating test. 5.3. The porcelain will have pull out test for embedded component and beam strength of porcelain base. 5.4. The manufacturer shall afford the inspection representing the purchaser or third party nominee all reasonable facilities, with charge, to satisfy him that the material is being furnished in accordance with this specification. The purchaser has the right to have the test carried out at his own cost by an independent agency whenever there is dispute regarding the quality of supply. 6.0 GUARANTEE The Bidder shall offer equipment performance guarantee for a minimum period of 1 year from the date of commissioning. Any damaged part or defective part of the equipment, the bidder has to replace at his cost. TECHNICAL SPECIFICATION 1.0 1.1 1.2 1.3 2.0 2.1 2.2 2.3 2.4 SYSTEM DETAILS Nominal system voltage, KV Highest system voltage, KV Nominal frequency, Hz GENERAL SPECIFICATION Rated voltage, KV Rated frequency, Hz Rated normal current, Amp Rated lightning impulse withstand voltage i) To earth and between pole, KV (Peak) ii) Across the isolating distance, KV (Peak)

7.0

33 36 50

11 12 50

36 50 400 A,

12 50 630, 800

170 195

75

2.5

2.6 2.7 2.8 2.9 2.10 2.11 2.12

Power frequency one minute withstand voltage, i) To earth and between pole, KV (RMS) ii) Across the isolating distance, KV (RMS) Temperature rise Rated short time current 3 Sec, KA Rated active load break capacity, Amps Transformer OFF-Load current breaking capacity, Amps Rated line changing breaking capacity, A(rms) Rated Peak withstand current Electrical endurance

70 28 80 -as per relevant IS25 16 400 200 10 10 6.3 6.3

2.13 2.14

Mechanical endurance Minimum insulator creepage distance, mm

25 KA 16 20 operations for 400 A ,200 operation for 200 A 1000 operation 900 300

117

3.10
1.0

TECHNICAL SPECIFICATION OF BATTERY BANK

SCOPE This Section of the Specification covers the design, manufacture, and testing at manufacturers work, of stationary type sealed, Valve Regulated Lead Acid Battery Bank, Battery Charger, complete with all required accessories for various Sub-stations. BATTERY BANK TECHNICAL PARTICULARS OF BATTERY BANK 1. 2. Battery Rating Type of battery 110 V-100 Ah to 1.75 ECV at C10 at 27 C Maintenance free valve regulated lead acid (MFVRLA) battery Batteries conforms to IS 15549:2005 Also conforms to International Standards (I) IEEE 1188 and 1189 (II) BS6290 Part 4/ IEC 896 F 100 P 55 Nos. 2000 cycles for 50 % depth of discharge or 1200 cycles for 80 % depth of discharge Above 90% Above 80 % < 1% of rated capacity 55 C continuously and 70 C short time (107.8 x 198.5 x 477)mm approx. 27 kg approx. 6 months from the date of manufacturing and the batteries shall be stored in covered area at 27 C Polypropylene co-polymer Highly absorbent micro porous spun glass matrix (AGM) Flat pasted Mild steel coated with acid resistance paint Bolted Batteries shall be charged in constant potential mode with current limit Voltage: 2.23-2.25 Volts per cell Current: Recommended- charging current is 45 amps Voltage: 2.3 Volts per cell Current: Recommended- charging current is 45 to 90 amps 9 Hrs for 90 % state of charge (or) 24 hrs for 100 % state of charge < 2% of the RMS value Lead coated heavy duty copper strips 118

2.0
2.1

3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.

Battery specification Manufacturers cell designation No of Cells Cycle life of Battery @ 27 C All efficiency WH Efficiency Self discharge/ Week Max, allowable ambient temp at which cell can safely operate Overall dimension of each cell Overall weight of each cell Recommended Max period of storage Material of container Type of separator Type of +ve & -ve plates Material of rack Method of connection between cells

19.

Recommended float charge

20.

Recommended boost charge

21. 22. 23.

Time required for boost charge from fully discharged condition at 27 C Voltage ripple allowable Type of connectors

2.1.1

PLATES Positive plates shall be made of flat pasted type using lead-cadmium antimony alloy for durability, high corrosion resistant, maintenance free, long life both in cyclic as well as in ,float applications. Negative plates shall be heavy duty, durable flat plate using lead calcium alloy pasted box grid. Negative plates shall be designed to match the life of positive plates and combination of negative and positive plates shall ensure long life, durability and trouble free operation of battery. PLC operated equipment should be deployed for preparation of paste to ensure consistency in paste quality. Conventional / manual type of paste preparation is not allowed. CONTAINER AND LID The containers and lids shall be made of a special grade polypropylene copolymer plastic material. They shall be sufficiently robust and not liable lo deformation under internal operating pressures and within the temperature range naturally encountered, leak proof, non-absorbent and resistant to the acid with low water vapour permeability. VENT PLUGS : Each cell shall be equipped with one-way safety valve with opening pressure of 51 psi and closing pressure 41 psi. The vent plug shall be made with suitable grade of fire retardant plastic material. Each valve opening shall be covered with flame barrier capable in preventing the ingress of flame into the cell interior when the valve opens and hydrogen / oxygen gas mixture is released. SEPARATORS : Separator shall be made of spun glass, micro porous matrix and shall be resistant to Sulphuric Acid. It shall be capable of keeping the entire electrolyte and shall be electrically insulated. Sufficient separator overlap and PVC shield protection to top and bottom edges of the plates is to be provided to prevent short circuit formation between the edges of adjacent plates. CONNECTORS : The connectors shall be lead coated copper of suitable size to join the cells. The connectors shall be suitably designed and coated to withstand corrosion due to sulphuric acid. The coating should be adequate and tenacious. All the copper inter cell connectors shall be provided with heal shrinkable sleeves except at the connecting points. ELECTROLYTE: The electrolyte shall be prepared from the battery grade Sulphuric Acid confirming to ISS: 266. The batteries shall be supplied in factory filled and charged condition. WATER Water required for preparation of electrolyte shall conform to IS: I069. PLATE CONNECTION Lugs of plates of like polarity shall be connected by lead burning to a horizontal strap having an upstanding terminal post adopted for connection to external circuit. Strap and post shall be caste with lead alloy. The positive and negative terminal posts shall be clearly marked for unmistakable identification. BOLTS AND NUTS Nuts and Bolts for connecting the cells shall be of superior grade passivated Stainless steel. TERMINALS Terminals shall be of integral lead terminal with solid copper core with M6 threading for fastening. The junction between terminal posts and cover and between the cover and container shall be hermetically sealed. BATTERY RACKS Batteries shall be installed on MS racks to be supplied by the Contractor to fit in the battery room. Racks/Trays shall be powder coated with anti corrosive paint. Rack shall accommodate 55 cells plus 2 spares. Racks/Tray shall be suitably treated before painting for protection against fungus growth and other harmful effects due to tropical environment. The colour of the supporting racks shall conform to RAL 7032 shade. a) cy H.V. test / Insulation tests.

2.1.2

2.1.3

2.1.4

2.1.5

2.1.6

2.1.7 2.1.8

2.1.9

2.1.10

2.1.11

119

3.11
2.1.12

TECHNICAL SPECIFICATION FOR BATTERY CHARGING EQUIPMENTS

GENERAL DESCRIPTION The battery charging equipment shall be capable of giving two rate of charging currents namely Boost Charge and Trickle Charge. The charging equipments capable of giving two rate of charging currents shall consist of two separate sections: Boost Charger Section & Trickle Charger Section. The Trickle Charger Section along with all necessary equipments is required for the purpose of float charging one battery bank of 55 cells of capacity 150 Ah at 10 hours discharge rate at the rate of 2.0 volts to 2.3 volts per cell and for meeting a constant D.C. load of 10 Amperes at 110 Volts D.C. simultaneously. The Boost Charger Section along with all necessary equipments is required to charge a battery bank of 55 cells of capacity 150 Ah at 10 hours discharge rate at the rate of 1.85 volts to 2.55 volts per cell and for meeting a constant D.C. load of 10 Amperes simultaneously. TYPE AND RATING i) TYPE The charger shall be static type, using Silicon Rectifiers. The rectifiers shall be arranged in three phase bridge circuit for full wave rectification. The charger unit shall be suitable for operation on 415 volts three phase, 4 wire, 50 Hz A.C. Supply. The Boost and Trickle Charger section shall have an arrangement for automatic and manual D.C. voltage regulating system with an Auto / Manual change over switch. ii). RATING The entire charger circuitry shall have two separate sections eg. Boast charger and Trickle charger sections and shall of following ratings:

2.1.13

2.1.13.1 Float Charger (a) D.C. Output Voltage: (i) The D.C. output voltage of the Float charger shall be 110 volts (nominal). (ii) The D.C. output voltage of the Float charger shall be adjustable between 110 volts to 126.5 volts. (b) D.C. Output Current: (i) The Trickle charger shall be capable of supplying a continuous D.C. load of 10 amperes and float a battery bank of 150 Ah at 10 hours discharge rate simultaneously at a normal voltage of 110 volts D.C. 2.1.13.2 Boost charger: (a) The D.C. output voltage of the Boost charger section shall be adjustable between 101 volts to 140 volts. (b) D.C. Output Current: The Quick charger shall be capable of charging a battery bank of 150 Ah capacity at 10 hours discharge rate and to meet a continuous D.C. load of 5 amperes simultaneously. Output current of the Boost charger shall not be less than about 20 Amperes. 2.1.14 OPERATION AND CONTROL REQUIREMENTS: The incoming A.C. supply for Quick and Trickle charger shall be controlled by rotary switches. In addition to the rotary switches supplies to the both chargers shall be controlled by two push button operated contractors having overload protection. RED & GREEN indicating lamps shall be provided to indicate ON & OFF conditions respectively of the Quick and Float charges in addition to the A.C. ON indication. During normal operation of the Trickle charger shall supply the normal direct current requirements of the substation and the station battery shall be floating on D.C. system. In the event of failure of A.C. supply or failure of the charger itself the battery shall come automatically across the load without any interruption. It is intended to supply the D.C. load of the equipment normally by the float charger during boost charging of the bank. Thus, when the Boost charger is switched ON the Boost charger and the battery bank shall be isolated from the float charger and the load automatically. If during boost charging operation, the A.C. supply fails, the battery shall come automatically across the load without any interruption. During the infinitely small time required for initiation of the contractor a reduced number of cells shall be available across the load, through the blocking diode. Provision shall also be made so that in the event of failure of Float Charger, the Boost charger shall supply the load as well as charging a battery bank. Arrangement shall be made to limit the voltages across the load to around 110 volts, even if the boost charger is operating at maximum charging voltage. This aspect shall be clearly brought out in the tender by the bidder. In this operation also, the battery bank should come across the load automatically and without any interruption in the event of A.C. mains failure.

120

2.1.15

VOLTAGE REGULATING SYSTEM The Float and Boost Charger sections shall have suitable arrangement for regulation of D.C. output voltage by the following methods. (a) Automatic Voltage Regulation. (b) Manual Voltage Regulation. (a) Automatic Voltage Regulation: The Automatic Voltage Regulation shall hold the voltage flat from zero to full load within 1% of pre-set value of the charger with a fluctuation of 10% in voltage and 5% in frequency in the A.C. input voltage. The setting device of the automatic voltage regulator shall be so designed that the D.C. output voltage can be set anywhere between (i) 100 volts to 126.5 volts for Float Charger and (ii) 100 volts to 140 volts for Boost Charger. The automatic voltage regulator shall be static type and its characteristics shall be supplied with the tender. (b) Manual Voltage Regulator: The Manual Voltage Regulator for Trickle charger shall have suitable equipments and means to control the D.C. output voltage with the ranges mentioned earlier. The voltage control shall be smooth and continuous. The charger shall have a change over switch for selecting Auto or Manual mode of regulation to regulate the D.C. voltage. The tenderer shall furnish all the details of the manual voltage regulator in the tender. Both the trickle and boost chargers shall be provided with alarm and indication for the following: (a) Mains on (b) Charger failed. (c) Rectifier element fuse blown. (d) Charger output fuse blown. (e) AC input failed In addition to the above arrangement for controlling, regulating and operation of the charger, the bidder may suggest and quote suitable alternative arrangement for the same. The right of acceptance of such an arrangement shall however, lie with the Employer.

2.1.16

INSTRUMENTS, EQUIPMENTS, ETC i) Rectifier Transformer The rectifier transformers shall be designed to operate at a frequency of 50 Hz and at the r.m.s. voltage between the lines on the line side of transformers of 415+10% volts. The rating of the rectifier transformer shall correspond to the rating of the associated rectifier assembly. The transformer should preferably be air cooled dry / synthetic oil filled type and shall conform to the latest issues of IS: 2026 and IS: 4540. ii) Rectifier Elements Rectifier elements shall be Silicon and shall be arranged in three bridge circuit. The rectifier elements shall be protected by HRC fuse with fuse blow out indication. The rectifier stacks shall be supplied with their own heat dissipating arrangement for natural air cooling. iii) Measuring Instruments: The instruments shall be flush type and shall have dust proof and moisture resistant enclosed cases, finished in black and suitable for tropical use. Elements shall be shock resistant and shielded from external magnetic fields. The instruments and meters shall have easy accessible means for calibration testing and adjustment and shall conform to relevant I.S.S. iv) Air Break Switches and Fuses: The series combination air break rotary switches and HRC fuses shall conform to provisions of the latest issue of IS-4064, IS-4047 and IS-2208. the air break switches and fuses housed in the charger panel shall be so arranged that when they are opened, the terminals are readily accessible. Switches shall be of rotary operated type preferably with silver to silver contacts of adequate making, carrying and breaking current ratings and shall open and close with snap action to minimise arcing. The ON and OFF positions of the switches shall be definite and shall be clearly indicated. All fuses shall be of HRC type conforming to the latest issue of I.S. 2208. v) The charger units shall be provided with but not limited to the following instruments and equipments. a) 3 Pole A.C. mains ON-OFF switches and HRC fuses of suitable capacity. b) 2 pole air break switches with HRC fuses of suitable capacity output side of chargers. c) Air break magnetic contactors of suitable ratings complete with push button and thermal overload devices and red and green indicating lamps for A.C. input ON/OFF to the chargers. d) Fuse blown out indication for D.C. output fuses. e) HRC fuses for protection of rectifier elements with fuse blow out indication.

121

f) g) h) i) j) k) l) m) n)

0-500 volts range, A.C. voltmeters to measure A.C. input voltage to the chargers. Accuracy class 1.0 as per I.S. 1248. Moving coil, flush mounting type voltmeters of suitable ranges to measure trickle, boost and battery voltages. Accuracy class: 1.0 as per I.S.-1248. Moving coil, flush mounting type ammeters of suitable scales to read the output currents of boost and trickle chargers and load current. Accuracy class : 1.0 as per I.S.-1248. Single pole D.C. contactors of suitable ratings. Blocking diode of adequate capacity. Cubicle illuminating lamps with door operated switches suitable for 240 volts A.C. All other equipments and accessories for indication and alarm annunciation as mentioned earlier. All other equipments not specifically mentioned but required for proper and satisfactory operation of the charger shall be provided. The charger assembly shall be complete with input / output terminals, cable glands, internal wiring, earthing terminals, rating plates, etc.

2.1.17

2.1.18

CONSTRUCTIONAL FEATURES: The whole battery charging equipments shall be housed in an indoor, floor mounting type; sheet metal clad, cubicle type enclosures which shall also be served as charger panels. The assembly shall be complete in all respect and shall contain all the components described in different clauses and which are essential for the proper operation and control of the equipments. The enclosures shall be totally enclosed dust tight and vermin proof. All doors and covers shall be filled with rubber gaskets. The panels shall have double leaf hinged doors at the back and shall be provided with locks and duplicated keys. The equipments in the panels shall be so located as not to cause congestion and accessibility to the equipments located herein shall be easy and convenient. All incoming and outgoing cables shall enter from bottom and suitable cable terminal boards with cable lugs shall be provided in side of each panel for incoming and outgoing cables. Each terminal of the terminal boards shall be serially numbered to facilitate connections. At least 20% extra terminals shall be provided in each terminal board. Suitable compression type cable glands with base plates shall also be provided. The terminal boards shall be easily accessible for inspection and checking. The panels shall have cable supports and metallic clips for supporting power and control cables for internal wiring of the panels. TESTS The battery charger and all the components of the charger shall be routine tested accordingly to their relevant standard. This shall include the following: b) Operational check for boost and float charger. c) Input / Output test of the chargers. d) Performance test of the charger. e) Temperature rise test of the rectifier transformer. f) Power frequency

122

3.12

TECHNICAL SPECIFICATION FOR DC DISTRIBUTION BOARD

1.0 General Features 1.1. The D.C. distribution boards shall be indoor, floor mounting of self supporting, sheet metal clad, and cubicle type. The panels should be totally enclosed, dust tight and vermin proof and shall be made of 2.0mm cold rolled sheet steel. The boards shall be provided with double leaf hinged doors at the back. All doors and covers shall be fitted with rubber gaskets. The doors shall be provided with locks and duplicated covers 2.0 Busbars 2.1. The busbars shall be of electrolytic copper of ample cross-section. The busbars shall be insulated from the structure by means of durable, non-hydroscopic, non-combustible and non tracking materials. 3.0 Detail Requirements 3.1. The 110 Volts D.C. distribution boards shall be provided with the following: i. One mains failure alarm relay. ii. One earth fault alarm relay. iii. One 110 Volts D.C. bell to be operated by the mains failure alarm relay. iv. One 110 Volts D.C. buzzer to be operated by the earth failure alarm relay. v. One double pole air-break circuit breaker of 200 amp capacity with thermal overload tripping arrangement to act as incoming breaker of the load bus. vi. One 0-150 volts D.C. moving coil voltmeter to measure the bus-bar voltage. The display is to be in digital. vii. One pilot lamp to indicate D.C. on conditions. viii. 250 volts, double pole double throw make before break switch with H.R.C. fuses of following ratings for outgoing feeders. a. 16 Amp, 4 Nos. b. 32 Amp, 3 Nos. c. 63 Amp, 1 Nos ix. One terminal Board/block for all feeder outlets including cable glands.

123

3.13
1.0 1.1. SCOPE

TECHNICAL SPECIFICATIONS FOR A.C. DISTRIBUTION BOARD

This section of the specification covers the design, manufacture, testing at works, transport to site, insurance, storage, erection and commissioning of 415 volts, A.C. 50 Hz A.C. Distribution Board complete with all equipments and accessories as described in subsequent clauses. CONSTRUCTIONAL FEATURES The L.T.AC. panels shall be outdoor, sheet metal clad type comprising of combination switch fuse units and bus bar chambers. and equipped with the circuits and equipments as specified later. The different circuits shall be mounted above and below the bus bar chamber to form a suitable arrangement, except that the incomings will be located at the front and mounted below the bus bar chambers. All equipments shall be suitable for the reception of the cables rising from the ground level. The switch boards shall be so designed as to be readily extensible. Required technical particulars of ACDB 1 . 2 Manufacturers Name & Co Bus Bars a) Make b) Continuous Current rating in Amps c) Material d) Current Density
Incoming Switch Fuse Unit a) Make b) Type c) Rated Voltage d) Continuous Current carrying Capacity in Amps Indication Lamps a) Make b) Type c) Voltage Fuse a) Make b) Type c) Rupturing Capacity Switch (triple/double pole) a) b) c)

2.0 2.1

2.2

200A Aluminium 0.9 Amps/sqmm Havells/ Schinder SFU 415 Volts AC 200A STD LED 220Volts Havells/ Schinder HRC 80 KA Havells/ Schinder/ EQV SF UNIT 63A/32A/16A

Make Type Rated Continuous Current carrying Capacity in Amps

Current Transformer a) Make b)

Type

c) Ratio d) VA burden rating e) Accuracy class f) Type of Insulation g) Security factor AC Meters/ Energy Meters (Details for Ammeters Voltmeters, Energy Meters shall be furnished separately) a) Make

Bar primary and ring type 100-200/5A 15 VA 1 PVC <5 AM KWH VM

M/S SML,or M/S 124

b)

Type

c)

Range

d) Accuracy Internal Wiring a) Make b) c) d) e)

L&T MI 96 mm sq. 3 ph, 4W 0-100 A ,200/5 0-200 A 0500 0-300A 1.5 Supercab/ EQV PVC Insulated Copper 1100 Volts Recommended Copper

Type Voltage Grade Size Material used

1 0

Cable Glands a) b) c) d)

Make Type Size Material used

Standard Compression type As per cable size Brass

1 1

Terminal Block a) b) d)

Make Type Material used

Eleco/ STD STUND Type Bakelite DMC

1 2

Switch Board a) b) c) d)

Overall Dimension Thickness of Steel metal Finish Approximate Weight

1500x900x500 mm(for nine feeders ACDB) 1.6 mm Light Grey 250Kg

3.0 3.1. 3.2. 4.0 4.0

COMBINATION MCCB UNIT All MCCB shall be of triple pole rotary operated type and shall open and close with snap action. The series combination MCCB shall conform to the provisions of latest issue of IS 13947-2. The MCCB shall be suitable for rated voltage of 415 volts AC., 50 Hz. The rated current of each unit shall be as specified before. BUS BARS The phase and neutral bus bars shall be of high conductivity (as per IS 5082) aluminum of adequate uniform cross section. The bus bars shall be insulated from the structure by means of durable non-hygroscopic, noncombustible and non-tracking materials. Bus bar joints shall be bolted type. The 415 Volts, L.T.A.C. switchgear shall have following circuits and equipments: (a) INCOMING: - One number fitted with following: (i) One 400/300 Amps. as required , unit fitted with cable glands suitable for 4 core XLPE cable labeled "Incoming". (ii) One voltmeter, 0-500 volts. (iii) One Ammeter, 0-500 Amps. (iv) One KWH Static Electronic Three phase Trivector meter having facility of downloading the data with connected CTs as mentioned. (b) OUTGOING :- Nos. 1 and 2 each comprising of:

5.0

125

One 300/200 Amps. as required, unit fitted with complete with direct connected round protecting pattern ammeter, scaled 0-300 Amps, and cable gland suitable for 4 core XLPE cable labeled as outgoing. Name Plate The board shall be provided with nameplate covering all technical data and also name of the project shall be clearly mentioned 7.0 INSPECTION. Inspection may be carried out by the purchaser or third party nominee at any stage of manufacture. The supplier shall grant free access to the purchaser's representative or third party nominee at a reasonable time when the work is in progress. Inspection and acceptance of any equipment under this specification by the purchaser shall not relieve the supplier of his obligation of furnishing equipment in accordance with the specification.

126

3.14
1.0

TECHNICAL SPECIFICATION FOR DISTRIBUTION TRANSFORMERS OF CAPACITY 100 KVA

SCOPE This specification covers the design, manufacture, testing at manufacturer's works, transport to site, insurance, storage, erection and commissioning of Oil immersed, naturally cooled, three phase double wound out-door type transformers of capacity 100 KVA, having working voltage of 11 KV/0.433 KV complete with all fittings and accessories for installation. Any fitting, accessory or operation which may not have been mentioned specifically in the specification, but which are normally used or necessary for safe and efficient working of the transformer shall be deemed to be automatically included in this specification.

2.0

STANDARDS The transformer shall conform in all respects to the following standards and codes as mentioned below: IS-335/K 83, BS-148, ASTM D-1275 IS-2026 (Part 1 to 4)-1977/81) IS-2099-1986 IS-3347, DIN 42531 to 33 IS-3639-1968 IS-6600-1972 IS-7421-1988 IS-10314-1982 CB & IP Publication No.275 IS-1180 (Part I & II) ISS-12444 & ASTM-B-49 ISS-5484 & ASTM B-233 : New insulating oil for transformer switchgear : Specification for power transformers : Bushing for alternating voltage above 1000 V : Dimensions for porcelain transformer bushing : Specification for fittings and accessories for power transformers : Guide for loading of oil immersed transformers : Specification for porcelain bushings for alternating voltage up to and including 1000 V : Specification for ceramic bushing for terminals : Manual on transformer : Outdoor distribution transformers up to and including 100 kVA : Copper wire rods : Aluminum wire rods

2.1

ISS-5/1961 No. 632 : Colours for ready mixed paints 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. SYSTEM DETAILS The transformers shall be suitable for outdoor installation with 3-phase 50 Hz, 11 kV system in which the neutral is effectively earthed and they should be designed suitable for service under fluctuations in supply voltage upto .:!:. 12 %. Permissible under Indian Electricity Supply Act and rules made there under. CLIMATIC CONDITIONS a) b) c) Maximum temperature of air in shade Minimum temperature of air in shade Maximum temperature of air in Sun 40C 2C 40C

3.0

4.0

127

d) e) f) g) h) i) j)

Maximum Humidity Average number of thunderstorm days Average numbers of dust storms per annum Maximum rainfall/annum Average rainfall Wind Pressure Altitude above MSL

93% 45 10 3500 mm 2280 mm 97.8 Kg/Sq.mm 100 m to 1000 m

5.0

TYPE AND RATINGS CONVENTIONAL (i) (ii) a) b) Capacity (Continuous rating) : 100 KVA No load voltage ratio at normal tap position Primary voltage : 11000 V Secondary Voltage : 433 Volts between phases and 250 volts between

phase to neutral

(iii) Nominal frequency : 50 Hz (iv) Highest system voltage : 12 KV (v) No. of phase :3 (vi) Winding connections : Delta/Star (vii) Vector group : DyII (viii) Cooling method : ONAN (ix) Impulse withstand voltage : 75 KV Peak (x) Power frequency withstand voltage : 28 KV rms (xi) Impedance voltage at 75C : 4.5% for 100 KVA AND 5% ABOVE 100 KVA UPTO 1000 KVA

6.0
a) b)

TEMPERATURE RISE ABOVE AMBIENT IN ACCORDANCE WITH IS-2026 Windings (temperature rise measure by resistance 45C method) - over an ambient temperature of 45C Top oil (temperature rise measured by thermometer) over an ambient temperature of 45C

40C

The temperature shall be continuously rated at specified voltage ratio, frequency. The temperature rise in the core, under the same loading condition, on any part of external surface should not exceed that permitted for the adjacent part of the winding. MAXIMUM ALLOWABLE LOSSES & IMPEDANCE Sl.No 1 Ratings in KVA 100 No-Load Loss in Watts 260 Full Load Loss in Watts at 75C 1760 % Impedance 4.5

7.0

These losses are maximum allowable and there 'would not be any positive tolerance. However, the manufacture can offer losses less than above. The offer will be evaluated as per the loss evaluation formula given in REC, K-5 Standard- 1997 as amended up-to-date.

128

8.0
8.1 8.2 8.2.1

TAPPING RANGE Tappings will be provided on the higher voltage in steps of 2% and 5% on all ratings. Tap Changing Method The tap changing device shall be off - circuit type. The tap changing shall be carried out by means of an externally operated tapping switch capable of being located and locked in any required position.

8.2.2 8.2.3

The taps shall be provided on HV side winding for variation of no load primary voltage over the range given in clause 3.0 of this specification. The location of tap changing device shall be such that an operator can very easily change the tap, while standing on the ground without the aid of any climbing platform.

8.2.4

A warning late indicating that switch shall not be operated' in 'ON' position be provided. TOLERANCES The tolerances on electrical performance shall be as shown below: a) Voltage ratio + 0.5% of the declared ratio or a percentage equal to 10% of the percentage impedance voltage, whichever is less. b) Impulse & Power Frequency Voltage The Distribution Transformers shall be capable of withstanding the power frequency and impulse test voltage. Nominal system voltage : 11 KV rms Highest test voltage : 12 KV rms Impulse test voltage : 75 KV peak Power frequency voltage : 28 KV rms Unless otherwise specified herein the test value of the transformers supplied should be within the tolerance permitted in the IS 2026 on the guarantee value.

9.0

10.0
10.1

DEISGN OF CORE The cores shall be constructed from high grade cold rolled non-aging grain oriented silicon steel laminations. The design of the magnetic circuit shall be such as to avoid static discharges, development of short-circuit paths within itself or to the earthed clamping structure and the production of flux components at right angles to the plane of laminations which may cause local heating. The core laminations shall be held rigidly by a steel framework which shall clamp them together to prevent any vibration. The core shall be provided with lifting lugs suitable for lifting the complete core and coil assembly of the transformer without transmitting the stresses to the laminations. The transformer shall be suitable for over fluxing due to combined effect of system voltage and frequency upto 12.5% without injurious heating. These laminations shall be as thin as possible consistant with mechanically strong constructions. At least one side of each lamination shall be coated with a hot oil proof insulating material. In case the manufacturer's standard method is different from this, It should be clearly described. The laminations should be free from rust and colour spots. The laminations shall be grade 41 (M4) or better grade. Core Clamping: The core shall be so insulated that there is no possibility of contact between edges and the core bolts. The bolts shall be tested at 2500 volts to earth. M.S. Channel to be used upto 100 kVA, 75 x 40 mm size on top and bottom. 2 x12 mm high tensile bolts to be used upto 100 kVA in parallel at each end. MS channel on LV side to be reinforced at equidistance if holes / cuttings is done on L T side to avoid bending of channel. MS channel to be painted with varnish / oil resistant paint. Flux Density should not be more than 1.60 webers sq. m (Tesla). No load current (Magnetizing current) shall not exceed 3 % of full load current upto 100 kV A and 1.25 % for 250 kV A and 315 kV A and will be measured by energizing the transformer at 433 Volts, 5Q Hz on the secondary. Increase of voltage of 433 volts by 10 % shall not increase the no-load current disproportionately high. Test for magnetic balance by connecting the LV phase by phase to rated phase voltage and hleasurement of a n, b n, and c n voltage will be carried out. 129

10.2

10.3 9.1.1 9.1.2 9.1.3 9.1.4 9.2 9.3

9.4

Number of steps of core shall be minimum of 5 Nos. upto 100 kVA and 7 Nos. for 250 kVA and 315 kVA. Diameter and area of core: Diameter of core shall not be less than 115 mm Effective area of core shall not be less than 92 sq. mm Tie rods: 4 Nos. of 12 mm diameter size (upto 100 kVA) and 8 Nos. of 16 mm diameter size for (250 and 315 kVA) of High tensile steel rods shall be effectively insulated. All top and bottom Yoke nuts and bolts and tie rods shall be painted with oil and corrosion resistant paint before use. Core base and bottom Yoke shall be supported with 75 x 40 mm. MS channel with proper bolting. Flat or cut channel will not be accepted. NOTE: Tenderers may also quote for the Amorphous core (low loss) and they should furnish design details in their bid proposal for verification.

9.5 9.5.1 9.5.2 9.6

9.7

9.8

10.0 10.1

DESIGN OF WINDING Material: Double paper covered insulated electrolytic aluminium conductor shall be used for all ratings except 250/315 KV A for which DPC insulated copper shall be used . Current density for HV and LV should not be more than 2.8 amp/sq.mm for copper (with tolerance of 5 % for LV winding) and 1.5 amp/sq.mm for aluminium conductor. Cross-section of conductor (in sq.mm)

10.2

10.3

Capacity in kV A 100 kVA 10.4 10.5

HV Winding 2.27

LV Winding 96

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 enameledcopper wire with multi-layered (not less than 13 layers) paper insulation. Necessary resin bonded paper insulation tubes or backlite bits may be used through. This shall be done with ferrules and crimping. 10.6 All the sleeves used in construction shall be fibreglass material. 10.7 The star point shall be done with aluminium ferrules and crimping. 10.8 The HT Jumpers from winding to the HT bushing should pass through resin bonded paper cylinders and fiberglass sleeves. 10.9 Vertical ducts and spacers shall be provided within each coil for HV and LV windings. Dovetail spacers shall be used in between HV coils and they shall be used in between HV coils and fixed to the vertical ducts which are provided between HV and LV. 10.10 Insulation Materials and Clearances 10.10.1 Electrical grade insulation Kraft paper of Triveni / Ballarpur make and Press Board of Senapathy Whitely or Ramon Make shall be used. 10.10.2 10.10.3 10.10.4 Radial clearances of LV coil to core (bare conductor) shall not be less than 4 mm Radial clearance of HV & LV shall not be less than 11 mm for all capacities. Phase to phase clearance between HV conductor shall not be less than 10 mm for 11 kV with a minimum of 2 x 1 mm Press Board to cover the tie rods.

130

10.10.5 10.10.6 10.10.7

The minimum electrical clearance between the winding and body of the tank (between inside surface of the tank and outside edge of the winding) should be 30 mm. Minimum end insulation to\earth shall be 25 mm . ., No. of coils HV / Phase 4 (min.) for 63 kVA and 100 kVA and 6 (min.) for 160 kV A and 315 kV A transformers. Thickness of locking spacers between HV coils - 10 mm min. No. of axial wedges between LV & HV winding equispared around 6 Nos. for 63 kVA and around 8 Nos. for 100 kVA and above capacity. Tap lead shall be insulated 1.5 mm thick with paper insulation. Manufacturing drawing showing various clearances shall be got approved by the State Electricity Board. Winding Connections and Vector Group The primary of the transformer should be connected in delta and the secondary winding should be connected in star in accordance with vector symbol Dy-II so as to produce a positive phase displacement of 30 between the primary and secondary voltage vectors of the same phase. The neutral should be brought out to a separate insulated terminal for the purpose of grounding etc. Current density for HV & LV should not be more than and 2.8 Alsq. mm for copper (with a tolerance of 5 % for LV winding) and 1.5 Alsq. mm for aluminium conductor. Winding Terminals a) HV side : the HV winding terminals should be brought outside the transformer tank through 3 Nos. of weather proof, out door type, brown glazed bushings conforming to ISS:3347 (Pt.V.Sec-l) 1965 for porcelain and I.S.S.:3347 (Pt.-V, see-II) : 1967 (metal parts) with upto be amendments and revisions. Arching horns with appropriate BIL. (80% of impulse voltage) should be mounted on the bushings.

10.10.8 10.10.9 10.10.10 10.10.11 10.11 10.11.1

10.11.2

10.12

LV Side : the LV v:inding terminals should be brought outside the transformer brown glazed bushing conforming to IS : 3347 (Pt-I, Sec-2) : 1965 (for porcelain parts) and IS : 3347 (Pt-I, sec-2) : 1967 (for metal parts) with upto date amendments and revisions. Arching horns with appropriate BIL (80% of impulse voltage) shou1d be mounted on the bushing. 10.13 Winding Construction a) The HV and LV winding coils should be circular and arranged cocentrically in such a manner that the lower voltage winding is placed next to the core and the magnetic axis of the winding should be made coincident as far as possible. b) The size of the HV winding wires shall be such as to have greater mechanical strength and lower current density. c) The flux density should not be allowed to exceed 1.9 Tesla under over voltage condition so that the core is not saturated. d) Top and bottom coils shall be supported by wooden discs to take care .of electro-mechanical rd forces under short-circuit conditions. 2/3 area of the coil should be covered by spacers. 11.0 DESIGN OF TANK 11.1 The transformer tank shall be of robust construction and shall be built of electrically welded MS plates. All joints of tank and fittings shall be --- tight and no bulging shall occur during service. The tank design shall be such that the core and windings can be lifted freely. The tank plates shall be of such strength that the complete transformer when filled with oil may be lifted bodily by means of the lifting lugs provided. Tank inside shall be painted by varnish. Top cover shall be slightly sloping towards HV bushing and cover the top with end walls. 11.2 I) Side Wall thickness : 3.15 mm

11.3

II) Top and bottom plate thickness : 5.00 mm The four walls of the tank shall be made of TWO "L" shaped sheets (without joints) fully welded at the

131

corners from inside and outside of the tank for withstanding a pressure of 1 kg/sq.mm for 10 minutes. All the tank plates shall be of such a strength that the complete transformer with oil and fittings can be lifted bodily my means of lifting lugs provided. 11.4 Reinforced of welding stiffner angle (40 x 40 x 5 mm) on all the outside walls of the tank shall be provided to form two equal compartments (upto 100 kVA) and three equal compartments above 100kVA. The tank through longer side walls shall be reinforced additionally by welding suitable size flat/angle vertically to provide sturdy and robust construction to withstand extreme pressure conditions. All joints of tank and fittings shall be oil tight and no bulging should occur during the service. The tank design shall be such that the core coil assembly can be lifted freely. The hooks that will be used for anchoring the core shall be so located as not to foul with the core coil assembly. "U" shaped pressure relief vent of 50mm dia pipe with 0.025 mm copper shim sheet as diaphram shall be provided on the top cover of the tank such that the pressure released should be directed to the ground. The vent shall be provided on opposite side of the CB operating rod. The diaphram shall be provided near to the top cover and other end of the vent pipe shall guarded with suitable mesh against entering of worms and resting. The diaphragm should burst at a pressure between 0.76 kg/sq.cm to 0.95 kg/sq.cm. Pressure test will be conducted by the inspecting officer on a transformer vent pipe against each lot offered for inspection. The diaphragm should burst at a pressure between 0.76 kg/sq.mm to 0.95 kg/sq.mm. For any operational failure of vent pipe and consequent damaged to the tank an addition to insisting for free replacement of the tank, the State Electricity Board may at its option, recover an estimated loss sustained by it from the manufacturer. Permanent deflection when the tank without oil is subjected to vacuum of 760 mercury shall not be more than 5 mm up to 750 mm length 6 mm up to 1250 mm length. The tank shall be capable of withstanding a pressure up to 0.7 kg/sq.cm without any deformation. Inside of the tank shall be painted with hot oil proof paint. The transformer tank top cover shall be fixed with bolts and four corner bolts shall be welded, to prevent opening of the cover at site by miscreants. In addition to this "U" clamps seals may be welded on the four sides of the top cover for further prevention of meddling and suitable continuous neoprene gasket (Rectangular Ring) to avoid leakage of Nitrogen and all the fittings including bushings in position shall be tested for leakage at a pressure of 0.7 kg/sq.cm inside the tank for 10 minutes. The above test shall be carried out before final sealing of the transformers. The tank shall be fitted with round cooling tubes of minimum of 38 mm outer dia and 1.25 mm thick bent and directly welded on both sides i.e., inside and outside 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. Steel surface shall be prepared by sand shot blast on chemical cleaning including phosphating as per IS : 3618. Heat resistant paint (hot oil proof) shall be provided inside the tank. On external surface one coat of thermo setting powder paint or two coats of zone chromate followed by two coats of synthetic 'thermal paint of dark admiralty gray shade conforming to 632 of JS : 5 of 1961 shall be followed: Heat dissipation by tank walls excluding top and bottom should be limited to 500 W / sq.mt up to the oil level, 250 Watts / sq.mt above oil level and 300 Watts /sq. mt for cooling tubes. The transformer shall be capable of giving continuous rated output without exceeding the specified temperature rise. Tenderer shall submit the calculation sheets. Total minimum oil volume and minimum weights KVA Rating Oil in Ltrs. (Incl. of oil observed in core coil assembly) Permissible oil absorption in Ltrs. 7 Core Lamination min. in Kgs. Winding with Insulation min in Kgs. 72

11.5

12.5.1

12.6

12.7

12.8

12.9 12.10 12.11

12.12

12.13 Sl.N o.

100

240

207

132

12.14 12.15 12.16

Lifting Lugs: 2 Nos. welded heavy duty lifting lugs of MS plate 8 mm. Thick suitably reinforced by vertical supporting flat welded edgewise below the lug on the side wall. Pulling Lugs: 4 Nos. of welded heavy duty pulling lugs of MS plate of 8 mm, thick shall be provided to pull the transformer horizontally. Top Cover Gasket & Bolts: i) The gasket provided in between top cover plate and tank shall be of 5 mm thick neoprene rubberized cork sheets confirming to IS:4352, Part-II. ii) GI nut bolts shall be of size 38" x 1 ~" with one plain and one spring washer suitably spaced to press the cover. iii) The height of the tank shall be such that the minimum clear height upto the top cover plate of 120 mm, is achieved from top yoke. CONSERVATOR a) The total volume of conservator shall be such as to contain 10% quantity of the oil. Normally 3% quantity of the total oil will be contained in the conservator b) Oil level indicator shall be provided on the side which will be with fully covered detachable flange with single gasket and tightened with MS nut bolts. The pipe from conservator tank connecting to main tank shall have a slopping flap so that the oil falling from the pipe shall not fall directly on the active job and shall fall on the side walls only. The conservator shall be provided with the drain plug and a filling hold with cover. In addition, the cover of the main tank shall be provided with an air release plug. BREATHER Breather joints will be bolted type in case of metal container. Breather made of synthetic materials may be provided subject to the purchaser's approval. Breather volume in gram of silicagel 250 gms. TERMINALS a) Bross rods 12 mm dia both for HV & LV upto 100 kVA b) Bross rods of 12 mm dia for HV only above 100 kvA c) Tinned copper rods of 20 mm dia both for LV and HV above 100 kV A BUSHINGS The porcelain portion of HT and L T bushings shall be of standard make and conform to IS-2099/1973 (HV), "Specification for High voltage porcelain bushings" and IS-7421/1974 for LV IS-3347 shall be outdoor type. The bushing rods and nuts shall be as per clause 18 of specification. The bushings shall be fixed to the transformers on sides with straight pockets and in the same plane. The tests as per IS-2099 11962 shall be conducted on the transformer bushings as detailed below: a) Dry Flash over voltage b) Wet flash ever voltage c) Dry 1 minute with-stand voltage d) Impulse withstand voltage (1.2/50 micro seconds - Ve wave) e) Manufacturer's test certification to be furnished for eyery lot of offer

13.0

14.0

15.0

16.0 16.1

16.2 16.3

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 level. Dimensions of the bushings of the following voltage class shall conform to Indian Standards mentioned below. Indian Standards for Porcelain Parts IS-3347/Part-I/Sec.1/1965/1979 ISS for Metal Parts IS-3347/Part-I/Sec.2/1979 (ass per IS 1180/1989) IS-3347/Part-III/Sec.2/1982

Voltage Class 1.1 KV

17.5 KV 16.4 16.5 16.6

IS-3347/Part-I/Sec.1/1972

A minimum phase to phase clearance of 75 mm for LV (up to 1.1 kV bushing) and 255 mm for HV (3.3 kV and above) bushings shall be obtained with the bushing mounted on the transformer. The bushings shall be fixed on sides with pockets in the same plane. Arcing horns shall not be provided and instead brass caps shall be provided. Brazing of all inter connections, jumpers from winding to bushing shall have cross section larger than the winding conductor. For copper, silver brazing alloy to be used. For aluminum L & T aluminum brazing rods shall be used. 133

16.7

In the case of LV bushings, the internal bushings shall be made of tough insulating material like epoxy and shall have embedded stem and a strong coupling connection (screwed), properly secured with a spIJt'pin.shall be used between stem of the internal and external bushings. The LV bushing shall be so located that even under the hottest conditions the level of the transformer oil shall be below the open.ing meant for fixing the LV bushings. The LV jumpers and bushing material shall be selected and designed for this condition. The design of the internal bushing for LV shall be such as to provide adequate earth clearance as stipulated i.n the clause 10, 2.1 of 18 1180 Part-I and creepage distance as per clause 7.1 of 18 2099. All other tests as per relevant standards shall be applicable. The terminal arrangement shall not require a separate oil chamber not connected to oil in the main tank. The LV bushing and HV bushing stems shall be provided with suitable 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 letter IU, IV, IW and low voltage windings for the same phase marked by corresponding small letters 2u, 2v, 2 w. The neutral point terminal shall be indicated by the letter 2 n. The vector diagram plate shall clearly indicate the method adopted -for marking the terminals both outside and interior. LIGHTNING ARRESTORS 9 KV 5 KA metal oxide lightning arrestors as per 18:3070/1974 Part-I/lEC-99 (the latest version) one number per phase shall be fixed under the HV bushings with earth connected to the body of transformers with necessary clamping arrangements.

16.8

16.9

16.10 16.11

16.12 17.0

18.0

TRANSFORMER OIL The transformer shall be supplied complete with first filling of oil and the same shall comply with IS335/1983 with latest version thereof. The ageing characteristics after accelerated ageing shall be as given in Appendix-C of S335/1983 (or) latest version. The characteristics of the oil shall be as follows

S.No. 1 2 3 4 5 6 7

Characteristic Electric strength (breakdown voltage) Electric dissipation factor (tan delta) at 90C Specific resistance (resistivity) at 27C (ohm-cm) Flash point (PM closed) Inter facial tension at 27C Neutralization valve (total acidity) Water content PPM 30 KV (Min) 0.01 (Max) 12 140C (Min)

Specified Value

0.03 N/M (Min) 0.05 mg/KOH/g (max) 35 (Max)

18.1

DRYING & OIL-FILLING The core and the winding after assembly shall be dried in a vacuum drying chamber to a temperature of 90C. after this drying process the slackness of bolts, nuts and other clamping arrangements shall be checked and tightened. The tank shall be filled with oil heated upto 80C in vacuum. The tenderer shall furnish the vacuum pressure under which the whole operation shall be carried out.

19.0

FITTINGS & ACCESSORIES i. ii. Rating Plate Diagram Plate

134

iii. iv. v. vi. vii. viii.

Two Nos. Earthing terminals Lifting lugs for lifting arrangements of main transformer core coil assembly also for tank cover. HV bushings 3 nos. with bimetallic terminal connectors LV bushings 4 nos. with bimetallic terminal connectors. Metal Oxide lightning Arrestor (disconnector type with GI Pipe Earth Strip of 25 X 4 mm). U-shaped pressure relief vent 0.025 mm Cu diaphragm on the top of the top cover for breaking at a pressure of 0.76 to 0.95 Kg/cm. ix. LV epoxy Bushings 4 Nos. x. Base Channels 75 X 40 mm xi. Weight content of a) Core; b) Windings; c) Tank & Fittings; d) Weight/ Quantity of Oil; e) Overall Weight xii. 5 Year guarantee embossed plate welded below name plate xiii. Dehydrating silica gel breaker xiv. Conservator with oil filling hole & cap, drain, valve & with 50 mm blocking valve. xv. Plain oil level, indicator with minimum marking xvi. Thermometer pocket xvii. Explosion vent (pressure release device with diaphragm xviii. 2 Nos. oil filter valves with plug one at top a the other at bottom. The bottom filter valve can also be used are drain valve. xix. 4 Nos. unidirectional rollers suitable for plates form mounting xx. OFF and externally hand operated tap changing switch with position indicating plate and provision for locking device for HV variation. xxi. On the rating plate Name of the Project followed by the name of the State Electricity Board" should invariably be inscribed. The rating plate and the terminal marking plate should be mode of durable and non-corrodible material and information as per clause 15.2 of ISS:2026/77 (Pt-I) or any other relevant standard should be embossed thereon. The rating plate and the terminal marking may be combined into one whole plate. On the rating plate "Property of Assam State Electricity Board" should invariably be inscribed. 20.0 2.0 GUARANTEED TECHNICAL PARTICULARS & DRAWINGS The guaranteed technical particulars of the transformers are as per the Annexure-II enclosed herewith. All appropriate information and data required in the Annexure should be carefully filled in and should be complete in all respects. The following drawings should be invariably be submitted in triplicate along with tender. a) b) c) 21.0 Outline Dimensions and General arrangements Wiring Diagram for auxiliaries Electrical connections

3.0

VERLOAD CAPACITY The tendered 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 15-6600/1972. The transformer shall be designed to obtain maximum efficiency at 75% load

22.0 22.1

TESTS Type Tests The tenderer shall submit copy of certificates of complete type tests carried out in a recognized laboratory in accordance with I.S.S. on similar distribution transformers (Protection) during the last three years. Test certificates of a period earlier than three years from the due date of the tender shall not be accepted except for short circuit test for which validity of test certified will be five years. Technical details of the transformers for which tests were carried out shall be clearly indicated in the test certificates, furnished along with the tender, so that designed aspects of the transformer offered can be easily identified to be similar with that for which certificates are furnished.

22.1.1 a. b.

The following Type tests shall be conducted. Temperature rise test for determining the maximum temperature rise after continuous full load run. The ambient temperature and time of test should be stated in the test certificates. Impulse voltage test as per Clause 12.1 of IS-2026 (Part 111/1997) as per latest version.

135

c. d.

Air pressure test as per Clause 18.13.1 of IS-1180/Part.II/1079. Short circuit withstand test: Thermal and Dynamic ability. The bidder shall furnish calculations in accordance with the IS-2026 to demonstrate the thermal ability of a transformer to withstand short circuit test. Un-balanced current: The value of unbalanced current indicated by the ammeter shall not be more than 2% of the full loan current.

e. 22.1.2 22.1.3

Special tests other type and routine tests, as agreed between purchaser and Tenderer shall also be carried out as per the relevant standards. Routine Tests Manufacturer's routine test certificates shall be furnished before offering the transformer for inspection The transformer shall be subjected to the following Routine Tests at the manufacturer's works in accordance with the REC specification No.23~1983, the IS: 1180 and IS: 2026.

a) Checking of weights, dimensions fitting and accessories, tank thickness, oil quantity, material, finish and workmanship as per purchase order and contract drawings. b) 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. c) Measurement of Ratio, polarity and winding resistance. Check of voltage and vector relationship.

d) Measurement of impedance voltage, short circuit impedance and load loss at rated current and normal frequency. e) f) g) h) i) j) k) 22.1.4 Measurement of No Load current and losses at service voltage and normal frequency. Measurement of No load current at 112.5% of rated voltage. Measurement of insulation resistance. Induced over voltage withstand test. Separate source voltage withstand test. Checking of name place and marking on the tank. Checking of dielectric strength of transformer oil. Acceptance and Routine Tests All acceptance and routine tests as stipulated in the relevant standards shall be carried out by the supplier in presence of purchasers representative. Following tests shall be carried out at manufacturer's works on one unit of each rating by the supplier in presence of purchase representative. a) b) c) d) e) 22.1.5 Temperature rise test. Measurement of unbalance current. Air pressure test on empty tank of transformer opened for physical verification test (Once only). The test certificates for all routine and type tests for the transformers and also for the bushings and transformer oil shall be submitted with the tender. Tests at Site: The purchaser reserves the right to conduct all tests on Transformer after arrival at site and the contractor shall guarantee test certificate figures under actual service conditions. Test Certificates The test certificates for all routine and latest (within 5 years) type tests for the transformers and also the bushing and transformer oil shall be submitted with tender. 23.0 INSPECTION All routine tests will be carried out on each and every transformer and temperature rise tests on one revisions unit out of a batch should be carried at the works of the manufacturer. The tender must give prior intimations (at least 15 days ahead) to the authority issuing the purchase order, regarding the readiness of

136

transformers for such testing so that he may depute his Engineers or third party nominee to witness the tests. All reasonable facilities should be extended to the ASEB/UAEDCL Engineer, who witness the testing so that he is satisfied that all tests are being carried out as per ISS: 2026/77. No extra cost will be paid by ASEB/APDCL for any of above mentioned tests. The purchaser has the right to have the tests carried out at his own cost by an independent agency whenever there is doubt regarding the quality of supply and testing. 23.1 Stage Inspection The stage inspection of the transformers during the manufacturing/ assembling stage shall be carried out by the purchaser's representative or third party nominee. The purchaser has absolute right to reject the raw material/component/sub-assemblies or complete equipment not conforming to the requirements of the specifications or of poor quality/workmanship. The purchaser at his option may collect the samples of the following raw material/components for his independent testing. a. b. c. d. 24.0 CRGO Lamination: HV Winding Wire: LV Winding Wire: Transformer Oil: One specimen sheet of 300-500 mm length and 500 mm width (for each lot of raw material used by the supplier) 1250 mm length specimen for each type 1250 mm length specimen for each type 5 lit., in bottle of 1 lit. each.

CHECKING BY COMPLETE DISMANTLING The purchaser shall have the right to select at random anyone transformer from the lot of transformer of a particular rating. The transformer will at the discretion of the purchaser, be completely dismantled and each and every item will be visually inspected and examined to ascertain whether requirements of specifications guaranteed particulars and type tested design are strictly followed or not, or whether norms as standardized by Indian Standard Specifications are adhered.

25.0

MOUNTING The under base of the transformer shall be provided with two channels of adequate size at suitable spacing for fixing on plinth.

26.0

NAME PLATE PARTICULARS The equipment shall be provided with a name plate covering name of manufacturer, year of manufacture, rating, other technical data as per specification and name of the project.

137

3.15

TECHNICAL SPECIFICATION OF STEEL STRUCTURES RS JOIST

1.0 SCOPE: 1.1. This specification calls for manufacture, stage testing, inspection and testing before dispatch, packing and delivery of R.S. Joists, 175x85mm and 150x80mm. 1.2. The materials shall conform, in all respect, to the high standard of design and workmanship and shall be capable of performing duties specified herein. Materials offered shall be complete in all respect. 2.0 STANDARDS: 2.1. Materials shall conform to the latest applicable Indian standards. In case bidders offer Steel Section and supports conforming to any other international specifications which shall be equivalent or better than IS, the same is also acceptable. sn 1 Standard IS 2062 IS 2062 IS:1852 Title Specification for R.S. Joists, M.S. Channels, M.S. Angles & M.S. Flats Chemical and physical composition of material Rolling and cutting tolerances for Hot rolled steel products.

2.2. In the paragraph above relevant Indian standards specification have been mentioned. However, the material meeting any other authoritative international standards, which ensures equal or better quality than the standards, mentioned shall also be acceptable. Material for which Indian Standards are not available, the relevant British standards and IEC recommendations will be applicable. Photocopy of all such standards according to which the materials have been offered should be attached. : 3.0 CLIMATIC CONDITIONS: The Steel Sections to be supplied against this specification shall be suitable for satisfactory continuous operation under the following tropical conditions:4.0 LENGTH:4.1. The materials to be supplied shall be in the following lengths: 4.2. (i) R.S. Joists 175x85 mm 9 meters to 11 meters (ii) R.S. Joists 150x80 mm 1.5 meters Any tolerance on negative or positive side shall not be accepted. 5.0 CHEMICAL COMPOSITION AND PHYSICAL PROPERTIES OF R.S. JOISTS 5.1. C H E M I C A L C O M P O S I T I O N S N C Mn S . P SI . CE (Carbon Equivalent)

CHEMICAL COMPOSITION FOR Fe 410 WA GRADE 0.23% MAX. 1.5% MAX 0.050% MAX 0.050% MAX. 0.40% MAX 0.42% MAX

. 5.2. M E C H A N I C A L P R O P E R T I E S SN 1. 2. 3. Tensile strength (min.) Yield stress Min. for thickness/diameter < 20 mm 20 40 mm 42 Kgf/mm2 N/mm2 or 410

- 26 kgf/mm2 OR 250 N/mm2 - 24 kgf/mm2 OR 240 138

4. 5. 6.

> 40 mm Elongation %( min.) Bend test (internal Dia)

N/mm2 - 23 kgf/mm2 OR 230 N/mm2 - 23% Min-3 t (t is the thickness of the material)

6.0 MARKING:6.1. It is desirable that the manufacture should put his identification marks on the finished materials. The mark shall be in legible English letters given with marking dies of minimum 18 mm size at the Interval of 3 meter mentioned as APDCL 7.0 INSPECTION AND TEST CERTIFICATE: 7.1. The materials to be supplied will be subject to inspection and approval by the representative of Employer. The Bidder is required to offer the finished material for inspection well in advance to the Employer. 7.2. The BILLETS/INGOTS from which materials shall be re-rolled and supplied to us shall be of tested quality as per IS: 2830/6914 (Latest revision) respectively and shall be arranged from their own source. The chemical composition and physical properties of the finished materials shall be as per relevant specification. 7.3. The materials shall be tested in ISI approved Laboratory of the approved Manufacturer having all facilities available for conducting all the tests as prescribed in relevant ISS. The Employer may get the material tested in the accredited laboratory by NABL. The testing charges whatsoever shall be to the Bidders account. 7.4. The Bidder is required to specifically indicate that the approved manufacturer:(i) Holds valid ISI License against respective ISS. (ii) That the materials offered shall bear ISI certification marks. (iii) Is required to submit a copy of the valid ISI License clearly indicating size and range of roll-able product against respective ISS. 8.0 GUARANTEED TECHNICAL PARTICULARS OF R.S Joists 8.1. Guaranteed Technical Particulars are to be furnished along with the bid.

139

3.16
1.0

TECHNICAL SPECIFICATION FOR EXECUTION OF WORK (FOR 33KV AND 11 KV LINES)

SCOPE : ERECTION OF 33 KV AND LINES WITH 9.75 M PSC POLES The scope covers the survey of the proposed route, tree clearance wherever necessary transport of materials to the locations, erection of the line testing of the line and handing over to the APDCL as per specification. Materials such as steel, cement, PSC Poles, top cleats, clamps, washers, earth wires, HBG metal, sand, water, cost of bolts and nuts etc., as given in Annexure-1 are to be procured by the contractor cost of which shall be included in the bid.

1.1

General : The Contractor should be well acquainted with the IE Rules 1956 as amended from time to time and with the Indian Telegraph Act 1889 so that necessary provisions therein may be followed.

1.2

ELECTRICAL CLEARANCE As per Indian Electricity Rules, 1956 ( amended version ) Sl. Particulars No. 1 Minimum height of any conductor of an overhead line across any street 2 Minimum height of any conductor of an overhead line along any street 3 Minimum height of any conductor (bare )of an overhead line erected elsewhere 4 Minimum height of any conductor (insulated )of an overhead line erected elsewhere 5 Minimum Clearance of an overhead line from building 6 7 8 9 10 Clearance between over-head line and communica-tion line Minimum Clearance from another line Phase to phase clearance ( min) Span Minimum clearance between LT line with 11 KV & 33 KV

33 KV line 6.4 metres 6.1 metres 5.2 metres

11 KV Lines

4.0 metres

3.7mtr. (vertical ) 2.0 mtr. ( horizontal) 2.130 meters 0.270 meters 1370 mm 50 m 6.1

6.2

1.3

SURVEY OF THE ROUTE The Tentative route map of the line to be erected will be furnished by the APDCL to the 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 the route map and as actually existing are noticed, the deviations must be brought to the notice of the APDCL Engineer. The APDCL Engineer if considered necessary shall make alterations, which shall be carried out accordingly and the APDCL after inspecting the surveyed route and the revised route map shall be given for final approval in writing. The contractor shall not commence the work until the final approval of the route map is given by the Engineer in charge in writing to the contractor.

1.4

WAY LEAVES AND TREE CUTTINGS Proposals for way leaves and right of way shall be submitted by the contractor. Permission will be obtained by the APDCL within reasonable time for which due notice shall be given by the Contractor. The Contractor shall arrange for tree cutting or tree branches cutting also. 140

The widths of tree clearance to be adopted for lines of various voltages are as detailed below: 1.4.1 33 KV LINE (Trunk Line) All growth within 6.096 M (20 ft) from the center line of support and all trees which may fall and foul the line. 1.4.2 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 APDCL 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. No trees shall be cut until the APDCL has made necessary arrangement with the authorities concerned and permission is given to the Contractor to fell such trees. The contractor shall arrange to remove the obstacles as soon as possible. At such times, when it may not possible for APDCL, to arrange right-of-way for excavation of pole pits or erecting the poles of stringing the line, then 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. EXCAVATION OF POLE PITS, STAY PITS AND D.P. 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 Vbars 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 with suitable explosives. The pits for the supports are excavated in the direction of the line as this will facilitate the erection of support 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 poles shall be in accordance with relevant sketch for the erection of pole or stay of D.P. etc. ERECTION OF POLES : PSC POLE : PSC poles should be erected perpendicular to ground level including excavation of earth pit having depth equal to 1/5 th the length of pole and cross-section 75 cm x 50 cm as directed by department including dragging and carrying of pole to site as per soil condition as given below. (i) earth filling with soil at bottom and surrounding with vigorous ramming; (ii) earth filling with soil at bottom and surrounding with vigorous with boulder packing including supply of boulder by contractor ( size of boulder 150mm x 200mm); (iii) grouting and mufflering in proportion 1:2:4 RCC foundation and filling of cement concrete as per specification including supply of cement , stone chips, shuttering etc. as directed ] POLE CLAMP: The pole clamp is to be made of MS flat of size 40 mm x 6 mm with necessary drilling of holes and painting with primer and anti corrosive paint suitable for different size of steel tubular pole and PSC pole.

1.4.3

1.4.4

1.5
1.5.1

1.6
1.6.1

1.6.2

1.7

ERECTION OF SUPPORTS After the excavation of pits is completed the supports to be erected may be brought to the pits 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. Before the pole is put into 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 weight of the pole uniformly on the soil.

141

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 verticalitys of the poles are 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 filing, 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 REC construction standard.

1.8

ERECTION OF D.P. STRUCTURES FOR ANGLE LOCATIONS (FOR 33 LINES): Generally, for angles of deviation more than 20 double pole structures of spacing 1.2 mts (4.0 ft) may be erected. The pits are to be excavated as per bisection of the angle of deviation. After the poles are erected, the horizontal / cross bracing should be fitted and the supports held in a vertical position with the help of temporary guys of manila rope of 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 curing of the concrete is completed. Four stays along the line, two in each direction and two stays along the bisection of angle of deviation are to be provided. Stay concreting may be done with M 400 concrete mixture The D.P. shall be erected as per the approved drawing.

1.9

ANCHORING AND PROVIDING GUYS FOR SUPPORTS Fitting of stay set on overhead line including digging of earth pit of area 90cm x 60 cm and depth of 1.4 m placing the stay rod with G.I stay wire Guy insulator on pole clamp , fixing of thimble bow etc with hard soil packing and ramming to fill up pit to ground level. Guys are to be provided to the supports at the following places (i) Angle locations, (ii) Dead end locations, (iii) Tee-off points, (iv) Steep gradient locations to avoid uplifted on the poles. The installation of guy will involve the following works: i) Excavation of pit and fixing of stay rod. ii) Fastening guy wire to the support. iii) 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 point is 30/45 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 loop is protected by the G.I. Thimble, where it bears 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 2 mts length above the ground level, duly painted with white and black stripe 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 of due leakage. No guy insulator shall be located less than 2.6 mts. from the ground. The anchoring and providing guys for supports (Single guy Bow guy fly guy) shall be done as per sketch enclosed. Bow guy and fly guy shall be provided as per field conditions. HT GUY INSULATOR Power Designation Dry one minute Wet one Minimum line of Insulator power frequency minute power failing load Voltage withstand voltage frequency withstand

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voltage 33 KV C 27 KV ( r.m.s) 13 KV ( r.m.s) 88 KN

[ for 33 KV , 2 insulators to be used in series]

1.10

FIXING OF CROSS ARMS INSULATORS

After the erection of supports and providing guys, the next step would be to mount the cross arms on the support 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 and 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 materials of the tools should be dropped or thrown from the pole top. The fixing of 33 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 will have to be procured by the contractor.

1.11

Back Clamps

The back clamps for fixing of the seating channels, V cross arms, horizontal cross arms and top cleats 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 8 mm M.S. Flat for 33 KV

1.12

Top Cleats

The top cleats shall be got fabricated with M.S. Channel of size 75 X 40 mm for 33 KV and shall be in accordance with REC construction standard

1.13

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 pins and tightened. In the case of strain or angles supports, where strain fittings are provided for this purpose, one strap of the strain fitting is placed over the cross arm before placing the bolts in the hole of the cross arms. The nut of the strap is so tightened that the strap can move freely in horizontal direction, as this is necessary to fix the strain insulator. The insulator 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. Disc Insulator Strings Each insulator string shall consist of following numbers of Disc Insulator units. Sl .No 1. 2. Type of String Suspension Tension No of Disc Insulator Unit for 33 KV 3 4 No of Disc Insulator Unit for 11 KV

1.14

STRINGING OF THE LINE CONDUCTORS For the guidance of the contractor certain dos and donts are given below before the workmen actually commence the stringing work.

1.14.1

Dos and Donts DOs ii. iii. iv. v. vi. vii. 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 suitable braking arrangement. 143

viii. ix. x. xi. xii. xiii. xiv. xv. DONTs i. ii. iii. iv. v. 1.14.2

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. Chromite or graphite conducting oxide-inhibiting grease should be used before cleaning with wire brush. Do not handle conductors without proper tools at any stage. Do not pull conductors without ensuring that there are no obstructions on the ground. Do not pull out excess quantity of conductor than is required. Do not make jumper connections on dirty or weathered conductor. 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: i. Transport of conductors to work site. ii. Paving and stringing of conductors. iii. Tensioning and sagging of conductors. iv. Joining of conductors. At the important crossing of roads, canals, navigable rivers, railways etc., flagmen should be in attendance to ensure that normal services are not unduly interrupted. These crossing 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 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 of 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 method, a trench of suitable depth slightly bigger than the conductor drum may be dug, so as to facilitate free rotation of the cable 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 trusses 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 arrangement 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 the remaining length from another end of the section any part of the conductor shall be left at a height of less than that of 5 meters, above the ground by rough sagging. Mid Span Jointing of Conductors The mid span jointing of conductors can be carried by twisting the joint at the ends and the wire should project a few centimeter, beyond the end of the sleeves. The projected wires are given a sharp bend to keep them from slipping out of the sleeve. The end of the sleeves are then held tightly by twisting wrenches and then 4 to 5 turns in one direction generally anti-clock wise direction. Crimping Tools are preferably to be used for joints and jumpers.

1.14.3

1.14.4

SAGGING AND TENSIONING On the completion of the paving of the conductors and making mid span joints if any, tensioning operations will commence. Temporary guys 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.

144

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 sag chart is to be provided. 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: a) Pre-stressing In this method the conductor is pulled up to tension considerably above the correct figures, but never exceeding 50% 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. b) Over-tensioning This method consists of pulling up the conductor to a tension a little above the theoretical tension for 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 throughout the entire length of 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 Slighting. The slighting 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 distance from the cross-arm equal to the length of complete strain insulator. Before the insulator set 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 in sufficiently 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 arm, stay or pole in some cases. After the stringing is completed, all poles, cross arms, insulators, fittings etc. are checked upto 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: i) Proper size of the tie binding wire which can be readily handled and with adequate strength is to be used. ii) The length of tie wire should be sufficiently long for making complete tie including the end allowances for gripping with ends. iii) 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. iv) The use of cutting pliers for binding the tie wire should be avoided. v) The tie wire which has been used previously should be reused Before tying the conductor to the insulator two layers of Aluminum tapes 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 hand books of aluminum conductor manufacturers and the same be referred 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 of deviation the conductor is placed inside groove and bound. Accordingly, there are two methods of tying 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.

145

The contractor shall be 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. 1.14.5 CONDUCTOR DAMAGE AND REPAIR If the conductor is damaged for whatever reasons, and damage is not repaired by 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 projection sharp points, cut or abrasion etc. giving satisfactory corona and R.I. performance. No joints or splice be made in spans crossing over main roads, railways, small rivers or intension spans. Not more than one joint per conductor shall be allowed in one span. The strength of the joint shall conform to IE Rule 75. 1.14.6 STRINGING.

Whatever necessary ground clearances have to be measured to ensure obtaining adequate line clearance as per IE Rule 77 (i) GUARDING : When an overhead line crosses or is in proximity of any telecommunication line arrangement shall be made to provide protective device or guarding. When an overhead line crosses or is in proximity of to another over head line or overhead lines of different voltage on same supporting structure guarding arrangement shall be provided so as to guard against the possibility of their coming into contact with each other. Every guard-wire shall be an actual breaking strength of not less than 635 kg and if made of iron or steel shall be galvanize. Every guard-wire shall be connected with earth at each point at which its electricity continuity is broken.

1.15
1.15.1

EARTHING PIPE EARTHING At D.P Locations, Pits are to be excavated the steel and metal parts are to be earthed by pipe earthing as per the drawing or sketch enclosed to this specification. Duly filling the pits with finely broken coke having granule sizes not more than 25 mm thick. The coke shall be maintained up to a distance of 300 mm for the pipe on all sides. The top edge of the pipe shall be at least 200 mm below the ground level. The CI 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 coke, excavation and back filling.

1.15.2

Pole Earthing: All Supports shall be properly earthed. CONCRETING The cement concrete used for the foundations shall be of M 400 grade. The full concreting for the poles if erected in excavated act shall be done so that the complete block will be of dimensions( 0.6 X 0.6 X 1.6) + 0.2 X 0.2 Mtr. (0.6 X 0.6 X 1/35) + 0.2 X 0.2 X 0.2 Mtrs. so as to maintain as exposed portion for 0.2 Mtrs height above the ground level. If augur is used for making pole pits, ramming shall be done after erection of pole. WORKMANSHIP The contractor shall entirely be responsible for 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 no 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.

1.16

1.17

146

1.18 1.19

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. 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. FINAL CHECKING, TESTING AND COMMISSIONING After the completion of the work final patrolling and checking of the line shall be done by the contractor to ensure that all foundations work, pole erection and stringing have been done as approved by the Engineer, and also to ensure that they are completed 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) Sufficient back filled earth is lying over each foundation pit and it is adequately compacted. ii) Concreting and coping of poles are in good and finally shaped conditions. iii) All the accessories and insulators are strictly as per drawings and are free from any defects or damages, what-so-ever. iv) All the bolts and nuts should be of G.I material and as per contractual provisions. v) The stringing on the conductor has been done as per approved sag and desired clearances are available. vi) No damage, minor or major to the conductor, earth wire, accessories and insulator strings still unattended are noticed. vii) 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 payable to the contractor against that contract or any other contract executed by him for APDCL. 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 tests desired by the Engineer shall be done by the Contractor and necessary labour, transport and equipment shall be provided by him. Any defects found out as a result of such tests, shall be rectified by the Contractor, forthwith, without any extra charges to APDCL,. 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 tests to be carried out. The APDCL, will arrange statutory inspection of the line and indicate the defects noticed. The Contractor has to rectify all such defects and intimate to APDCL, Engineer. After satisfactory tests on the line and an approval by the Engineer the line shall be energized at full operating voltage before handing over.

1.20

1.21

SUPPLY OF CONSTRUCTION MATERIALS BY THE CONTRACTOR The Contractor has to make his own arrangements for procurement, supply and use of construction materials like cement, M.S. rounds, HBG metal and sand.

1.22

CEMENT The contractor has to make his own arrangements for the procurement of cement to require specifications required for the work subjected to the follows: a) The contractor shall procure cement, required for the works only from reputed cement factories (Man producer) acceptable to the Engineer-in-Charge. The contractor shall be required to be furnished to the Engineer-in Charge bills of payment and test certificates issued by the manufacturers to authenticate procurement of quality cement from the approved cement factory. The contractor shall make his own arrangement for adequate storage of cement. b) The contractor shall procure cement in standard packing of all 50 kg per bag from the authorized manufactures. The contactor shall make necessary arrangement at his own cost to the satisfaction of

147

Engineer-in-Charge for actual weighment of random sample from the available stock and shall conform to 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 hags brought and kept on site Godown. Cement bags required for testing shall be supplied by the contractor free of cost. However, the testing charges for cement will be borne by the APDCL. If the tests prove unsatisfactorily, then the charges for cement 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, an account of failure to meet with required quality and standard. d) 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 rested and approved by Engineer-in-Charge for the purpose and the contractor shall at all times, keep his records upto date to enable the Engineer-in-Charge to apply such checks as he may desire. e) Cement which has been unduly long in storage with the contractor or alternatively has deteriorated due to inadequate 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.

1.23

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 Standards or equivalent and licensed to affix ISI or other equivalent certification 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 specification for steel.

1.24

INFORMATION AND DATA a) The information furnished is the best available however, the APDCL does not guarantee the correctness of 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 APDCL of or otherwise. The information has been produced as found, communicated to ascertained or otherwise/learned by the APDCL. 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 exist in the designated borrow areas or quarry sites. The APDCL does not accept any responsibility either in handing over the quarries or procuring the materials or any other facilities. The Tenderer 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 work as required at the rates quoted by him.

b)

148

3.17
1.0 SCOPE

TECHNICAL SPECIFICATION FOR PSC POLES [9.75 M]

This covers design manufacturing, testing at works, transport to site, insurance, storage, erection and commissioning of PSC poles shall be of solid rectangular with an overall length of 9.75M suitable for use in overhead 33KV / 11 KV lines 2.0 Applicable Standards

The pre-stressed concrete pole (psc ) shall comply with the relevant provisions mentioned' in the' following Indian Standards or the latest versions thereof. a) IS: 1678, Specification for pre-stressed concrete poles for overhead power, traction and telecommunication lines. b) c) IS: 2905, Method of test for concrete poles for overhead power and telecommunication lines. IS: 7321, Code of Practice for selection, handling and erection of concrete poles for overhead power and telecommunication lines. REQUIRED TECHNICAL PARAMETERS FOR 9.75 M PSC POLES 3.0 3.1 3.2 3.3 Terminology For the purpose of this specification, following definitions shall apply: Average Permanent Load That fraction of the working load which may be considered of long duration over a period of one year. Load Factor The ratio of ultimate transverse load to the transverse load at first crack. Transverse The direction of the line bisecting the angle contained by the conductor at the pole. In the case of a straight run, this will be normal to the run of the line. Transverse Load at First Crack For design, the transverse load at first crack shall be taken as not less than the value of the working load. Working Load The maximum load in the transverse direction, that is ever likely to occur, including the wind pressure on the pole. This load is assumed to act at a point 600 mm below the top with the butt end of the pole planted to the required depth as intended in the design. 3.6 Ultimate Failure The condition existing when the pole ceases to sustain a load increment owing to either crushing of concrete, or snapping of the pre-stressing tendon or permanent stretching of the steel in any part of the pole. Ultimate Transverse Load The load at which failure occurs, when it is applied at a point 600 mm below the top and perpendicular to the axis of the pole along the transverse direction with the butt end of the pole planted to the required depth as intended in the design. Application 9.75 M PSC Pole These poles shall be used for 33 kV lines, and for special locations in 11 kV lines, such as road crossings, 149

3.4 3.5

3.7

4.0 4.1 4.2

etc. 5.0 6.0 Material Cement The cement used in the manufacture of pre-stressed concrete poles shall be ordinary or rapid hardening Portland cement conforming to IS: 269 (Specification for ordinary and low heat Portland cement) or IS: 8041 E (Specification for rapid hardening Portland cement), or high strength ordinary Portland cement conforming to IS: 8112 (Specification of high strength ordinary Portland cement). Aggregates Aggregates used for the manufacture of pre-stressed concrete poles shall confirm to IS: 383 (Specification for coarse and fine aggregates from natural sources for concrete). The nominal maximum size of aggregates shall in no case exceed 10 mm (for poles above 9.0 M) and 12 mm (for 7.5 and 8.0 M poles). Water Water should be free from chlorides, sulphates, other salts and organic matter, Potable water will be generally suitable. Admixture Admixture should not contain Calcium Chloride or other chlorides and salts which are likely to promote corrosion of pre-stressing steel. Pre-stressing Steel

7.0

8.0

8.1

8.2

The pre-stressing steel wires including those used as un-tensioned wires (See Annexure. I, II & III), should conform to IS: 1785 (part-I) (Specification for plain hard-drawn steel wire for pre-stressed concrete. Part-I cold drawn stress relieved wire), IS: 1785 (part-II) (Specification for plain hard-drawn steel wire) or IS: 6003 (Specification for indented wire for pre-stressed concrete). The type designs given in Annexure-I, 2 II and III are for plain wires of 4 mm diameter with a guaranteed ultimate strength of 175 kg/mm . The concrete mix shall be designed to the requirements laid down for controlled concrete (also called design mix concrete) in IS: 1343 (Code of practice for pre-stressed concrete) and IS: 456 (Code of practice for plain and reinforced concrete), subject to the following special conditions: 2 2 a)Maximum works cube strength at 28 days should be at least 400 kg/cm (for poles above 9.0 M) and 420 kg/cm (for 7.5 and 8.0 M poles). b)The concrete strength at transfer should be at least 200 kg/cm (for poles above 9.0 M) and 210 kg/cm (for 7.5 and 8.0 M poles). c) The mix should' contain at least 380 kg of cement per cubic meter of concrete. d) The mix should contain as Iowa water content as is consistent with adequate workability. If it becomes necessary to add water to increase the workability, the cement content also should be raised in such a way that the original value of water cement ratio is maintained. 9.0 DESIGN REQUIREMENTS
2 2

The poles shall be designed for the following requirements: a)The poles shall be planted directly in the ground with a planting depth as per IS: 1678. b) The working load on the poles should correspond to those that are likely to come on the pole during their service life. Designs given in Annexure I,ll and III are for 140 kg, 200 kg, 300 kg, and 400 kg., applied at 0.6 M from top. The factor of safety for all poles above 9.5 M shall not be less than 2.0. For 7.5 M and 8.5 M poles, the factor of safety shall not be less than 2.5. The average permanent load shall be 40% of the working load. The F.O.S. against first load shall be 1.0. At average permanent load, permissible tensile stress in concrete shall be 30 kg/cm . 150
2

c)

d) e) f)

g)

At the design value of first crack load, the modulus of rupture shall not exceed 53.0 kg/cm for M-400 2 concrete and 55.2 kg/cm for M-420 concrete. At the design value of first crack load, the modulus of rupture shall not exceed 53.0 kg/cm for M-400 concrete.
2

h)

i)The ultimate moment capacity in the longitudinal direction should be at least one fourth of that il1 the transverse direction. j) The maximum compressive stress in concrete at the time of transfer of pre-stress should not exceed 0.8 times the cube strength. The concrete strength at transfer shall not be less than half the 28 days strength ensured in the design, 2 2 i.e., 400 x 0.5 = 200 kg/cm or 420 x 0.5 = 210 kg/cm .

k) 10.0

Service Conditions PSC poles have to be designed to suit the following climatic conditions: a Maximum temperature of air in shade 40C )b Minimum temperature of air in shade 2C ) c Maximum temperature of air in sun 45C ) d Maximum humidity 93% ) e Average number of thunder storm days per 45 Days ) annum f Maximum rainfall per annum 3500 mm )g Average rainfall per annum 2200 mm )h 2 Wind pressure 97.8 Kg/m ) 100 to 1000 M i) Altitude above MSL

11.0

Dimensions and Reinforcements The cross-sectional dimensions and the details of pre-stressing wires should conform to the particulars given in Annexure-I, II and III. The provisions of holes for fixing cross-arms and other fixtures should conform to the REC standards .

12.0 12.1

Manufacture Attire--stressing wires and reinforcements shall be accurately fixed as shown in drawings and maintained in position during manufacture. The un-tensioned reinforcement, as indicated in the drawings, should be held in position by the use of stirrups which should go round all the wires. AII wires shall be accurately stretched with uniform pre-stress in each wire. Each wire or a group of wires shall be anchored positively during casing. Care should be taken to see that the anchorages do not yield before the concrete attains the necessary strength.

13.0

Cover The cover of concrete measured from the outside of pre-stressing tendon shall be normally 20 Nm.

14.0

Welding and Lapping of Steel The high tensile steel wire shall be continuous over the entire length of the tendon. Welding shall not be allowed in any case. However, jointing or coupling may be permitted provided the strength of the joint or coupling is not less than the strength of each individual wire.

15.0

Compacting Concrete shall be compacted by spinning, vibrating, shocking or other suitable mechanical means. Hand 151

compaction shall not be permitted. 16.0 Curing The concrete shall be covered with a layer of sacking, canvass, Hessian or similar absorbent material and kept constantly wet up to the time when the strength of concrete is at least equal to the minimum strength of concrete at transfer of pre-stress. Thereafter, the pole may be removed from the mould and watered at intervals to prevent surface cracking of the unit, the interval should depend on the atmospheric humidity and temperature. The pre-stressing wires shall be detensioned only after the concrete has attained the specified strength at 2 transfer (i.e., 200 or 210 kg/cm as applicable). The cubes cast for the purpose of determining the strength at transfer should be cured, as far as possible, under conditions similar to those under which the poles are cured. The transfer stage shall be determined based on the daily tests carried out on concrete cubes till the specified strength indicated above is reached. Thereafter the test on concrete shall be carried out as r detailed in IS: 1343 (Code of p 3ctice for pre-stressed concrete). The manufacturer shall supply, when required by the owner or his representative, result of compressive test conducted in accordance with IS: 456 (Code of practice for plain and reinforced concrete) on concrete cubes made from the concrete used for the poles. If the owner so desired, the manufacturer shall supply cubes for test purposes and such cubes shall be tested in accordance with IS: 456 (Code of practice for plain and reinforced concrete). The detensioning shall be done by slowly releasing the wires, without imparting shock or sudden load to the poles. The rate of detensioning may be controlled by any suitable means either mechanical (screw type) or hydraulic. The poles shall not be detensioned or released by cutting the pre-stressing wires using flames or bar croppers while the wires are still under tension. Separate eye-hooks or holes shall be provided for handling the transport, one each at a distance of 0.15 times the overall length, from either end of the pole. Eye-hooks, if provided, should be properly anchored and should be on the face that has the shorter dimension of the cross-section. Holes, if provided for lifting purposes, should be perpendicular to the broad face of the pole. Stacking should be done in such a manner that the broad side of the pole is vertical. Each tier in the stack should be supported on timber sleeper located as 0.15 times the overall length, measured from the end. The timber supported in the stack should be aligned in a vertical line. Poles should be transported with their broad faces placed vertically and, in such a manner that the shocks are avoided. Supports should be so arranged that they are located approximately at a distance equal to 0.15 times the overall length from the ends. The erection of the pole should be carried out in such a way that the erection loads are applied so as to cause moment with respect to the major axis, i.e., the rope used for hoisting the pole should be parallel to the broader face of the pole. 17.0 17.1 Earthing Earthing shall be provided by having length of 8 SWG GI wire embedded in concrete during manufacture and the ends of the wires left projecting from the pole to a length of 100 mm at 250 mm from top and 150 mm below ground level.

17.2 Earth wire shall not be allowed to come in contract with the pre-stressing wires. 17.3 18.0 Tests Transverse Strength Test Poles made from ordinary Portland cement shall be tested only on the completion of 28 days and poles made from rapid hardening cement only on the completion of 14 days, after the day of manufacture. The poles may be tested in either horizontal or vertical position. If tested in horizontal position, provisions shall be made to compensate for the overhanging weight of the pole, for this purposed, the overhanging portion of the pole may be supported on a movable trolley or similar device.

152

The pole shall be rigidly supported at the butt end for a distance equal to the agreed depth of planting. Load shall be applied at a point 600 mm from the top of the pole and shall be steadily and gradually increased to the design value of the transverse load at first crack. The deflection at this load shall be measured. A pre-stressed concrete pole shall be deemed not to have passed the test if visible cracks appear at a stage prior to the application of the design transverse load for the first crack. The load then be reduced to zero and increased gradually to a load equal to the first crack load plus 10% of the minimum ultimate transverse load, and held up for 2 minutes. This procedure shall be repeated until the load reaches the value of 80 per cent of the minimum ultimate transverse load and thereafter increased by 5 per cent of the minimum ultimate transverse load until failure occurs. Each time the load is applied, it shall be held for 2 minutes. The load applied to pre-stressed concrete pole at the point of failure shall be measured to the nearest five Kilograms. The pole shall be deemed not to have passed the test if the observed ultimate transverse load is less than the design ultimate transverse load. 19.0 Measurement of Cover After completion of the transverse strength test, the sample pole shall be taken and checked for cover. The cover of the pole shall be measured at 3 points, one within 1.8 meter from the butt end of the pole. the second within 0.6 meters from the top and the third at an intermediate point and the mean value compared with the specified value. The mean value of the measured cover should not differ by more than () 1 mrn from the specified cover. The individual values should not differ by more than () 3 mm from the specified value. If these requirements are not met, the workmanship with reference to aligning of the end plates and prestressing wires and assembly of moulds should be improved and inspection at pre-production stage tightened suitably. 20.0 MARKING

The pole shall be clearly and indelibly marked with the following particulars either during or after manufacture but before testing at a position so as to be easily read after erection in position. a)Month and year of manufacture b)Transverse strength of pole in Kg c)Maker's serial No and mark and Project .

21.0 INSPECTION Inspection may be carried out by the purchaser or third party nominee at any stage of manufacture. The supplier shall grant free access to the purchaser's representative or third party nominee at a reasonable time when the work is in progress. Inspection and acceptance of any equipment under this specification by the purchaser shall not relieve the supplier of his obligation of furnishing equipment in accordance with the specification and shall not prevent subsequent rejection if the equipment is found defective. S L NO 1 ITEM PARAMETERS

Type of Pole

9.75 M P.S.C pole 9.75 Mts. 1.8 Mts. 350 mm

8.5 M Pole 8.5 Mts. 1.5 Mts. 300 mm

PSC

7.5 M pole 7.5 Mts. 1.5 Mts. 250 mm

P.S.C

3 4 5

Length of pole Depth of Plantation Bottom Depth

153

6 7 8 9

Top Depth Breath Diameter of pre-stressing wire No. of tensioned wire per pole

175 mm 120 mm 4 mm 22 Nos of 4mm dia. 175 KG / SQMM 1865 kg / wire As per IS : 1343 /1960 21.45 KG 3.540 KG ( 4 nos ,5 mm in bottom & 4 nos ,5 mm in top 3 mm dia of 150 c/c 12 mm 750 KG 20 mm 2.5 M-420 675 KG Projecting from the pole at length of 50 MM at 215 from top & 150 MM below ground level at 1.8 M

162 mm 112 mm 4 mm 16 Nos 4mm dia. 175 KG SQMM 1865 kg / wire As per IS : 1343 /1960 13.60 KG 4 nos ,5 mm in bottom & 4 nos ,5 mm in top ) 3 mm dia of 150 c/c 12 mm 550 KG 20 mm 2.5 M-420 500 KG Projecting from the pole at length of 50 MM at 215 from top & 150 MM below ground level at 1.5 M of

140 mm 105 mm 4 mm 12 Nos of 4mm dia. 175 KG SQMM 1750 kg / wire As per IS 1343 /1960 9.0 KG 4 nos ,5 mm in bottom & 4 nos ,5 mm in top ) : /

10

Minimum Ultimate Tensile strength of 4 MM HT wire Minimum initial pull of 4 mm wire Spacing HT wires

11 12

13 14

Quantity of HT wire/ pole Link & spiral

15

M.S spiral

3 mm dia of 150 c/c 12 mm 360 KG 20 mm 2.5 M-420 350KG Projecting from the pole at length of 50 MM at 215 from top & 150 MM below ground level At 1.25 M

16 17 18 19 20 21 22

Maximum Aggregate size Total weight per pole Minimum clear cover Factor of safety Concrete grade Ultimate Load Earthing shall be provided by 4 MM dia. Galvanized iron wire embedded in concrete

23

one marks to be provided at ground level 28 days cube strength of concrete ( Min) as per IS : 456/2000.

24

420 KG SQ.CM

420 KG SQ.CM

420KG/SQ.CM

154

3.18

TECHNICAL SPECIFICATION FOR STEEL TUBULAR POLES FOR OVERHEAD LINES

1.0 SCOPE : 1.1 This specification covers the general requirements towards design, manufacture, testing at manufacturers works, supply and delivery for tubular steel poles of circular cross section ( swaged type ) for overhead lines. 2.0 STANDARD : 2.1. The tubular steel poles shall conform to the latest edition of Indian Standard specification IS: 2713 ( Part I, III ) : 1980 Specification for Steel Tubular poles The Steel Tubular Poles conforming to other internationally accepted, which ensure equal or higher quality than the standards, mentioned above also be acceptable. In case the bidder who wish to offer material conforming to the other standards, salient points of difference between adopted and specific standards with authentic English Translation shall be furnished. 3.0 Topography and Climatic Condition : 3.1. The materials offered, shall be suitable for operation in tropical climate and will be subjected to the sun and inclement weather and shall be able to withstand wide range of temperature variation. For the purpose of design, average atmospheric temperature may be considered to be 50 C with humidity nearing saturation. 4.0 Materials : 4.1. The materials used in construction of tubular steel poles shall be of the tested quality of steels of minimum tensile strength 540 MPa ( : 55 Kgf/mm2 ). Or 410MPa as the case may be. 4.2. The materials, when analysed in accordance with IS : 228 ( Part-III : 1972 ) and IS : 228 ( Part-IX) shall not show sulpher and phosphorous contents of more than 0.060 percent each. 5.0 Types, Size and construction : 5.1. Tubular Steel Poles shall be swaged type. 5.2. Swaged poles shall be made of seamless or welded tubes of suitable lengths swaged and jointed together. No circumferential joints shall be permitted in the individual tube lengths of the poles. If welded tubes are used they shall have one longitudinal weld seam only : and thelongitudinal welds shall be staggered at each swaged joint. 5.3. Swaging may be done by any mechanical process. The upper edge of each joint shall be chamfered if at an angle of about 45o. The upper edge need not be chamfered if a circumferential weld is to be deposited in accordance with clause No. 5.3 2 of IS: 2713 ( Part-I) :1980. 5.4. The length of joints on swaged poles shall be in accordance with clause No. 5.4 of IS: 2713(Par-I): 1980. 5.5. Poles shall be well-finished, clean and free from harmful surface defects. Ends of the poles shall be cut square. Poles shall be straight, smooth and cylindrical. The weld joints, if any, shall be of good quality, free from scale, surface defects, cracks, etc. 5.6. Tolerances for outside diameter, thickness, length, weight and straightness shall be in accordance with IS: 2713 (Part-I) : 1980. 5.7. The poles shall be coated with black bituminous paint conforming to IS : 158-1968 throughout, internally and externally, upto the level which goes inside the earth. The remaining portion of the exterior shall be painted with one coat of red oxide primer as specified in IS: 2074-1979. 6.0 Earthing Arrangements : 6.1. For earthing arrangement a through hole of 14mm diameter shall be provided in each pole at a height of 300mm above the planting depth. 7.0 PRINCIPAL PARAMETERS SL NO 1. 2. 3. ITEM DESCRIPTION Type of Pole Overall Length Planting Depth PARAMETERS SP-76 14.5 M 2.0 M PARAMETER SP-66 12.0 M 2.0 M PARAMETERS SP-60 12.0 M 2.0 M

155

4. 5. 6.

Load Applied from top at a distance of Height above ground Length of sections Bottom a. a Middle b. Top c.

0.60 M 12.5 M

0.60 M 10.0 M

0.60 M 10.0 M

6.5 M 4.0 M 4.0 M & 219.1 x5.90 193.7 x4.85 165.1 x 4.5 380 KG 514 kgf 724 kgf tensile 410 MPa ( 42 2 KGf / mm ) A Mild Steel base plate of size 400 mm x 400 mm x 8 mm shall be welded at the bottom of the pole. The inner side & outer underground portion of the pole is to be painted with black bituminous paint conforming to IS : 158-1968 throughout,[ internally and externally, up to the level which goes inside the earth]. The balance outer portion of the pole 9 12.5m) is to be painted with 2 coat of metal primer and 2 coats of aluminium paint.

5.80 M 3.10 M 3.10 M

5.80 M 3.10 M 3.10 M

7. a b c 8. 9. 10. 11. 12.

Outside Diameter thickness of section Bottom, MM Middle ,MM Top,MM Approx. Wt of pole crippling load breaking load Ultimate strength Base Plate

219.1 x5.90 193.7 x4.85 165.1 x 4.5 322 KG 650 kgf 916 kgf 410 MPa ( 42 2 KGf / mm ) A Mild Steel base plate of size 4004008 mm shall be welded at the bottom of the pole. The inner side & outer underground portion of the pole is to be painted with black bituminous paint conforming to IS : 158-1968 throughout,[ internally and externally, up to the level which goes inside the earth]. The balance outer portion of the pole 9 12.5m) is to be painted with 2 coat of metal primer and 2 coats of aluminium paint.

165.1 x 5.40 139.7 x 4.50 114.3 x 3.65 208 KG 333 kgf 469 kgf 410 MPa ( 42 KGf 2 / mm ) A Mild Steel base plate of size 4004008 mm shall be welded at the bottom of the pole.

13.

Painting

The inner side & outer underground portion of the pole is to be painted with black bituminous paint conforming to IS : 158-1968 throughout,[ internally and externally, up to the level which goes inside the earth]. The balance outer portion of the pole 9 12.5m) is to be painted with 2 coat of metal primer and 2 coats of aluminium paint.

8.0 Tests and Test Certificates : 8.1. The following tests shall be conducted on finished poles : 156

A. Tensile test and chemical analysis for sulpher and phosphorous , B. Deflocation test, C. Permanent set test, and D. Drop test. 8.2. In addition to above verification of dimensions as per IS : 2713 (Part-III) : 1980 shall be carried out during acceptance of lots. 8.3. Number of poles selected for conducting different tests shall be in accordance to clause No.10.1.1 and No. 10.1.12: of IS: 2713 (Part-I) 1980. 8.4. Tests shall be carried out before supply of each consignment at the manufacturers woks and test certificates should be submitted to the purchaser for approval prior to delivery. 8.5. Re-tests, if any, shall be made in accordance with IS: 2713 (Part-I) 1980. 8.6. Purchaser reserves the right to inspect during manufacturing and depute his representative to inspect/test at the works. 8.7. If any extra cost is required for carrying out the above specified tests, the same shall be borne by the tenderer. 9.0 Marking : 9.1. The poles shall be marked with designation, manufacturers identification, year of manufacture and name of the purchaser: APDCL 9.2. The poles may also be marked with the ISI certification mark if applicable.

10.0 Performance :10.1. The bidder shall furnish a list of the major supplies effected during the last 3 (three) years indicating the volume of supply and actual delivery dates alongwith the bids. 10.2. Bids may not be considered if the past manufacturing experience is found to be less that 3 (three) years. 11.0 Deviation :13.1 Any deviation in technical specification shall be clearly indicated with sufficient reasons thereof. Purchaser shall however reserve the right to accept and/or reject the same without assigning any reasons what-soever. 12.0 Guaranteed technical particulars : 12.1. The tenderer shall furnish all necessary guaranteed technical particulars in the prescribed proforma enclosed hereinafter.

157

Annexure B TECHNICAL GUARANTEED AND OTHER PARTICULARS. (To be filled in by the Tenderer) 1. Type of Pole offered 2. a) Whether tubes are of seamless constn. Or welded type. b) Is it manually welded tubes? If so, state name/address of manufacturer c) It is ERW tubes? If so, state name/address of manufacturer 3. Overall length 4. Effective length of section a) Bottom b) Middle c) Top 5. Effective dia thickness of section a) Bottom b) Middle c) Top 6. Approximate weight (Kg.) 7. Breaking Load (Kg.) 8. Working Load (Kg.) 9. Weight/Mtr. i) Top Section (kg) ii) Middle Section (kg) iii) Bottom Section (kg) 10. Crippling load (kg) 11. Load for permanent set 12. Load for temporary deflection 13. Joint length

158

3.19
1.0 SCOPE :

TECHNICAL SPECIFICATION FOR GALVANIZED CHANNEL CROSS ARMS

3.0

This specification covers the design, manufacture, testing at manufacturer's works, transport to site, insurance, storage, erection and commissioning of Galvanized Cross Arm and channel used for 33KV, 11 KV & line complete with all accessories as specified. Standards The M.S Cross Arm and channel supplied under this specification shall conform the latest issue of the relevant Indian Standards IS 226:1975, Regulations etc. except where specified otherwise. The rolling and cutting tolerance for steel product conforming to IS: 266 shall be those specified in the IS: 1852-1973 with latest revision. Galvanization conforming to latest version of 1S:2629 In the event of conforming to any standards other than the Indian Standards, the salient features of comparison shall be clearly set out separately

3.0

GENERAL REQUIREMENT :

i. ii. iii.

The cross arm shall be fabricated grade of mild steel of channel section as per requirement. All steel members and other parts of fabricated material as delivered shall be free of warps, local deformation, unauthorized splices, or unauthorized bends. Bending of flat strap shall be carried out cold. Straightening shall be carried out by pressure and not by hammering. Straightness is of particular importance if the alignment of bolt holes along a member is referred to its edges. Holes and other provisions for field assembly shall be properly marked and cross referenced. Where required, either by notations on the drawing or by the necessity of proper identification and fittings for field assembly, the connection shall be match marked. A tolerance of not more than 1mm shall be permitted in the distance between the center lines of bolt holes. The holes may be either drilled or punched and, unless otherwise stated, shall be not more than 2mm greater in diameter than the bolts. When assembling the components force may be used to bring the bolt holes together (provided neither members nor holes are thereby distorted) but all force must be removed before the bolt is inserted. Otherwise strain shall be deemed to be present and the structure may be rejected even though it may be, in all other respects, in conformity with the specification. The back of the inner angle irons of lap joints shall be chamfered and the ends of the members cut where necessary and such other measures taken as will ensure that all members can be bolted together without strain or distortion. In particular, steps shall be taken to relieve stress in cold worked steel so as to prevent the onset of embitterment during galvanizing. Similar parts shall be interchangeable. Shapes and plates shall be fabricated and assembled in the shop to the greatest extent practicable. Shearing flame cutting and chipping shall be done carefully, neatly and accurately. Holes shall be cut, drilled or punched at right angles to the surface and shall not be made or enlarged by burning. Holes shall be clean-cut without torn or ragged edges, and burrs resulting from drilling or reaming operations shall be removed with the proper tool. Shapes and plates shall be fabricated to the tolerance that will permit fielderection within tolerance, except as otherwise specified. All fabrication shall be carried out in a neat and workmanlike manner so 159

iv.

v.

vi.

vii.

viii. ix.

x.

as to facilitate cleaning, painting, galvanizing and inspection and to avoid areas in which water and other matter can lodge. Contact surfaces at all connections shall be free of loose scale, dirt, burrs, oil and other foreign materials that might prevent solid seating of the parts. Welded joints not permissible. The rolling and cutting tolerance for steel product conforming to IS: 266 shall be those specified in the IS: 1852-1973 with latest revision. all dimensions are subject to the following tolerances: a) dimensions up to and including 50mm:+1mm: and b) dimensions greater than 50mm: +2% The channel cross arm shall be properly brushed to make it free from rust. For galvanized channel : All ferrous parts including all sizes of nuts, bolts, plain and spring washers, support channels, structures, shall; be hot dip galvanized conforming to latest version of 1S:2629 or any other equivalent authoritative standard. The zinc coating shall be smooth, continuous and uniform. It shall be free from acid spot and shall not scale, blister or be removable by handling or packing. There shall be no impurities in the zinc or additives to the galvanic bath which could have a detrimental effect on the durability of the zinc coating. Before picking, all welding, drilling, cutting, grinding and other finishing operations must be completed and all grease, paints, varnish, oil, welding slag and other foreign matter completely removed. All protuberances, which would affect the life of galvanizing shall also be removed. The weight of zinc deposited shall be in accordance with that stated in Standard IS 2629 and shall not less than 0.61kg/m with a minimum thickness of 86 microns for items of thickness more than 5mm, 0.46kg/m (64 microns) for items of thickness between 2mm and 5mm and 0.33kg/m (47 microns) for items less than 2mm thick. he raw materials and fabrication thereof in respect of cross arm shall be furnished along with dimension. The hole for fixing of insulator and pole clamp shall be provided as per requirement. One copy of the drawing of cross arm for each size shall be furnished along with the technical bid. a. Sl No. 1 2 3 4 5 6 7 8 9 REQUIRED TECHNICAL SPECIFICATION FOR GI CHANNEL CROSS ARM [100x50x6x3200 ] Description Particular Type of cross arm Size Material Length Breath Width Thickness Hole for insulator fixing of G.I Channel cross arm 100 x 50x 6 x 3200 mm Mild Steel channel 3200 mm 100 mm 50 mm 6 mm 26 mm 1525 mm

xi. xii. xiii.

xiv. xv.

xvi. xvii. xviii.

Center to distance of hole

center

160

10 11 12

Hole for pole clamp Weight Galvanization

18 mm 29.5 kg (approx) The cross arm shall be properly brushed to make it free from rust and hot dip galvanized confirming to IS: 2629. IS: 266; IS: 1852-1973:

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

Standard applicable

Description Type of cross arm Size Material Length Breath Width Thickness Hole for foxing of insulator Center to center distance for hole Weight Galvanization

Particular GI Channel cross arm 75 x 40x 40x6 x 2200 mm Mild Steel channel( galvanized) 2200 mm 75 mm 40 mm 6 mm 20 mm 1070mm 16 kg (approx) The cross arm shall be properly brushed to make it free from rust and hot dip galvanized confirming to IS: 2629.

3.20
i)

TECHNICAL SPECIFICATION FOR 33 KV & 11KV DISC INSULATOR (B&S) 70 KN

Scope: This specification covers design, manufacture, testing at manufacturers works, supply and delivery of strain insulators use on 11 KV and 33 KV overhead power line. ii) Standard: a) Strain insulators Ball & Socket type suitable for 11 kV & 33 kV lines shall be conforming to Indian standard Specification IS: 731:1971 and IS: 3188 with its latest amendments and revisions and having mechanical failing load of 70 KN. b) Insulators conforming to any other internationally accepted standard which ensure equal or higher quality than the standard mentioned will be acceptable. c) Where the material is offered according to the internationally accepted standard a copy of the specification shall be attached with the tender. iii) General requirements: a) The porcelain shall be sound, free from defects, thoroughly vitrified and smoothly glazed. Unless and otherwise specified glaze shall be brown in colour. The glaze shall cover all the porcelain parts of the insulator except those areas which serve as support during firing or are left unglazed for purpose of assembly. b) The design of the insulator shall be such that stress due to expansion and contraction in any parts in any parts of the insulator shall not lead to deterioration. The porcelain shall not engage directly with hard matel. c) Cement used in the construction of insulator shall not cause fracture by expansion or loosening by contraction and proper care shall be taken to locate the individuals parts correctly during commencing. 161

The cement shall not give rise to chemical reaction with metal fittings and its thickness shall be uniform as possible. i) The insulator shall be multi petticoat type./The insulator shall be in one piece.

iv) Basic Parameter: Sl Particular no 1 Type of insulator 2 Applicable Standard 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 v) a) Material Type Colour Size Minimum failing load Socket cap Ball pin Security clip Creepage distance Nominal System voltage Highest system voltage (rms) Wet one minute power frequency test(rms) Dry one minute power frequency test (rms) Power frequency puncture withstand (rms) Impulse voltage withstand test(Peak) Power frequency flush and voltage (dry) Power frequency flush and voltage (wet) Visible discharge test

Disc insulator, 70 KV (B&S type) IS: 731:1971 and IS: 3188, IS: 2544/1973 Porcelain [sound, free from defects, thoroughly vitrified and smoothly glazed] Ball & Socket Brown 255x145 mm 70 KN Malleable cast iron hot dip galvanized of size 16 mm dia High tensile/ forged hot dip galvanized Phosphor bronze W type 580mm ( for 33 KV)& 400 mm ( for 11 KV) 33kV/11 KV 36 KV/12 KV 75 KV/35 KV 75 KV /35 KV 180 KV /105 KV 170 KV / 75 KV 95 KV ( r.m.s) 80 KV ( r.m.s) 27 KV ( r.m.s)

Mechanical Load: The minimum failing load of the insulator shall 70 KN and the load shall be applied transverse.

vi) Creepage Distance: a) The minimum total creepage distance for insulator shall be suitable for heavily polluted and humid atmospheric conditions and shall be 400mm (for 11KV) & 900mm (for 33 K) in vertical position. vii) Marking: a) Each insulator shall be legibly and indelibly marked to show the following: i) Name and trade mark of the manufacturer ii) Month and year of manufacture iii) Minimum failing load in KN iv) Country of manufacturer. v) ISI certificate marking if any The marking on porcelain shall be printed and shall be applied before firing. viii) Packing: a) All insulators shall be suitably packed and crated to standard packing practice as required under Railway Regulation to withstand rough handling during transit. ix) Tests: The insulator shall stand the entire following test as per IS: 731/1971 (incorporating latest amendments and revisions). 162

a)

b)

Type tests The following type tests shall be conducted on the insulators (which have already passed the routine test): i) Visible discharge test (power frequency voltage) ii) Impulse voltage withstand test iii) Impulse voltage flashover test iv) Verification of dimension v) Wet one minute power frequency test and wet flashover tests vi) Visual examination vii) Mechanical failing load test viii) Porosity test The tenderer shall furnish copies of test certificates of the type test carried on identical manufacturer with guaranteed performance data for the insulators which they offer for supply. The report of type tests (on the insulator which is passed the routine tests) tested in the National Test House, Alipore and or such similar Government recognized Test House/ Institutions shall be invariably submitted along with the tender. Sample/ Acceptance tests: The samples (after withstanding the routine test) shall also be subjected to the following sample acceptance tests as per ISS. ix) Verification of dimensions x) Temperature cycle test xi) Mechanical failing load test xii) Power frequency puncture withstands test xiii) Porosity test The following routine and factory tests shall be conducted at the time of manufacture as per ISS. xiv) Visual examination xv) Electrical test Guaranteed technical particulars: (To be filled by the tenderer) 1) Name and address of manufacturer. 2) Trade mark of manufacturer to the legibly marked in the insulator. 3) Mechanical characteristic. a. Total creepage distance in mm. b. Overall height of insulator in mm c. Overall diameter of insulator in mm. d. Overall weight of insulator in Kg. e. Minimum failing load in KN. 4) Electrical characteristic a. Visibly discharge voltage. (power frequency voltage) b. Dry one minute power frequency withstands voltage. c. Wet one minute power frequency withstands voltage. d. Power frequency puncture withstands voltage. e. Impulse (1/50 micro second wave) withstands voltage. f. Impulse flashover (1/50 micro second wave) voltage. g. Impulse flashover (1/50 micro second wave) voltage negative. h. Dry flash over voltage. i. Wet flash over voltage. 5) Standard specification to which insulator will conform. 6) Other particulars, if any.

c)

d)

x)

xi) Inspection: All tests and inspections shall be carried out at the place of manufacturer unless otherwise agreed by the purchaser and the manufacturer at the time of purchase. The manufacturer shall afford the inspector representing the purchaser all reasonable facilities, without charge to satisfy that the materials are being purchased as per specifications. The purchaser reserves the right to have tests carried out at his own cost by an independent agency, whenever there is dispute regarding the quality of the material supplied. xii) Drawing and Sample: Drawing specifically showing all dimensions is to be submitted along with technical bids. Sample should be furnished alongwith the tender for verifications. Firms whose samples have been approved earlier need not submit the same. 163

3.21
1.0

TECHNICAL SPECIFICATION FOR HARDWARE FITTING FOR DISC INSULATOR, 70 KN( B& S)

Scope: This specification covers design, drawings, manufacture, testing at manufacturers works, supply and delivery of hardware fittings for strain insulator of ball & socket type . The fitting shall consist of the following component : a) Cross arm strap conforming to IS: 2486 ( Pt-II)-1989. b) Forged steel ball eye for attaching the socket end of the strain insulator to the cross arm strap. Forging shall be made of steel as per IS : 2004-1978. c) Aluminium alloy thimble socket made out of permanent mould cast , high strength aluminium alloy for attaching to the strain insulator on one end and for accommodating the loop of the helically formed dead-end fittings at the other end in its smooth internal contour. The thimble socket shall be attached to the strain insulator with the help of locking pin as per the dimension given in IS: 2486(PT-II)-1989 d) Helically formed dead-end grip having a pre-fabricated loop to fit ito the grooved contour to the thimble on one end and for application over the conductor at the other end. The formed fitting shall conform to the requirement of IS:12048-1987. Tests: The helically formed fittings for strain insulators shall be subjected to tests as per IS:12048-1987. The other hardware fittings shall be tested as per IS:2486 (Part-I) Packing: For packing of strain clamps and related hardware, double gunny bags or wooden cases shall be used. The fittings shall be properly protected against damage. The gross weight of the packing shall not normally exceed 50 Kg. Helically formed fittings shall be packed in card board / wooden boxes. Fittings for different sizes of conductors shall be packed in different boxes and shall be complete with their minor accessories fitted in place and colour codes on tags / fittings shall be marked to identify suitability for different sizes of conductors as per IS:12048-1987 Inspection: All tests and inspections shall be made at the place of manufactur 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. The purchaser has the right to have the tests carried out at his own cost by an independent agency whenever there is dispute regarding the quality of supply.

2.0

3.0

4.0

164

3.22
1.0
SCOPE

TECHNICAL SPECIFICATION FOR 33 kV AND 11kV PIN INSULATOR

This specification covers the design, manufacture, testing at manufacturer's works, transport to site, insurance, storage, erection and commissioning of insulators required for 33 kV and 11kV lines.

2.0

STANDARD The pin insulators shall comply with the Indian Standard specification IS : 731/1971 as amended from time to time having mechanical failing load of 10 K.N for 33 kV insulator and 5KN for 11kV insulator.


2.1 2.2

Insulators conforming to any other internationally accreted standards which ensure equal or higher quality than the standard mentioned would also be acceptable. Where the material is offered according to the inter-national standard a copy of the specification shall be attached with the tender.

General requirement: The porcelain should be sound, free from defects, thoroughly vitrified and smoothly glazed. Unless otherwise specified, the glaze shall be brown colour. The glaze shall cover all the porcelain parts of the insulators except those areas which serve as support during firing or are left unglazed for purpose of assembly. The design of the insulator shall be such that stress due to expansion and contraction in any part of the insulator shall not lead to deterioration. The porcelain shall not engage directly with hard metal. Cement used in the construction of insulator shall not cause fracture by expansion or loosening by contraction and proper care shall be taken to locate the individual parts correctly during cementing. The cement shall not give rise to chemical reaction with metal fitting and its thickness shall be as uniform as possible. The insulator shall be multi-petty-coat type. BASIC PARAMETER: Sl No 1 2 3 4 5 6 7 8 9 Particulars Type of insulator Applicable Standard Material Dimension Minimum failing load Creepage distance Nominal System voltage Highest system voltage (rms) Wet one minute power frequency

2.3 2.4

2.5

3.0

33 KV Pin Insulator

11kV Pin Insulator IS : 731/1971

Porcelain sound, free from defects, thoroughly vitrified and smoothly glazed. 155x160 mm 210x280x145 mm 5KN 10 KN 580 mm 33kV 36 KV 75 KV 320mm 11kV 12kV

165

10

11

12

13

14

test(rms) Dry one minute power frequency test (rms) Power frequency flush over voltage (Dry) Power frequency flush over voltage (Wet) Power frequency puncture withstand (rms) Impulse withstand voltage test(Peak)

95 KV

95 KV

80 KV

180 KV

170 KV

4.0

MECHANICAL LOADS The minimum failing load of the insulators shall be 10 KN for 33 kV and 5KN for 11kV and the load shall be applied in transverse direction.

5.0

CREEPAGE DISTANCE The minimum total creepage distance for 33kV insulators shall be 580 mm and 320mm for 11 kV insulators.

6.0

MARKING Each insulator shall be legibly and indelibly marked to show the following: a. b. c. d. e. f. Name or trade mark of the manufacturer Month and year of manufacture Minimum failing load in KN Country of manufacture ISI certificate mark, if any Name of the Project

The marking on porcelain shall be printed and shall be applied before firing.

7.0

Type Tests The following type tests shall be conducted on 'a suitable number of individual insulator unit, components, materials or complete strings:

a)Verification of dimensions b)Thermal mechanical performance test c)Power frequency voltage withstand and flashover test (i) dry (ii) wet d)Impulse voltage withstand and flashover test (dry) e) Visible discharge test (dry) f)RIV test (dry)

166

g)Mechanical failing Load Test (for pin insulator only) h)24 hrs. mechanical strength test (for strain / string insulator only)

8.0

Acceptance Test a) b) c) d) e) f) g) h) i) j) k) l) m) n) o) p) Visual examination Verification of dimension Temperature cycle test Galvanizing test Mechanical performance test Test on locking device for ball and socket coupling Eccentricity test Metallurgical test Grain test Inclusion rating For metal fittings only (in black condition) Chemical analysis Microstructure. Mechanical failing load test (for Pin Insulator only) Electro-mechanical strength test (for strain insulator only) Porosity test Puncture test(for Strain Insulator only)

9.0

ROUTINE TEST a) b) c) Visual Inspection Mechanical routine test (for Strain Insulator only) Electrical routine test (for Strain Insulator only)

10.0

Tests During Manufacture

On all components as applicable a)Chemical analysis of zinc used for galvanizing b)Chemical analysis, mechanical, metallographic test and magnetic particle inspection for malleable castings. c)Chemical analysis hardness tests and magnetic particle inspection for forgings d)Hydraulic Internal Pressure tests On disc insulator shells

11.0
11.1

Test Reports Copies of type test reports shall be furnished in at least three (3) copies along with one original. One copy shall be returned duly certified by the Owner only after which the commercial production of the concerned materials shall start. Copies of acceptance test reports shall be furnished in at least six (6) copies. One copy shall be returned duly certified by the Owner, only after which the material shall be despatch. Record of routine test reports shall be maintained by the Contractor at his works for periodic inspection by the Owner's representative. Test certificates of test during manufacture shall be maintained by the Contractor. These shall be produced for verification as and when desired by the Owner. Inspection 167

11.2

11.3

12.0

a)

The Owner's representative or third party nominee shall at all times be entitled to have access to the works and all places of manufacture, where. insulator, and its component parts shall be manufactured and the representatives shall have full facilities for unrestricted inspection of the Contractor's and ;1ubContractor's works, raw materials, manufacture of th::; material and for conducting necessary test as detailed herein. The material for final inspection shall be offered by the Contractor only under packed condition as detailed in the specification. The Owner shall select samples at random from the packed lot for carrying out acceptance tests. Insulators shall normally be offered for inspection in lots not exceeding 5000 nos. the lot should be homogeneous and should contain insulators manufactured in the span of not more than 3-4 consecutive weeks. The bidder shall keep the Owner informed in advance of the time of starting and the progress of manufacture of material in their various stages so that arrangements could be made for inspection. No material shall be dispatched from its point of manufacture before it has been satisfactorily inspected and tested unless the inspection is waived off by the Owner in writing. In the latter case also the material shall be dispatched only after satisfactory testing for all tests specified herein have been completed. The acceptance of any quantity of material shall be no way relieve the Contractor of his responsibility for meeting all the requirements of the specification and shall not prevent subsequent rejection, if such material are later found to be defective.

b)

c)

d)

e)

13.0

BID DRAWING The Bidder shall furnish full description and illustration of the material offered. The Bidder shall furnish along with the bid the outline drawing (6 copies) of each insulator unit including a cross sectional view of the insulator shell. The drawing shall include but not limited to the following information: a. Dimensions with manufacturing tolerances b. Minimum creepage distance with positive tolerance c. Protected creepage distance d. Eccentricity of the disc i. Axial run out ii. Radial run out e. Unit mechanical and electrical characteristics f. Size and weight of Pin Ball Shank / ball and socket parts g. Weight of unit insulator disc h. Materials i. Identification mark j. Manufacturer's catalogue number After placement of award, the Contractor shall submit fully dimensioned insulator drawings containing all the details, in four (4) 'copies to Owner for approval. After getting approval from Owner and successful completion of all the type tests, the Contractor shall submit 20 more copies of the same drawing to the Owner for further distribution and field use at Owner's end.

14.0

Guaranteed Technical Particulars The guaranteed technical particulars in respect of the Pin Insulators offered shall be submitted along with the tender.

168

3.23
1.
1.1.

TECHNICAL SPECIFICATION FOR G.I. PIN OF 33kV and 11kV PIN INSULATOR

Scope
This specification covers design, manufacture, testing at manufacturers works, transport to site, storage, insurance, erection and commissioning of galvanized forged steel pins for use in 11 KV and 33 kV lines.

2. Standard 2.1. The galvanized Iron forged steel pins shall be of type L-230 N conforming to IS 2486 (PT-I/1971) and IS: 2486 (PT11/1963) having stalk length of 300 mm and shank length of 150 mm with minimum failing load of 10 kN. Details of the pin are shown in the drawing. 2.2. The pins conforming to any other internationally accepted standards which ensure equal or higher quality than the standard mentioned would also be acceptable. 3. 3.1. General Requirements The pins shall be single piece obtained by process of forging. They shall not be made by joining, welding, shrink fitting or any other process for more than one piece of materials. They shall be of good finish, free from flaws and other defects. The finish of the collar and the shank is avoided. All ferrous pins, nuts spring washers shall be galvanized and small fittings like spring washers, nuts etc. may be electroplated with zinc. The threads of nuts and tapped holes etc. shall be rounded. The galvanizing should be as per ISS: 2633/1964. The dimensions of the 33kV Pins shall be as follows:

3.2.

3.3.

Particulars Minimum failing load Stalk length Shank length Thickness of collar Diameter of collar Diameter of shank Threaded length of shank Diameter of stalk head Threaded length of stalk 3.4. 3.5.

33kV Pin 10KN 230mm 150 mm 6 mm 50 mm 24 mm 100 mm 27.78 mm 47 mm

11kV Pin 5KN 165mm 150mm 5mm 40mm 20mm 100mm 18.29 40mm

The pins shall have minimum failing load of 10 kN and 5KN for 33 kV.and 11kV Pin respectively.

Tests Pin shall comply with the following tests. 3.6. Type test: a) Visual examination test b) Verification of dimensions c) Checking of threads d) Galvanizing test e) Mechanical strength tests e) 3.7. Routine test: a) Visual examination test 3.8. Acceptance test: Checking of threads on heads a)Galvanizing test b)Mechanical test 4. Inspection 4.1. All tests and inspections or shall be carried out at the place of manufacturers unless otherwise agreed by the purchaser and the manufacturers at the time of purchase. A manufacturer shall afford the inspector or third party nominee representing the purchaser all reasonable facilities, without charge to satisfy that the materials are being purchased as per specification. The purchaser reserved the right to have the test carried out at his cost by an independent agency, whenever there is dispute regarding the quality of the materials supplied. 5. Marking 5.1. The pins shall be marked with name of manufacturer, year and name of project.

169

3.24
1.0 Scope

TECHNICAL SPECIFICATION FOR AAA WOLF & RACCOON CONDUCTOR

2.0

This specification covers design, manufacture, testing at works, transport, insurance, storage, erection and commissioning of All Aluminum Alloy Stranded Conductors at site in 33 KV. Conductor Size xiii) 19/3.40 mm (175 mm Alloy Area) wolf xiv) 7/3.81 mm ( 80 mm Alloy Area ) - Raccoon Applicable Standards Unless otherwise stipulated in this specification, the conductor shall comply with IS:398 (Part-IV)- 1994 or the latest version thereof. Properties of Wires The properties of Aluminium alloy wires to be used in the construction of the stranded conductors shall be as in the following Table-1 Table-1 Cross area of Maximum Diameter Mas nominal breaking load Resistance at 20 C s Dia after stranding wire Nominal Mm 3.40 3.81 Min mm 3.37 3.77 Max mm 3.43 3.85 mm
2

3.0

4.0

Max Kg/Km 24.5 1 30.7 8 KN 2.80 3.34 Ohm/Km 3.67 2.938

Stamdar d Ohm/Km 3.96 2.851

9.079 11.401

5.0

Properties of Conductors The properties of stranded all aluminium alloy conductors of various sizes shall be as in the following tableII All Aluminium Alloy Conductors ( AAAC) Calculate d resistance at 20 C (Max) 6 Ohm/Km 0.1969 0.425 Approx calculated breaking load 7 KN 50.54 23.41

Nominal Alloy Area 1 mm


2

Stranding & Wire dia 2 Mm 19/3.40 7/3.81

Sectional area 3 2 mm 172.52 79.81

Approx. overall dia 4 mm 17.00 11.43

Approx. Mass 5 Kg/Km 474.02 218.26

173 80 6.0 7.0

8.0 8.1

Free From Defects The wire shall be smooth and free from all imperfection such as spills, splits etc. Joints in Wires Conductors containing three/seven wires. There shall be no joint in any wire of a stranded conductor containing three/seven wires except those made in the base rod or wire before final drawing. Stranding The wires used in the construction of a stranded conductor shall before stranding satisfy all the relevant requirements of this standard.

170

8.2

The lay shall be within the limits given in Table-III Lay Ratios for Aluminium Alloy Stranded Conductors No. of wires in conductors 7 19 Min. 10 10 Lay ration Max 14 16

8.3 9.0

The outer layer shall be right handed. The wires in each layer shall be evenly and closely stranded. Climatic Conditions The conductor shall be designed to suit for the climatic conditions specified in these bidding documents. 10.0 Tests The samples of individual wires for the test shall normally be taken before stranding. The manufacturer shall carry out test on samples taken out at least from 10% of aluminium wire spools. However, when desired by the purchaser, the test sample may be taken form the stranded wires. However the minimum breaking load test shall be done on a sample taken from stranded wires and the minimum breaking load shall not be less than the value indicated in Table-I. The wires for alloy conductors shall comply with the following tests as per IS: 398(Part-IV)-1994 i) Breaking loads test. ii) Elongation test iii) Resistance test 11.0 Packing and Marking The conductors shall be owned in reels or drums conforming to the latest version of IS: 1778-1980 Specification for reels and drums for bare wire and name of the project TDF shall be indicated clearly on the drums. 10.1 10.1.1 Packing The gross mass of packing of various conductors shall not exceed by more than 10% of the values given in the following table: Conductor size Gross Mass 2 175 mm alloy area ( 19/3.40mm) 2500 80 mm Alloy Area (7/3.81 mm) 1600 KG The normal length of various conductors shall be as given in the following table: Normal Length 1.1 Km 1.3 KM

10.1.2

Conductor size 2 175 mm alloy area ( 19/3.40mm) 80 mm Alloy Area (7/3.81 mm) 10.1.3 10.1.4

Longer lengths shall be acceptable. Short length , not less than 50% of the normal length shall be acceptable to the maximum extent of 10% of the quantity ordered 10.2 marking. The following information be marked on each package. a) Manufacturers name. b) Trade Mark, if any. c) Drum or identification number. d) Size of conductor e) Number & lengths of conductor f) Gross Mass of the package g) Net mass of the conductor h) ISI certification mark. i) Name of the Project TDF

11

INSPECTION All tests and inspection shall be made at the place of manufacture. The manufacturer shall afford the inspection representing the purchaser or third party nominee all reasonable facilities without charge to satisfy him that the material is being furnished in accordance with this specification.

171

3.25 TECHNICAL SPECIFICATION FOR HARDWARE FITTINGS INCLUDING TENSION CLAMP ASSEMBLY (Aluminium Alloy) FOR RACCOON AND WOLF CONDUCTOR 1.0 Scope: This specification covers design, drawings, manufacture, testing at manufacturers works, supply and delivery of suspension clamp for use with Raccoon (7/3.81mm-80 sqmm)/Wolf (19/3.4mm-175 sqmm )conductors within the state of Assam. 2.0 Standard: The material and process adopted in the manufacture shall conform to the provision of the following standards amended up-to-date IS: 2486 specification for Insulator fitting for overhead power lines. 3.0 General: The tension clamps offered shall be made of die cast high strength aluminium alloy and shall be suitable for use with Raccoon and Wolf conductors together with one set of preformed armour rods. Suitable sheet metal liner shall be provided. The clamp shall move easy oscillation around horizontal axis. The bidder is to quote separately for suspension clamp: i) Envelope type ii) Bottom free centre type design. The single tension clamp shall consist of the following components: Description Quantity Material 1. Ball hook without provision for 1 no. Forged Steel Arching horn 2. Socket type without provision for 1set. MCI Arching horn 2. Tension clamp for AAAC 1 no Alumium alloy Raccoon /Wolf conductors The clamp shall be of high corrosion resistant, light in weight, have low effective power loss and small moment of inertia enabling it to follows freely the movements of the conductor The tension clamp shall also be provided with suitable socket or clevis eye for connecting it to the insulator string. The seat and clamping surface should be smooth, without any projections or sharp bends and should be formed to support the conductor on long, easy curves at the comparatively sharp bends. Minimum failing load = 70 KN. The slip strength of tension clamp shall not exceed 15% of the breaking load of the conductor. 4.0 Tests: The hardware fittings shall be subjected to all the tests in accordance with relevant Indian Standard Specifications. The purchaser shall have the right to carryout acceptance tests, in the presence of representatives of the purchaser. The bidder shall submit type test certificate along with the tenders. The following tests shall be carried out. i) Type Test: (a) Slip Strength test for clamp. (b) Mechanical test for clamp & fittings (c) Heating cycle test. (d) Verification of dimensions. (e) Galvanizing / Electroplating test. (f) Visual examination test ii) Acceptance Test: a) Dimensional test. b) Galvanizing test. c) Mechanical test for clamp & fittings d) Electrical Resistance Test. Routine Test: a) Visual examination test. b) Routine mechanical test

iii)

172

Guaranteed Technical Particulars (GTP) and drawing specifically showing all dimensions are to be submitted along with technical bids

3.25
1.0

TECHNICAL SPECIFICATION FOR P.G CLAMP FOR AAA RACOON /WOLF CONDUCTOR Scope:

The scope covers design, manufacturing, testing at work, transport at site, insurance, storage, erection and commissioning of P.G. Clamp suitable for Conductor size Wolf/Raccoon/Weasel/3 Bolt Type strictly conforming to IS : 2121 and Galvanising conforming to IS : 2633 as per the following:

2.0

Standards: P.G. Clamps suitable for conductor size, wolf/raccoon/weasel 3 bolt types strictly conforming to IS : 2121 and galvanizing conforming to IS: 2633 as per the following: P.G. clamp body to be made from aluminium alloy Clamps nuts and bolt and washer should be made of hot deep galvanized steel Spring washer be made of electro-galvanize special steel.

Conductor Style No. A-83 A-81 Wolf Racoon

Maximum conductor diameter in mm 20.78 14.45

Dimensions A mm 140 95 B mm 76 57 C mm 42 30 D mm 5/8 1/2 E mm 1 2 No of Bolts 3 2

Approx . Weight Kg. 0.51 0.18

3.0

Inspection may be carried out by the purchaser or third party nominee at any stage of manufacture. The supplier shall grant free access to the purchaser's representative or third party nominee at a reasonable time when the work is in progress. Inspection and acceptance of any equipment under this specification by the purchaser shall not relieve the supplier of his obligation of furnishing equipment in accordance with the specification and shall not prevent subsequent rejection if the equipment is found defective.

173

3.26
1.0

TECHNICAL SPECIFICATION OF XPLE CABLE FOR 11kV SYSTEM

SCOPE: The specification covers the design, testing, supply and delivery in proper packed condition of different grade of 1 or 3 core. Aluminium Conductor, Cross-linked polyethylene (XLPE) insulated, PVC sheathed, armoured, screened Power Cables. LOCATION: The cables may be laid buried directly in ground at a depth of one metre in average, any where in Assam and terminate for outdoor connection to a power transformer or to overhead lines and also indoor connection for indoor switchgear. The cables may also be laid within covered cable trenches, in cable racks or open-air ladder trays etc. for certain portion of lengths. SYSTEM DETAILS: 3.1 Voltage grade (KV) of cable required 3.1 Service Voltage 3.2 Highest Voltage 3.3 Earthing System 3.4 B.I.L. for Cables 3.5 Fault Level (Maxim.) found. 3.6 Frequency

2.0 1.1

1.2

3.0

6.35/11 11 KV 12 KV Solidly Earthed 75 KV for 11 KV See Clause Error! Reference source not 50 C/S.

4.1 4.2

STARDARDS: The cable shall conform to the following standards to the extent of LAEDCL requirement is fulfilled. 1) IS : 7098 (Part II) (Latest) :Specification for cross-linked polyethylene Insulated PVC Sheathed Cables for working Voltage from 3.3 KV up to and including 33 KV. 2) IS:8130 1984 IS:5830 1984 IS:3975 1979 IS:10810 1984 IS:10418 1982 :Specification for Conductors for insulated electric cables and flexible cords. :PVC insulation & sheath of electric cables. : Armour for cables (for 3 Crore). : Methods for test for cables. : Cable Drum for Electric Cables.

3) 4) 5) 6) 3.3

The cable, joints, outdoor and indoor termination and their accessories and fittings may conform to other Indian and/or equivalent standards or important publications to improve upon their performance, but shall not fall short of the requirement of this specification. The tenderer shall clearly indicate such standards in their offers.

5.0 5.1 a)

ELECTRICAL CHARACTERISTICS & PERFORMANCE: Description of Cable: 6.35/11 KV Grade 3-Crore : Same as above but insulation shielding with black semi-conducting tape not necessary. Inner sheath to be wrapped not extruded and strip armoured. The design shall fully conform to IS:7098 (Part II).

174

b) SPECIFIC TECHNICAL REQUIREMENTS Technical parameters of the cable shall be as follows: S l N o 1 2 3 4 5 6 7 8 9 1 0 1 1 1 2 1 3 1 4 a Particulars Unit 11 KV

Rated voltage Type of insulation Single Core Armoured /Unarmoured Material of Conductor System Highest System Voltage Material Voltage Grade Conductor Size Nominal dimention of Al. round wire Nominal thickness of XLE insulationr sheath Approx overall cable diameter Current rating In ground at 30
0C 0C

KV -

KV Sq. mm

11 XLPE Single , three Armoured Material to IS: 8130, H4 Grade Aluminium Conductor, Stranded compacted Circular 11 KV Earthed 12 Stranded Aluminium 6.35/11 KV 1x185,3x120 1x300 2.0mm[for 1x300sqmm ], 2.0mm [for 1x185sqmm & 2.5mm[3x120 sqmm], 3.6 mm 61.50mm [for 3x120sqmm], 35.50mm [for 1x185sqmm] 40.00 mm [ for 1x300 sqmm],

In air at 40

1 5 1 6 1 7

Maxm. Conductor Temp Short Ckt.Current second duration

219A(3x120sqmm), 296A(1x185sqmm) 381 A(1x300 sqmm) 288A(1x120sqmm), 378A(1x185sqmm) 512 A(1x300 sqmm o 90 C at maxm. Continuous current for 1 11.3KA-for120 sqmm, 17.5 KA-for 185 sqmm, 28.3 KA for 300 sqmm. o 130 C for one hour

1 8 1 9 2 0 2 1 2 2 a

Maxm.Permissible emergency overload temp. at 25% overload to 100 hrs. per year or 500 hrs. in life of cable Maxm. Permissible short circuit temperature Conductor Screening Insulation Screening Conductor Screening Insulation Insulation Screening : : For 33 KV :

250 C for one hour

Extruded, cross linked, semi-conducting compound of.5 mm for 11KV

Extruded, cross linked, semi-conducting compound of.5 mm for 11KV XLPE of thickness, 3.6 mm (Nominal) for 11KV Combination of black extruded semi-conducting tape as the non-metallic part and annealed copper 0.06 mm (minimum) thick tape lapping as metallic part. For 1 core cable, the non-magnetic metal Armour will act as metallic part insulation screening. 175

2 3 2 4

Inner Sheathing

For 11 KV : :

It is same but semi-conducting tape is not required

Armouring

2 5 2 6 2 7 a

Overall Sheathing

Approx. length of cable in a Drum End Sealing Max. Tan-delta at room temp. At nominal phase to neutral voltage (Uo): Maxm. Increment of tandelta between 0.5 Uo to 2 Uo at room temp: Partial discharge value Impulse Tests H.V. Tests between Conductors & Screen/Armour Maxm. D.C. Rtance/Km

Black extruded PVC, Type ST-2 compound for 33 KV and wrapped PVC tape for 11 KV as per ISS. For 1 core there will be no inner sheath. Single layer of round galvanized steel wires/strip for 33 KV and galvanized steel strips/wire for 11 KV (3 core) as per IS. For 1 core, there will be non-magnetic metal Armour. Coloured PVC, type ST-2 compound to IS: 5831, extruded for both 33KV and 11KV thickness shall be as per ISS 250 metres with a tolerance of 5% (for 3 core), 500 metres 5% (for 1 core) H.S. Caps (see clause Error! Reference source not found.) (Heat Shrinkable) 0.004

0.002

2 8 2 9 3 0 3 1

20 Pc (Maxm.) at 1.6 Uo. 170 KV for 33 KV and as per ISS for 11 KV 48 KV (rms) for 33 KV for 5 minutes and as per ISS for 11 KV As per relevant I.S.S

* NB the above parameters are applicable for three core and single core cable, if not otherwise specified. CABLE CONSTRUCTION: 5.3 XLPE underground cable is to be manufactured in continuous catenaries process at controlled elevated temperature and pressure in inert atmosphere with use of suitable materials for XLPE semiconducting, insulation and XLPE screen. The inner and outer semi-conducting sheaths and main polyethylene insulation between the sheaths are to be simultaneously extruded during the Triple Extrusion Process of manufacturing and main insulation of the Cable is to be extruded unified. The XLPE Cables in this specification does not have any metal sheath and the short circuit rating of the cable will depend on the conductivity and continuity of the strands of the armour wires, which shall be ensured by guarding against corrosion. 5.4 5.5 CONDUCTOR SCREENING A semi-conducting cross-linked polyethylene (XLPE) screening shall be extruded over the conductor to act as an electrical shield which together with elimination of the so called Strand Effect prevents to a great extent air ionization on the surface of the conductor. INSULATION:

5.6

The main insulation of the Cable shall be extruded unfilled, chemically cross-linked polyethylene (XLPE) inert gas cured satisfying the requirement of ISS: 7098 (Part- II) 5.7 INSULATING SCREEN:

The screen shall be made up as given in Clause 22the metal screen eliminates tangential stress electrostatic field surrounding the conductor and uniform electrical stress in the insulation. The semi conducting polyethylene (XLPE) screen shall be extruded over the main poly ethylene-insulating wall to prevent partial discharge at the surface of the insulation. The copper tape shall be wrapped over the semi conducting tape or extrusion as mentioned earlier for 3 core cables. The metal screen so formed 176

around the cores shall be in contact with one another as the cores are laid up at triangular configuration. For single core cable, Aluminium wires armoring shall constitute the metallic part of insulation screen. Conductor screening, insulation and insulation screening shall be extruded in triple extrusion processes so as to obtain continuously smooth interfaces. 5.8 The mechanical and chemical properties of the materials for semi conducting screens are much more important than their electrical properties, but for obtaining the high overall degree of electrical properties of an E.H.V. cable, the inner and outer semi conducting, sheaths and the main polyethylene insulation between the sheaths shall be simultaneously extruded during the manufacturing, process known as triple extrusion. The advantages are: i) The partial discharge level at the surface of the insulation is brought to a minimum. ii) There will be no displacement of the semi conducting screen and insulation during expansion and contraction due to load cycles and bending. iii) The semi conducting screens are easily removable during joining and termination operations. Note: Manufacturers not having triple extrusion process will be disqualified. The Tenderer shall have to produce necessary process line at the time of bidding. 5.9 LAYING UP: The phase identification of the cores shall be either by colour or numerals as per I.S.S. for 3 core cables only. Core Colour Numeral Red 1 Yellow 2 Blue 3 The screen cores shall be laid up with interstices filled with PVC fillers and taped a binder tape as to obtain a reasonably circular cable. INNER SHEATH: The cable core shall be supplied with bedding of PVC (Inner sheath) in the form of extruded PVC sheath for 33 KV cables. Wrapped PVC tapes shall be used for 11KV thickness as per clause 23 of special technical parameters and as per relevant IS. 5.11 ARMOUR: The cable shall be wire armoured /steel strip in case of 33KV and wire/strip armoured 11 KV, three core cables to insure an adequate return path for the flow of fault current and also provide suitable mechanical protection. Steel wires/aluminum wire / steel strips of required size in requisite number as per clause 24 of special technical parameters shall be laid closely in the spiral formation to protect the circumference of the cable fully and to provide adequate cores section area for flow of maximum fault current within limits of specified temperature rise and duration of fault. Direction of the lay of the armour shall be opposite to that of the cable cores in case of single core cable armour should be of non-metallic material. OUTER SHEATH: A reliable surving shall be necessary for maintaining conductivity of the armour particularly under corrosive condition in the form of jacket. Cable shall be therefore finished with extruded PVC over sheath of thickness as per clause 25 of special technical parameters. The quality of PVC over sheath (jacket) shall be ensured for service reliability against moisture intrusion and shall confirm to type ST-2 of IS : 5831. The colour of the outer sheath shall be follows: For 11 KV cable : Blue The sheaths shall be protected against white ants, vermin and termites by suitable, durable and reliable measures. The suppliers shall suggest suitable materials for use, in the event of damage to the over sheath to prevent the passage of moisture along the cable.

5.10

5.12

177

5.13

CABLE IDENTIFICATION:

The following shall be embossed on the outer sheath for the identification. a) Manufacturers Name or Trade Mark. b) Voltage Grade. c) Nominal section and material of conductors and number of cores. d) Year of manufacture. e) Inscription of length of cables at 1.0 mtr interval. f) Name of purchaser LAEDCL; g) Marking Power shall be embossed throughout the length of the cable at 10 mtr spacing. h) Type of insulation i.e. XLPE 5.13.1 CEILING OF CABLE ENDS: The cable ends of the cable in the wooden drum for delivery shall be sealed with heat shrinkable caps. 7.0 WOODEN DRUMS: The cable shall be packed in non-returnable wooden drums. The following information shall be marked on each drum. a) Drum identification number. b) Manufacturers name, Trade name / Trade mark, if any. c) Nominal sectional area of the conductor of the cable. d) Number of cores e) Type of cable and voltage grade with cable code f) Length of cable in cable drum g) Direction of rotation of drum (by means of an arrow) h) Appox. Weight: tare: gross: i) Year and country of manufacture j) Purchase order number k) Date of delivery l) Name of the purchaser. Drum shall be proofed against attack by white ant or termite conforming to IS: 10418. The Drums may also be marked with ISI certificate mark, as applicable. Safe pulling force 8.0 : 30 N/mm (for conductor)
2

Tests to be performed as per IS:7098 (part II) Tenderer shall have to submit type test report (tested at CPRI Bangalore/Bhupal) along with the Bid. Bidder will be disqualified for non-submission of type test reports. 8.1 a) Type test all the test mentioned below are to be made as per details given in IS:10810 Test on conductor i. Tensile test (For aluminum) ii. Wrapping test for aluminum iii. Resistance test. Test for armuoring wire strips. Test for thickness of insulation and sheath. Physical test for insulation. i. Tensile strength and elongation at break ii. Ageing in air oven. iii. Hot test iv. Shrinkage test. v. Water absorption (Gravimetric) Physical tests for outer sheath i. Tensile strength and elongation at break ii. Ageing in air oven. iii. Shrinkage test. iv. Hot deformation v. Heat shock vi. Loss of mass in air oven

b) c) d)

e)

178

vii. viii. f) g) h)

Thermal stability Thermal Stability

i) j) k) l) m)

Partial discharge test Bending test Dielectric power factor test i. As a function voltage ii. As a function of temperature Insulation resistance (volume resistivity) test Heating cycle test Impulse with stand test High voltage test Flammability test

8.2 The following test on screen cable shall be performed successfully on the same test sample of completed cable, not less than 10 m. in length between the test accessories. a) PD test b) Bending test followed by PD test c) Di-electric power factor as function of voltage d) Di-electric power factor as a function of temperature e) Heating cycle test followed by Di-electric power factor as a function of voltage and PD test. f) Impulse with stand test and g) High voltage test as per para 30 of special technical parameters If a sample fails in test (g) one more sample shall be taken for this test, preceded by test (b) and (e) 8.3 Acceptance test : the following shall constitute acceptance test: a) b) c) d) e) f) g) h) i) J) Tensile test (For aluminum) Wrapping test for aluminum Conductor resistance test Test for thickness of insulation and sheath Hot set test for insulation Tensile strength and elongation at break test for insulation and outer sheath PD test (Screen enables) only on full drum length High voltage test, and Insulation resistance ( volume resistivity) test Spark test on extruded un-insulated outer PVC sheath as per provision clause no 3.2 IEC standard (Publication no.229 of 1982)

8.4 Routine test: The routine test shall be carried out on all cables manufacturer in accordance with this specification. The following routine test shall be made on cable length as specified in ISS. a) Conductor resistance test b) Partial discharge test on full drum length c) High voltage test as per clause 29 of special technical parameters 8.5 Test witness a) b) All tests shall be performed in presence of purchaser representatives if so desired by the purchaser. The contractor shall give at least 15 days advance notice for witnessing such tests.

179

9.0

Test Certificate 9.1 Certified copies of all routine test carried out at work shall be furnished in 6 copies for approval of the Purchaser. The cable shall be dispatched from works only after receipt of Purchasers written shop test report. approval of

9.2

9.3

Type test certificates of the cable offered shall be furnished. Otherwise the cable shall have to be type tested on similar rating as per clause 10 free of any charges to prove the design.

10.0

Descriptive literatures test results etc. The following details for the cable shall be submitted with bid a) Manufacturers catalogue giving cable construction details and characteristics b) Manufacturing process in details for cables highlighting the steps of control i. Contamination ii. Formation of water trees iii. Effects of by products of cross linking iv. Stress control etc. c) Cross section drawing of the cable d) Cable current ratings for different types of installation inclusive of derating factors due to ambient temperature, grouping etc. e) Over-load characteristics of the cable without endangering the normal life and electrical quality of the insulation. f) Complete technical date of the cables. g) Type test certificate from government testing units/government authorized testing units. with the quality assurance plan submitted by the firm, the offer shall be liable for rejection.

11.0

Guarantee: The guarantee period should either be 60 (Sixty) month from the date of commissioning or 68 (Sixty eight) month from the date of material received at site. The tenderer shall have to replace the damage cable (electrical damage/physical deformation) within 30 days from reporting.

180

3.27

TECHNICAL SPECIFICATION FOR CABLE END TERMINAL KIT (OUTDOOR AND INDOOR)

Heat shrinkable termination Kit for 6.35/11kV XLPE ,Cable ( 1-core,300 sq mm & 185 sqmm, 3core -120 sqmm ) both for outdoor and indoor should be as per IS : 13753 and relevant international standard. The terminal cable kit should be for the following technical parameter of cable. SPECIFIC TECHNICAL REQUIREMENTS:Technical parameters of the cable shall be as follows: S Particulars Unit l N o 1 2 3 4 5 6 7 8 Rated voltage of cable Type of insulation Core Armoured /Unarmoured Material of Conductor System Voltage Highest System Voltage Conductor Size KV KV Sq. mm 6.35/11kV XLPE Single , Armoured Aluminium 11 KV Earthed 12 300 Sq mm , 1- core 185 Sq mm , 1- core And 120 sqmm,3-core Stranded Aluminium

Material

ELECTRICAL PERFORMANCE FOR TERMINAL KIT AC Dry withstand voltage DC withstand voltage for 30 minute Lighting impulse withstand voltage Partial Discharge Standard tail length for outdoor Standard tail length for indoor KIT COMPONENT Terminal Lug Heat Shrinkable Adhesive Lined Terminal Sleeve Lug Sealing Tape / Mastic Rain Shed for 12 KV System Anti Tracking Sleeve Stress Control Sleeve Stress Control Mastic Constant Force Spring Roll Copper Braid for Screen Earthing Worm Drive Clip Adhesive Line Gland Sleeve Tinned Copper Braid duly fitted with Terminal Lug at one end + Solder Bock 1 No 1 No 1 Strip 2 Nos. 1 No. 1 No 1 Strip 1 No 1 No 1 No 1 No 1 No 35 KV / 1 minute 48 KV 75 KV 12.7 KV < 5 pc 600 mm 450 mm

181

3.28
1.0

TECHNICAL SPECIFICATION OF CONTROL CABLES

SCOPE: 1.1 Specification calls for design, manufacture, stage testing, inspection and testing beforedispatch, packing and delivery of Copper control cables and Aluminum power cables for 33/11KV substations. 1.2 The control and power cables shall be ISI marked, 1.1 KV Grade. The cores shall have a size of 2.5 sq.mm for control cables and 4 sq. mm. power cable, using solid/stranded Copper conductor with different number of cores as specified below:1.3 COPPER CONTROL CABLES Unarmoured i) 12 Core 2.5 sq.mm, solid conductor ii) 7 Core 2.5 sq.mm., solid conductor. iii) 4 Core 2.5 sq.mm., solid conductor iv) 2 Core 2.5 sq.mm., solid conductor

2.0

STANDARDS: 2.1 The control and power cables shall conform to the latest applicable Indian Standards. In case bidders offer control and power cables conforming to any other International Standards which shall be equivalent or better than IS, the same is acceptable. Cables for which Indian Standards arenot available, the relevant equivalent International Standards will be applicable. Please attach photocopy of all such standards according to which the cables have been offered (i). IS: 1554: PVC insulated (Heavy Duty) Control Cables for working voltage & including 1100 Volts. (ii). IS: 3961: Recommended current ratings for PVC insulated and PVC sheathed heavy duty cables (iii). IS: 4905: Methods of random sampling (iv). IS: 5831: PVC insulation and sheath of electric cables (v). IS: 8130: Conductors for insulated electric cables and flexible cords (vi). IS: 10418: Wooden drums of electric cables (vii). IS: 10810: Methods of tests for cables

3.0

GENERAL TECHNICAL REQUIREMENTS AND CONSTRUCTIONAL DETAILS: 3.1 Cables shall be suitable for laying on racks, in ducts, trenches, conduits and underground buried installation with chances of flooding by water. Cables shall be designed to withstand mechanical, electrical and thermal stresses developed under steady-state and transient operating conditions as specified elsewhere in this specification. 3.2 CONTROL CABLES Control cables shall be of 1.1 KV grade, multicore (as specified in Clause 1.3 above), PVC insulated, PVC inner sheathed, un armoured, PVC outer sheathed with solid copper conductor conforming to latest version of IS: 1554 or equivalent International Standards. 3.3 The conductor shall be made from high conductivity copper rods complying with latest version of IS:613 or equivalent International Standards. The conductor shall consist of annealed copper wires complying with IS: 8130 with latest amendments or equivalent International Standards. 3.4 POWER CABLES: Power cable shall be of 1.1 KV grade, multicore (as specified in Clause 1.3 above), PVC insulated, PVC inner sheathed, PVC outer sheathed with stranded conductor. 3.5 INSULATION: Conductor shall be provided with PVC insulation applied by extrusion in accordance with latest version of IS: 5831 or equivalent International Standards. The average thickness of insulation shall be in accordance with the IS: 1554 (Part-I) with latest amendments or equivalent International Standards. Insulation shall be so applied that it fits closely on the conductor and shall be possible to remove it without damages to the conductor. 3.6 CODE IDENTIFICATION: Colouring of insulation shall identify cores of the cables of upto 5 cores. Following colour schemes shall be adopted:-

182

S N 1 2 3

No of Cores 2 core 4 core 7 core

Colour Scheme Red and Black Red, Yellow, Black, Blue and Grey a) Two adjacent cores (counting and direction core) in each layer, Blue and Yellow, remaining cores Grey or in accordance with the scheme given in IS 1554 b). Cables having more than 5 cores, as an alternate to the provision of (a) above, core identification may be done by numbers as indicated in latest version of IS: 1554 (PART-I) 10 core identification.

3.7

LAYING UP OF CORES:

In multi-core cables, the cores shall be laid up together with a suitable lay, the outer most layer shall have righthand lay and successive layer shall be laid with opposite lay, where necessary, the interstices shall be filled with non hygroscopic materials. 3.8 INNER SHEATH:

The laid up cores shall be provided with inner sheath applied by extrusion. It shall be ensured that the shape be as circular as possible. The inner sheath shall be so applied that it fits closely on the laid up cores and it shall be possible to remove it without damage to the insulation. Thickness of inner sheath shall be conforming to latest version of IS: 1554 (Part-I) or equivalent International Standards. 3.9 FILLER AND INNER SHEATH:

Filler and inner sheath shall be of the following: Unvulcanised rubber, or Thermoplastic materials, or Proofed tape (for inner sheath only) Unvulcanised rubber or thermoplastic material used shall not be harder than PVC used for insulation and outer sheath. Material shall be chosen to be compatible with temperature ratings of the cable and shall have no deterious effect on any other component of the cable. 3.10 OUTER SHEATH:

The Over the outer sheath shall be applied by extrusion. It shall be applied: inner sheath in case of unarmoured multicore cables Outer sheath shall be so applied that it fits closely over insulation / inner sheath / armouring. It shall be possible to remove it without damage to the insulation / inner sheath. The colour of the outer sheath shall be black.Thickness of outer sheath insulation shall conform to latest version of IS: 1554 Part-I or equivalent international standards. 4.0 IDENTIFICATION: 4.1 In addition to manufacurers identification on cable as per clause-17.1 of IS: 1554 (Part-I) with latest amendments, following marking shall also be embossed over outer sheath at every three meters:Cable size and voltage grade Word APDCL and Name of manufacturer ISI marking and sequential marking by means of embossing The embossing shall be in line throughout the length of the cable and shall be legible and indelible. 5.0 PACKING AND MARKING: 5.1 Cables shall be supplied in non-returnable drums. The surface of the drum and outer most cable layer shall be covered with waterproof layer. Both the ends of the cables shall be properly sealed with heat shrinkable PVC or rubber caps, secured by U nails so as to elliminate ingress of water during transportation storage and erection. Following information should be stenciled on the drum: Reference no of relevant Indian or International Standard. Manufacturers name, brand name or trade mark Type of cable and voltage grade Number of cores

183

Nominal cross-sectional area of the conductor Cable code Colour of cores Length of cable on the drum Number of lengths on drum (if more than one) Direction of rotation of drum by means of an arrow Approximate gross weight Running end of cable Country of manufacturer and year of manufacture 5.2 As mentioned, the cable drum must bear relevant Indian/International Standard certification Mark. In this connection, a certified photostat copy of valid standard marking license rights duly attested must be submitted along with the inspection offer as documentary evidence. In absence of these documents, the inspection offer will not be considered. STANDARD DRUM LENGTH: 6.1 Standard drum length for cable shall be 500/250 metres. 6.2 TOLERANCE: Tolerance on the overall diameter of the Cable shall be 2 mm over the declared value in the techanical data sheets of Guaranteed Technical Particulars. Length per drum shall be subjected to maximum tolerance of 5% of the standard drum length. The Employer shall have option to reject cable drums with shorter length. Over all tolerance in total quantity for each type and size of cables shall be 2%. 7.0 TESTS: 7.1 All types and sizes of cable being supplied shall be subjected to Type tests, Additional test, Routine tests and Acceptance tests as specified below at the expense of manufacturer and according to relevant standards. 7.2 TYPE TESTS AND ADDITIONAL TESTS:

6.0

It is essential to furnish all the type test reports for each type and size of cable as stipulated in latest version of IS: 1554 (Part-I) and following Additional Tests: Loss of mass test Heat shock test Thermal stability test Accelerated water absorption test Dielectric strength retention test Above tests shall be conducted in NABL approved Testing laboratories only. 7.3 ACCEPTANCE TEST

Acceptance test shall be caried out on each type and size of cables on cable drums selected at random as per following plan :. Numbers of Drums in the Number of Drums to be taken S.No Tests as samples

1 2 3 4 5

Upto 50 51 to 100 From 101 to 300 From 301 to 500 From above 501

2 5 13 20 32

7.4

The following shall constitute acceptance tests :Annealing Test Conductor Resistance Test Wraping Test Tensile Test Test for Thickness of Insulation and Sheath Tensile Strength and elongation test before ageing and after ageing at break of insulation 184

and sheath High Voltage Test (Water Immersion Test) High Voltage Test at Room Temperature 7.5 ROUTINE TESTS:

Routine test shall be carried out for each drum of cables of all types and sizes. Following shall constitute routine tests : Conductor Resistance Test Resistance Test High Voltage Test at Room Temperature

7.6 i. ii. iii. iv.

While preparing cable schedules for control/protection purpose following shall be ensured: Separate cables shall be used for AC & DC. For different cores of CT & PT/CVT separate cable shall be used At least one (1) cores shall be kept as spare in each copper control cable of 4C, 5C or 7C size whereas minimum no. of spare cores shall be two (2) for control cables of 10 core or higher size. For control cabling, including CT/PT circuits, 4.0 sq.mm. size copper cables shall be used per connection

185

3.29
1.0

SPECIFICATION FOR 1.1 kV GRADE SINGLE CORE UNARMOURED L.T. XLPE CABLE SCOPE:

1.1.

This specification covers design, engineering, manufacture, stage testing, inspection and testing before supply and delivery at site of 1.1 kV grade single core 16/25/50/95/120/185/240/300 Sq. mm. XLPE Cables for use with effectively earthed distribution system. It is not the intent to specify completely herein all the details of the design and construction of material. However the material shall confirm 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. Normally the offer should be as per Technical Specification without any deviation. But any deviation felt necessary to improve performance, efficiency and utility of equipment must be mentioned in the Deviation Schedule with reasons duly supported by documentary evidences and advantages of such deviation. Such deviation suggested may or may not be accepted. But deviation not mentioned in Deviation Schedule will not be considered afterwards. Location The cables may be laid buried directly in ground at a depth of one metre in average, anywhere in Assam and terminate for outdoor connection to a distribution transformer or to overhead LT lines and also indoor connection for indoor switchgear

1.2.

1.3.

2.0
2.1

STANDARDS: The materials shall conform in all respects to the relevant Indian Standard amendments thereto. Specifications with latest

Indian Standard No.

Title Specification for Cross Linked Polyethylene Insulated PVC Sheathed Cables for working Voltages Up to and including 1100V PVC insulation and sheath of electric cables Conductors for insulated electric cables and Flexible cords Specification for armouring Specification for cable drum

Internationally Recognized standard IEC 502 (1983) IEC 502 (1983) IEC 228 (1978)

IS-7098 Part-I/1988 IS-5831/1984 IS-8130/1984 IS 3975/1979 IS-10418/1982

3.0.

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. . 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. Moderately hot and humid tropical climate, conducive to rust and fungus growth. SYSTEM DETAILS : 186

The material shall conform to the following parameters: Sl. No. 1. 2. 3. 4. 5. 4.0 4.1 Specification Item Outdoor Type of Installation System Voltage System Frequency No. of Phases System of earthing 433 V (+10% -15%) 50 Hz +/- 5% Three Solidly grounded

4.2 4.2.0

S l N o

Cabl e Size (Sq. mm)

1 2

25 120 240

TECHNICAL REQUIREMENTS: MAIN FEATURES: The power cables shall be of LT 1.1 kV Grade, stranded compacted, high conductivity, aluminum conductor, XLPE insulated, ST-1 type extruded PVC outer sheathed, conforming to relevant standards suitable for LT AC three phase, 50 c/s, effectively earthed distribution system. MATERIALS AND CONSTRUCTION: SPECIFIC TECHNICAL REQUIREMENTS Technical parameters of the cable shall be as follows Min. Max Max. current . A.C Min. D.C Shor carrying Min. Resi Min. thickn Min Resist t Ckt capacity at Al. thickn stan weig ess of Overa ance curre 0 30 C Stra ess of ce at ht. Outer ll dia at nt/sec 0 (Amps) nd XLPE 70 C Kg/ 0 sheath (mm) 20 C (KA/ (mm) (Oh Km Gr (mm) (Ohm/ 1sec) A m/K ou Km) ir m) nd 7 0.9 1.8 11.0 1.200 1.54 96 9 2.4 169 0 8 19 1.2 1.8 19.0 0.253 0.32 22 2 11.3 538 5 5 68 Bc, xnc mn vn CONDUCTOR: The cable conductor shall be made from stranded aluminum to form compacted shaped conductor having resistance within the limits specified in IS-8130/1984 INSULATION: The XLPE insulation shall be suitable for the specified system voltage. The manufacturing process shall ensure that the insulation is free from voids. The insulation shall withstand mechanical and thermal stresses under steady state as well as transient operating conditions. The extrusion method shall give smooth surface of insulation. The insulation shall be so applied that it fits closely on the conductor and it shall be easily possible to remove it without damaging the conductor. OUTER SHEATH: Extruded PVC outer sheath of black colour shall he applied with suitable additives to prevent attack by rodents and termites. Outer sheathing shall be designed to offer high degree of mechanical protection and shall also be heat, oil, chemical, abrasion and weather resistant. Common acids, alkalies, saline solutions etc., shall not have adverse effects on the PVC sheathing material used. CONSTRUCTION: 1) All materials used in the manufacture of cable shall be new, unused and of finest quality. All materials shall comply with the applicable provisions of the tests of the relevant Standards. 2) The PVC material used in the manufacture of cable shall be of reputed make.No recycling of the PVC is permissible. The purchaser reserves the right to ask for documentary proof of the purchase

4.2.1

4.2.2

4.2.3

4.2.4

187

4)

of various materials to be used for the manufacture of cable and to check that the conductor is complying with quality control. Cables shall have suitable fillers laid up with the conductors to provide a substantially circular cores section before the sheath is applied. Fillers shall be suitable for the operating temperature of the insulation & compatible with the insulation material

4.2.5

4.2.6

4.2.7

CURRENT RATING: The cables shall have current ratings and derating factors as per relevant Indian Standards. The current ratings shall be based on maximum conductor temperature of 90 deg. C with ambient site condition specified for continuous operating at the rated current. OPERATION: Cables shall be capable of satisfactory operation, under a power supply system frequency variation of +/- 5 c/s, voltage variation of +10% or-15%. Cables shall have heat and moisture resistance properties; these shall be of type and design with proven record on Distribution Network service. LENGTH: The cable shall be supplied in wooden drums and the standard drum length shall be as follows2 1x25 mm 1000 meters +/- 5% 2 1x120 mm 500 meters +/- 5% 1x240 Substandard drum length of not less than 100 meters upto a maximum of 5% of the quantities ordered shall be accepted. However substandard drum length upto a maximum of 5% shall be acceptable only in a particular lot offered for inspection IDENTIFICATION: For identification of individual cores, coloured strips of red, yellow and blue colours respectively shall be used on the cores to identify phase conductors as per relevant ISS. EMBOSSING: The cable shall be embossed through out the length with the name of the manufacturer and the letters "Property of APDCL., Specification No., voltage grade with cable size and the year of manufacture". The embossing shall be done only on the outer sheath, the distance between any two consecutive embossings shall not be more than 2 Meter. The cable shall also be embossed (clearly visible) for the verification of its length at intervals of 1 Meter say 1,2,3 up to full length. GUARANTEED TECHNICAL PARTICULARS: The guaranteed technical particulars as detailed in the specification annexure-I shall be guaranteed and a statement of guaranteed technical particulars shall be furnished in the format along with the bid without which the Bid shall be treated as Non -Responsive. Immediately after completion of the electrical tests (during routine/acceptance tests), the ends of the cable shall be enclosed by rubber/PVC caps of wall thickness not less than 2.5 mm and then sealed by non hygroscopic material (the cores being suitably insulated from the cap). The cap shall be of robust construction and tight fit, and it shall have the trademark of the manufacturer embossed thereon TESTS: Type Test: The material offered shall be fully type tested at independent test laboratories by the Bidder as per the relevant standards but test reports shall not be more than five years old from the date of opening of bid. The bidder shall furnish complete set of following type test reports along with the bid. The bids received without these type test reports shall be treated as Non-responsive. 1. Tests on conductors 2. Test for thickness of insulation and sheath 3. Physical tests for insulation 4. Physical tests for outer sheath 5. Insulation resistance test 6. High voltage test Acceptance and Routine test: All acceptance and routine tests as stipulated in the relevant standards shall be carried out by the supplier in presence of purchaser's representative.

4.2.8

4.2.7

4.2.8

5.0. 5.1

5.2.

6.0

INSPECTION: 6.1 The inspection shall be carried out by the purchasers representative during manufacture and before dispatch. The supplier shall keep the purchaser informed in advance, about the manufacturing programme so that arrangement can be made for inspection.

188

The manufacturer shall grant free access to the purchasers representative, at a reasonable time, when the work is in progress. Inspection and acceptance of any equipment under this specification by the purchaser, shall not relieve the supplier of his obligation of furnishing the equipment in accordance with the specification and shall not prevent subsequent rejection if the equipment is found to be defective. 6.2 All Acceptance tests and inspection shall be made at the place of manufacturer unless otherwise especially agreed upon by the Bidder and purchaser at the time of purchase. 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 (incase of foreign supply) advance intimation to enable the purchaser to depute his representative for witnessing the acceptance and routine tests. Material shall be dispatched only after getting the dispatch authorization from Inspectors representing purchaser, after successful testing. 6.3 If successful type tests have been carried out on the offered design during last five years (counted from the date of tender opening), repetition of type tests is not required. On the other hand, if the offered design is not type tested during last five years, the cable shall be subjected to all type test in accordance with IS: 1554 (Part-I)/1988 and amendment thereof at recognized test house of repute. All charges/fee/transportation etc. to conduct these tests shall be borne by Contractor. Regular supply of the material shall commence only after successful type testing and dispatch authorization from the competent authority. However, the purchaser reserves the right to get cable type tested at any stage during the currency of contract at his own expenses in any reputed test house. The transportation and arrangement of testing of sample to test laboratory shall be the responsibility of the contractor. 6.4 Routine tests report shall be sent by the manufacturers with their offer for inspection, the following acceptance tests as laid down in the referred ISS (with latest amendments) shall be carried out by the inspecting officer of the APDCL on Samples selected at random as per Appendix `A in IS-1554 (Part-I) 1988. 1. Tests on conductor a) Tensile test b) Conductor resistance test 2. Test on armoring strips: a) Measurement of dimension b) Tensile test c) Elongation test & winding test d) Zinc coating 3. Test for thickness of insulation and sheath 4. Tensile strength and elongation at break of insulation and sheath 5. Insulation Resistance Test 6. High voltage test at room temperature Reference to I.S.S. IS: 8130-1984 IS: 8130-1984 IS: 3975 1979 IS: 3975 1979 IS: 3975 1979 IS: 2633 1984 IS: 5831 1984 IS:5831 1984 IS: 5831 1984 IS: 1554 (Part-I) 1988

7.0

In addition to above, length/weight check and bending test on one drum per inspection shall also be carried out by the inspecting officers for which contractor will make all necessary arrangements and provide all necessary facilities at his own cost. CALBE DRUMS: The cables shall be supplied in non-returnable substantially lagged wooden drums of heavy construction suitable for transportation by goods train or truck and for storage at site. The wood used for construction of the drum shall be properly seasoned and sound and wood preservative shall be applied to the entire drum. All ferrous parts shall be treated with a suitable rust preventive finish or coating to avoid rusting during transit or storage. The drum shall also conform to specn. No. IS: 10418-1982 with latest amendment thereof. Each drum shall have the following information marked on it with indelible ink alongwith other important information including technical data: 1. 2. 3. 4. 5. 6. 7. Property of APDCL & Specification No. Designation of consignee & destination railway station. Drum Number. Aluminium Core Cable. Cable rating eg. Voltage grade, No. of cores, sizes etc. Height of empty drum. Length of Cable. 189

8. 9.

Gross weight of drum with cable. Year of manufacture.

8.0

PACKING AND TRANSPORT: All the material covered under this specification shall be adequately packed for transportation by Rail/Road. A layer of waterproof paper shall be applied to the surface of the drums and over the outer cable layer. A clear space of atleast 40 mm shall be left between the cable and the laggings. The packing shall be adequate to protect the cable from damage, in transit and contractor shall be responsible for it and make good at his own expense any and all damages due to improper packing etc. VARIATION OF QUANTITY: The supplied quantity can vary within Plus/Minus 1% of the ordered quantity.

9.0

190

3.30

TECHNICAL SPECIFICATION FOR STAY SET (HT )

1.0 Scope: 1.1. This specification covers the design, manufacture testing at manufacturer's works, transport to site, insurance, storage, erection and commissioning of the Stay Sets (HT) required from the distribution lines at designated locations. 2.0 Standard: 2.1. All the materials of stay sets shall comply in all respects with the requirements of the latest edition of the relevant Indian or British Standard specification except in so far as they are modified this specification. 3.0 Design Consideration: 3.1. Stay Rods shall be Galvanised and shall be of circular Cross-section with bow, thimble, nuts and bolts. The Rods shall be threaded at one end up to a minimum of 30 cm length and shall be complete with Galvanised M.S. Anchor Plates with all necessary accessories. All parts shall be heavily galvanised. 4.0 Testing: 4.1. Type and Routine Tests should be carried on different components of each stay sets as per relevant Indian Standard specification and certified copies of the above should be submitted along with the tender. 5.0 Schedule Requirement: Stay sets complete with Thimble bow stay Rod/Anchor plate with nuts etc. and made of Rolled mild Steel Rod and plates as per detailed given below: 5.1. Anchor Plate: I) Thickness not below 5 mm. II) Size not below 300 mmX300 mm with smooth edges (for HT) III) Well galvanised IV) Materials M.S. Rolled plate V) About 20 mm square hole at centre for locking the plate with the Anchor Rod (for HT) 5.2. Anchor Rod: VI) Length 1800 mm or above VII) Threaded length 30 cm or above VIII) Diameter 18 mm or above (for HT) IX) Anchor plate and head: square size 30mm X 30mm with thickness 25 mm having matching square size shank for locking the Anchor plate. X) One ratched lock nuts, grooves must match the grooves at bow flange XI) One check nut. XII) Materials H.S. XIII) Component well galvanised with extra care for the threaded portion. XIV) Both lock and check nuts should be matching to the Anchor Rod thread such that punching of thread after assembly at site safeguards them against removal. 5.3. Thimble: The match bow diameter and bend should be well galvanised. 5.4. Bow: Rod diameter 12mm/16mm or above overall length 35cm/40cm or above. Flange with well formed locking grooves matching the locking nut, bow ends will be riveted securely with the flange. All items to be galvanised. 6.0 Inspection: 6.1. All tests and inspections shall be carried out at the place of manufacturer unless otherwise agreed by the purchaser and the manufacturers at the time of purchase. A manufacturer shall afford the inspector representing the purchaser or third party nominee, all reasonable facilities, without charge to satisfy that the materials are being purchased as per specification. The purchaser reserves the right to have the test carried out at his cost by an independent agency, whenever there is dispute regarding the quality of the materials supplied. 7.0 Marking 7.1. The equipments shall be marked with name of manufacturer, year and name of project.

191

3.31
1.0 Scope

TECHNICAL SPECIFICATION FOR G.I. STAY WIRE

The specification covers design, manufacturing and testing, transporting to site, insurance, storage, erection and commissioning of G.I. Stay Wire 7/10SWG and 7/14SWG. 2.0 Materials. The wire shall be manufactured from steel, made by any suitable process and shall not contain sulphur and phosphorus exceeding 0.065 percent each. The wires shall be coated with Zinc Grade Zn 98 of IS:209-1966 The general requirements for the supply of Galvanized stay strand shall be in accordance with IS:13871967 Construction Grades: The wire shall be of Grade-I and tensile strength range 45 up to and including Kg/mm The Galvanized stay strand shall be of 7/2 mm and 7/3.15 mm. the lay of the strands shall be of the length of 7/2 mm and Tables-I of IS: 2141-1963. the wires shall be so stranded together that when and evenly distributed pull is applied at the end of the completed strand each wire will take equal share of the pull. The length of the strand which may be supplied without joints in the individual wires comprising it, depend on the length of wire which may be carried by the bobbin in a normal stranding machine. The normal lengths of strand which shall be supplied without joints in the individual wires, excluding welds made in the rod before drawing shall be as given below. The lengths may be exceeded by agreement between the manufacturer and the purchaser. Diameter of wire in strand Normal length without joints of weld 3.15 mm 1000 M 2.0 mm 3000 M In cases where joints are permitted, they shall be made by welding of brazing joints in the same wire shall be separated by a length of not less than that shown in 3.3 and joints in different wires in a strand shall not be less than 20 M apart. Freedom from Defects :

3.0 3.1 3.2

3.3

3.4

4.0
4.1

Each coil shall be warranted to contain no weld joint or splice other than in the rod before it is drawn and those permitted in 3.4. The wire shall be circular and shall be free scale, irregularities imperfections flaws splits and other defects. The Zinc coating shall be smooth, even the bright. 5.0 Tests: 5.1 Chemical Analysis: Unless otherwise agreed to between the purchaser and the supplier, the chemical analysis be carried out. 5.2 Tensile Test: The wire when tested in accordance with IS: 1521-1960, on gauge length of 100 mm shall have the minimum tensile strength specified in Tables 1 of IS : 2141/1968 according to the grade of the wire. 5.2.1 The tensile strength of the finalised strand shall be not less tI~an 93 percent of the aggregate of the single wires. 5.3 Delivery test: The wire shall be subjected to the wrapping test in accordance with IS : 1755/1961. When wrapped eight times round its own diameter and on being subsequently strengthened the wire shall not break or split. 5.3.1 Coating test: The uniformity of Zinc coating shall be tested by the method specified in IS : 2633/1964. The wire shall withstand the number or dips as specified in IS : 4826-1968. 6.0 Marking: 6.1 Each coil shall be provided with a label, fixed firmly on the inneJ part of the coil, bearing 'the following information. a.Manufacturer's name or trade mark b.Lot number and coil number c.A brief description and quality of the materials. d.Weight and e.Any other particulars specified by the purchaser f.Name of the project TDF.

6.2 7.0

The label may also be marked with the ISI certification mark. Inspection: The test should be carried out in presence of the inspecting officer deputed by purchaser or third party nominee and the test should be in conformity with relevant IS .

192

3.32
1.0

TECHNICAL SPECIFICATION OF HT GUY INSULATOR

Scope This specification covers design, manufacture, testing, transport to site, insurance, storage, erection and commissioning of the strain type porcelain Guy Insulator used in distribution overhead power lines.

5.0

Standard This insulators shall comply with Indian Standard specification IS: 5500/1969 and as amended from time to time except where they conflict with the requirements in this specification. Offers conforming to any other internationally accepted standard which ensure equal or higher quality than the standard mentioned will be acceptable.

6.0

General Requirements This porcelain shall be sound, free from defects, thoroughly vitrified and smooth glazed. The design of the insulator shall be such that stresses to expansion and contraction at any part of the insulator shall not load to its deterioration. The glaze, unless otherwise specified, shall be brown in colour. The glaze shall cover the entire porcelain surface parts except those areas that serves as supports during firing or area otherwise required to be left unglazed.

7.0

Insulator Characteristics The Guy Strain Insulators shall have the electrical and mechanical characteristics as shown below: H.T. Strain Type Porcelain Guy Insulator 1) Length 140 mm 2) Diameter 85 mm 3) Cable hole dia 25 mm + 1.5 4) Minimum failing load 88 KN 5) Creepage distance 48 mm 6) Dry one minute power frequency withstand 27 KV (rms) voltage 7) Wet one minute power frequency withstand 13 KV (rms) voltage

8.0

Test All insulators shall comply the following test as per IS : 5300 A) Routine test: The following shall be carried out as., routine test. a) Visual Examination

Every insulators shall be visually examined. The insulators shall be free from physical distortion of shape and defects, and thoroughly verified and smoothly glazed. They should be free from cracks or any other defects likely to be prejudicial to the satisfactory performance in service. b) Type test:

193

The following shall constitute the type test and those shall be conducted in the order given below: i. Visual examination ii. Verification of dimensions iii. Temperature cycle test iv. Dry one minute power frequency voltage withstand test v. Wet one minute power frequency voltage withstand test vi. Mechanical strength test vii. Porosity test. The number of samples for type test are to be agreed to between the purchaser and the supplier. c) Acceptance Test (to be conducted in the following order) i. ii. iii. iv. Verification of Dimensions Temperature cycle test Mechanical strength test Porosity test

The number of samples for acceptance test shall be in accordance to IS: 5300.

d) Type test certificate from National Test House/ Govt. recognized institutions/ Govt. recognized public Testing Laboratories are also to be submitted along with the offer, failing which the offer is liable for rejection.

9.0

Marking

Each insulator shall be legibly and indelibly marked to shown the following: a.Name of trade mark of the manufacturer b.Year of manufacture and name of project TDF 2010-11 Marking on porcelain shall be printed and shall be applied before firing. Insulators may also be marked with the ISI certification mark.

10.0

Inspection All tests and inspections shall be carried out at the place of manufacturer unless otherwise agreed by the purchaser and the manufacturer at the time of purchase. The manufacturer shall afford the inspector representing the purchaser or the third party nominee, all reasonable facilities, without charge, to satisfy that materials are being furnished in accordance with the specification. The purchaser reserves the right to have the test carried out at his own cost by an independent agency whenever there is dispute regarding the quality of materials supplied.

11.0

Drawing Drawing specifically showing all dimensions is to be submitted along with technical bid.

194

Bid document/ABY-Bijni S-S_________________________________________________________________________________

3.33
1.0

TECHNICAL SPECIFICATION FOR G.I. WIRE Scope

2.0

This specification covers the manufacturing, testing at works, transport to site, insurance, storage, erection and commissioning of Galvanised Iron Wire of sizes 4 mm and 5 mm diameter. General requirements It relating to the supply of mild steel wire shall be as per IS: 1387/1967 and the wire shall be drawn from the wire rods conforming to IS: 7887/1975. The requirements for chemical composition for the wires shall conform to IS:7887/1975. Mild steel wire for General Engineering purpose shall be of following sizes: I) 4mm - diameter (8 SWG) II) 5mm - diameter (6 SWG) Tolerance permitted on the diameter of wire shall be as per Table -1 of IS:280/1978. Climatic Conditions The cross arms should be suitable for the climatic condition mentioned In these bidding documents: Mechanical Properties Tensile Test: Tensile strength of wire when tested in accordance with IS: 1521-1972, shall be within the limits given in Table-2 of IS: 280/1978. Wrapping Test: Wires shall be subjected wrapping test in accordance with IS: 1755-1961. The wire shall withstand without breaking or splitting. being wrapped eight times round its own diameter and subsequently straightened. Surface finish a. The wire shall have galvanized finishes. The galvanized coating of steel wire shall conform to the requirements for anyone of the types of coatings given in IS: 4826-1968 as per agreement with the purchaser. The coating test for finishes other than galvanized, copper coated or tinned shall be subject to between the purchaser and the manufacturer. Unless otherwise agreed to the method of drawing representative samples of the material and the criteria for conforming shall be as prescribed in Appendix (A) of IS: 280/1978. All finished wires shall be well and cleanly drawn to the dimensions specified. The wire shall be sound, free from splits, surface flaws, rough jagged and imperfect edges and other harmful surface defects. Each coil of wire shall be suitably bound and fastened compactly and shall be protected by suitably wrapped.

3.0 4.0 4.1 4.2

5.0

b. c. d.

e.

6.0

Marking Each coil of wire shall be marked legibly with the finish size of wire, lot number and trade mark of the name of the manufacturer. The material may also be marked with the ISI certification mark and name of the project TDF. INSPECTION Inspection may be carried out by the purchaser or third party nominee at any stage of manufacture. The supplier shall grant free access to the purchaser's representative or third party nominee at a reasonable time when the work is in progress. Inspection and acceptance of any equipment under this specification by the purchaser shall not relieve the supplier of his obligation of furnishing equipment in accordance with the specification and shall not prevent subsequent rejection if the equipment is found defective.

7.0

195

Bid document/ABY-Bijni S-S_________________________________________________________________________________

INDEX Sl.No. 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 6.10 6.11 6.12 6.13 6.14 6.15 6.16 6.17 6.18 6.19 6.20 6.21 6.22 6.23 6.24 6.25 6.26 6.27 6.28 6.29 6.30 6.31 6.32 6.33 6.34 Technical Specification for Special Technical Specifications For Construction of New 33/11 kV Sub-station Special Technical Specifications for New Sub-station Civil Works & Switchgear PSC Pole 9.75 M GI channel cross arm 33kV & 11kV Disc Insulator 70kN Hardware fittings for 11kV &33kV 33kV Disc Insulator 70kN Tension clamp for AAA Wolf & Raccoon conductor PG clamp for Wolf & Raccoon conductor AAA Wolf & Raccoon conductor 33kV Pin Insulator GI Pin for 33kV Pin insulator 33kV VCB 33kV Relay & Control panel for Transformer & Feeder 33kV &11kV LA 33kV & 11kV Isolator 33kV CT & 33kV/110V PT 100AH Battery Bank & Charger ACDB DCDB 11kV 7 Unit VCB for feeder 11kV Cu. Control Cable Cable Kit for XLPE cable 11kV GOAB Switch 11/0.4kV, 100kVA Tr. 11kV DO Fuse 11kV XPLE CABLE 1.1 KV GRADE SINGLE CORE UNARMOURED L.T. XLPE CABLE 11kV & 33kV Composite Insulator HT Stay Set GI stay wire 7/10 SWG HT Guy Insulator C.I. Earth Pipe, 1.8M length GI wire for earthing Danger Plate Page No.

CLIMATIC AND ISOCERAUNIC CONDITIONS The climatic and isoceraunic conditions at site under which the materials /equipment shall operate satisfactorily are as follows:a) Maximum temperature of air in shade: 40 C b) Minimum temperature of air in shade: 2 C c) Maximum Humidity: 93 % d) Isoceraunic level: 60 e) Average of rainy days per annum: 150 f) Average number of days of thunderstorm per annum: 25 g) Average number of days of dust storm per annum: 10 h) Average annual rainfall: 2280 mm i) Number of months of tropical monsoon per annum: 5 (May to Sept.) j) Maximum wind pressure: 150Kg/sq. m. k) Altitude (above mean sea level): 50 to 250m a. The reference ambient temperatures assumed for the purpose of this specification are: a) Maximum ambient temperature: 45C b) Maximum average daily ambient temperature: 35C c) Maximum average yearly ambient temperature: 30 C

196

Bid document/ABY-Bijni S-S_________________________________________________________________________________

SECTION -7

GUARANTEED TECHNICAL PARTICULARS

197

Bid document/ABY-Bijni S-S_________________________________________________________________________________

GUARANTEED TECHNICAL PARTICULARS FOR PSC POLES [9.75M ] (To be filled in by the bidder) SL NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 ITEM Name and address of manufacturer Type of Pole Applicable Standard Length of pole Depth of Plantation Bottom Depth Top Depth Breath Diameter of pre-stressing wire No. of tensioned wire per pole Minimum Ultimate Tensile strength of 4 MM HT wire Minimum initial pull of 4 mm wire Spacing HT wires Quantity of HT wire/ pole Min Quantity of cement Quantity of Stone chips Quantity of sand Link & spiral M.S spiral Maximum Aggregate size Total weight per pole Minimum clear cover Factor of safety Concrete grade Ultimate Load Earthing shall be provided by 4 MM dia. Galvanized iron wire embedded in concrete one marks to be provided at ground level 28 days cube strength of concrete ( Min) as per IS : 456/2000. PARAMETERS

9.75 M PSC pole

198

Bid document/ABY-Bijni S-S_________________________________________________________________________________

GUARANTEED TECHNICAL PARTICULARS FOR VACUUM CIRCUIT BREAKER (To be filled in by the bidder) 1. 2. 3. 4. 5. 6. 7. Name of the Manufacturer Country of Origin Manufactures type and Designation Number of poles Rated Voltage (KV) Standards Applicable Normal Current Rating a)IEC conditions b)Site conditions Frequency in cycles per second Making capacity in peak kilo-amperes Breaking capacity a) 11. 12. Symmetrical in KA

8. 9. 10.

13.

14. 15.

16. 17. 18. 19. 20. 21. 22.

23. 24.

b) A-Symmetrical in KA Three second short time current rating Total Break time in milli second a) At 10% rated interrupting capacity b) At 30% rated interrupting capacity c) At 60% rated interrupting capacity d) At 100% rated interrupting capacity Maximum temperature rise above ambient a) Live parts (Degree C) b) Enclosure (Degree C) Whether suitable for three phase auto reclosing Breaker a) Opening time in milli seconds with no current b) Opening time in Milli-seconds at rated breaking current c) Arcing time in milli-seconds d) Time in milli-seconds from Arc Extinction to contact fully open e) Dead time in mill-seconds for three phase reclosing f) Time in milli-second j) From circuit energized to contacts make ii) From contacts make to contacts fully closed 1.2/50 microsecond lightening impulsive with stand voltage to earth (in KV peak) One minute power frequency dry. Withstand voltage to earth (in KV rms) One minute power frequency wet withstand voltage to earth (in KV rms) First pole to clear factor Out of phase switching capability of the breaker Rated out of phase breaking current Switchgear component load requirement a) Circuit breaker i) Spring charging motor ii) Close coils iii) Open coils iv) Heaters b) Control cubicle i) Relays ii) Heaters iii) Indications c) Other requirements Maximum line charging current that the breaker can interrupt (in Amperes) Maximum over voltage developed while breaking line charging 199

Bid document/ABY-Bijni S-S_________________________________________________________________________________

25. 26.

27. 28. 29. 30.

31.

32. 33. 34. 35. 36.

37. 38.

39. 40. 41. 42. 43.

44.

45.

46. 47.

48. 49. 50. 51. 52. 53.

current a) Supply slide (KV) b) Line side (KV) Maximum shunt capacitor bank switching capacity of breaker (single bank MVA) Maximum cable charging current breaking capacity (in Amps) and corresponding over voltage (in KV) a) Supply side b) Line side Short line fault current breaking capacity (KV) Maximum over voltage developed while breaking magnetizing current of transformer (KV) Rated operating duty cycle Minimum clearance in air a) Between poles (mm) b) Between live part (mm) to earth c) Between live part to ground level (mm) Creepage distance a) To ground (mm) b) Between terminals (mm) Protected creepage distance (mm) Number for breaks in series per pole Type of main contacts Type of arcing contacts a) contact silver plated or not b) Thickness of silver plating c) Contact pressure d) Electric contract resistance at 20 degree C (ohm) Type of device, if any used to limit rate of rise of restricting voltage Number and type of spare auxiliary switches provided a) Those closed when breaker is closed b) Those open when breaker is closed Rated voltage of auxiliary contacts Material of auxiliary contact Current carrying capacity of auxiliary contacts Type and make of vacuum interrupter Dynamic load to be transferred to foundation a) Co-Operation (Compressive) b) Co-operation (Tensile) Guaranteed number of operations a) With no load current b) With full fault current c)Those adjustable with respect to position of main contact Over all dimensions i) Height (mm) ii) Width (mm) iii) Length (mm) Weight of complete circuit breaker for foundation design Seismic level for which the breaker is designed a) Horizontal acceleration b) Vertical acceleration Height of supporting structure Material of supporting structure Noise level of circuit breaker at 5 meters distance Whether the circuit breaker is fixed trip or trip-free Short circuit type test report Porcelain bushings i) Type ii) Dry flashover voltage iii) Wet flashover voltage iv) Dry 60-S withstand test voltage v) Wet 80-S withstand test voltage 200

Bid document/ABY-Bijni S-S_________________________________________________________________________________

vi) vii) viii) ix) x) xi) xii) xiii) xiv) a) b) xv)

Under-oil flashover or puncture withstand test voltage (power frequency) Full wave impulse withstand test voltage Creepage distance in air (total) mm Protected creepage distance (mm) Whether the bushing is suitable for outdoor installation and extreme humid conditions Weight of the assembled bushing (Kg) Whether terminal connection for all bushing included in scope of supply Test (routine/type) to be conducted on the bushing Bushing, clearance in (mm) Between phases Between phase to ground Performance guarantee

201

Bid document/ABY-Bijni S-S_________________________________________________________________________________

GUARANTEED TECHNICAL PARTICULARS 33 kV CONTROL AND RELAY PANELS FOR FEEDER (To be filled in by the bidder) Technical Particulars A. METERS a i) Type of instrument aii] Name of manufacturer b) Size c) Whether magnetically shielded or not d) Limits of error in the effective range e) Scale length f) Short time overload capacity g) VA burden i) Current coil ii) Potential coil h) BSS grade accuracy i) Description leaflet reference Nos. submitted STATIC ENERGY METERS a) Rating of current coil & potential coil b) Continuous withstand capacity of the above coils c) Limits of error at unity pf and i) 125/25% rated current ii) 10% rated current iii) 5% rated current d) Limits of error at 0.5 pf (lag) and i) 125/25% rated current ii) 10% rated current e) Power losses per element i) Current coil ii) Potential coil f) Minimum running current (percent of marked current) g) Variation of voltage to cause a change of not more than 1% at any load from full to 1/10 h) Variation of air temperatures maximum temperature co-efficient of error in percent per Deg.C at i) Unity pf ii) 0.5 pf (lag) i) Variation dur of heating by main current in percent at i) Unity pf ii) 0.5 pf (lag) j) Variation of frequency percent error due to 5% variation in frequency i) At unity pf ii) At 0.5 pf (lag) k) Overload capacity i) Continuous ii) second l) Excess voltage permissible fr 30 minutes m) Type of register mechanism with register constant n] Type of instrument o] Name of manufacturer PROTECTIVE RELAYS . Non-directional over current relays a i) Type of instrument aii] Name of manufacturer 202 M.W. Meters Volt Meters Ammeters

B.

C. C1

Bid document/ABY-Bijni S-S_________________________________________________________________________________

b) c) d) i) ii) c)

C2 D.

Current coil range Tap range Power consumption Highest tap Lowest tap Time of operation at maximum time dial setting at i) 5 times tap setting current ii) 10 times tap setting current f) Type of characteristic g) Whether draw out type or not h) Trip contact rating Amps i) Whether seal in contact provided or not 2. Non-directional earth fault relays a) Type b) Current coil range c) Tap range d) VA burden i) Highest tap ii) Lowest tap e) Power consumption i) Highest tap ii) Lowest tap f) time of operation at maximum time dial setting at i) 5 times tap setting current ii) 10 times tap setting current g) Whether draw out type or not h) Trip contact rating Amps i) Whether seal in contact provided or not Differential Relay ANNUNCIATIONS a) Type of annunciation system offered b) Make of the system c] Any deviation from specification to be stated. c) Sequence and scheme of operation of the annunciation system (Drawings shall be enclosed) together with details of components involved. TECHNICAL PARTICULARS OF THE SYSTEM a) Response time b) Burden for pre-warm up facility per window c) No. of lamps per window d) Burden per window i) With flashing ii) With steady light iii) During off condition f) Whether annunciation system is suitable for 110 V DC supply GENERAL a) Panel sheet thickness b) Over all dimensions i) Width ii) Depth iii) Height c) Total weight of panel d) Internal finish e) External finish

Details as above to be provided along with manufacturers leaflets

E.

F.

203

Bid document/ABY-Bijni S-S_________________________________________________________________________________

GUARANTEED TECHNICAL PARTICULARS OF 33KV ISOLATOR (To be filled in by the bidder) 1.1 1.2 1.3 1.4 1.5 1.6 1.7 Suppliers name & address Manufacturer's name & address Guaranteed delivery schedule System Voltage Maximum permissible service voltage Continuous current rating Short time current rating i) for 1 sec ii) for 3 sec 1.8 1.9 1.10 Rated peak short circuit current Rated peak short circuit current of earthing blade Temperature with corresponding to i) Maximum current rating at 60 deg. C ambient temperature ii) Short time current rating 1.11 1.12 1.13 Fault current which can be made by earth switch Maximum current that can be safely interrupted between equi-potential busbars Clearance in air (minimum) in mm i) between phases ii) between live parts and earth iii) distance between centres of outer stacks of insulators Power frequency withstand voltage test for complete assembled switches i) Against ground a) Dry, KV b) Wet, KV ii) Across open contacts a) Dry, KV b) Wet, KV iii) Between phases a) Dry, KV b) Wet, KV 1.15 Particulars of main contacts in fixed (main and earthing switch) and moving contacts (main and earthing switch) i) Type ii) Material iii) Surface treatment iv) contact area v) Contact pressure 1.16 1.17 1.18 Current density of minimum cross section of switch blade No. of operations without need for inspection Type and materials of connectors 204

1.14

Bid document/ABY-Bijni S-S_________________________________________________________________________________

1.19 1.20 1.21

Whether arcing contacts provided and if yes, give materials used Whether adjustable gap type arcing horns provided and if yes, give materials used Insulators i) Creepage distance of insulators in mm ii) Bending strength of insulators in KN

1.22 1.23

location and type of bearings Weight of complete isolators with insulator i) With earthing blade, Kg ii) Without earthing blade, Kg

1.24 1.25 1.26 1.27 1.28

Operating efforts required for manual operation, Kg Type of interlocking between isolating switch and earth switch Details of mounting (centre to centre) Guaranteed weight of mounting structure including nuts and bolts in Kg Auxiliary contacts i) Normally Open (NO) contacts ii) Normally Close(NC) contacts

1.29

Auxiliary DC Supply

205

Bid document/ABY-Bijni S-S_________________________________________________________________________________

Guaranteed technical particulars of 33kV Current Transformer (To be filled in by the bidder)

1.0 1.1 2.0 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13 2.14 2.15

2.16 2.17

2.18 2.19 2.20 2.21 2.22 2.23 2.24 2.25

2.26 2.27 2.28 2.29

General Manufacturers name and address Current Transformer Standard applicable Type Rated voltage kV Rated frequency Hz No of cores Rated primary current Rated secondary current Turns ratio Rated output VA Accuracy class Accuracy limit factor Instrument security factor Maximum Knee point voltage ,V Max. secondary resistance Ohm Exciting current, mA i) At knee point voltage ii) at 50% of knee voltage iii) at 50% of knee voltage( at highest ratio tab) Rated output at different tap, VA One minute power frequency withstand voltage, kV(rms) i) Primary winding ii) Secondary winding Standard impulse withstanding voltage of primary winding kV(peak) Creepage distance mm Rated thermal current A Rated short time current kA Rated time for above current(sec) Rated dynamic current kA(peak) Class of insulation Rated continuous current temp. rise over ambient degree Time period for which secondary winding can be left open when rated primary current is flowing in primary winding Quantity of oil litre Total weight Kg Whether PRV provided

206

Bid document/ABY-Bijni S-S_________________________________________________________________________________

Guaranteed technical particulars of 33kV Potential Transformer (To be filled in by the bidder)

Sl no. 1.0 1.1 1.2 1.3 1.4 1.5 1.6

Specification Manufacturers name and address Potential Transformer Standard applicable Type Rated voltage kV Rated frequency Hz One minute power frequency withstand voltage, kV(rms) i) Primary winding ii) Secondary winding Standard impulse withstanding voltage of primary winding kV(peak) Creepage distance mm Temperature at 1.2 times rated burden in degree C Quantity of oil litre Total weight Kg Hermetically scaling arrangements Transformation ratio Rated burden VA Accuracy class Maximum ratio error with rated burden and at 5% normal voltage

1.7 1.8 1.9 1.10 1.11 1.12 1.13 1.14 1.15 1.16 1.17

207

Bid document/ABY-Bijni S-S_________________________________________________________________________________

GUARANTEED TECHNICAL PARTICULARS OF ALL ALUMINUM ALLOY CONDUCTOR (AAAC) (To be filled in by the bidder) Sl.No. 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 9.1 a) 9.2 a) 9.3.0 9.3.1 a) b) c) 9.3.2 9.3.3 10.0 a) b) c) 11.0 11.1 11.2 a) b) 11.3 11.4 11.5 11.6 11.7 11.8 a) b) c) d) e) f) g) 11.9 a) b) c) 12.0 13.0 14.0 14.1 a) Description Makers name & Address Conductor size and Code IS Standard applicable Wire diameter in mm Diameter of complete conductor in mm Number of strands Sectional area of alloy Aluminum Total sectional area Particulars of Raw Materials Aluminum Minimum Purity of Aluminum Zinc Minimum Purity of Zinc Aluminum Strands after stranding Diameter Nominal Maximum Minimum Minimum breaking Load Strand Maximum Resistance of 1 M length Galvanizing Minimum weight of zinc coating per uncoated wire surface Minimum number of one minute dips galvanized strand can withstand in the test Minimum number of twists in a gauge length times dia of wire which the strand can withstand in the torsion test (after stranding) AAAC stranded conductor UTS of conductor Lay ratio of conductor st 1 layer nd 2 layer D.C resistance of conductor at 20C Standard length of conductor Continuous current rating at 75C (Enclose supporting calculations) Final modulus of elasticity Co-efficient of Linear Expansion Strand Standard diameter Minimum Maximum Cross-Sectional area of Nominal diameter wire Weight in Kg/KM Minimum breaking load Before Stranding After stranding Coefficient of linear expansion Joints in strands Aluminum Alloy Method of making joint Ultimate tensile Strength of Joint Maximum single length of conductor that can be manufactured if required for single stretch Tolerance of standard length of conductor Direction of lay for outside layer Linear mass of the conductor Standard Unit Particulars

mm mm Nos. mm mm

% %

Mm Mm Mm kN Ohm gm/m Nos. Nos.

kN Max

Ohm/Km M

mm

mmNos.

Kg/kN

Meter %

Kg/KM 208

Bid document/ABY-Bijni S-S_________________________________________________________________________________

b) c) 15.0 16.0 a) b) 17.0 18.0 19.0 20.0

Minimum Maximum No. of cold pressure butt welding available at works Standard according to which the conductor will be manufactured and tested Certification mark if any Test Certificate enclosed Initial & Final sag and tension charts furnished Stress/Strain data corresponding to different tensions temperatures furnished Curves/tables of creep compensation corresponding to different tension temperatures furnished PERFORMANCE GUARANTEE

Kg/KM Kg/KM

Yes/No

GUARANTEED TECHNICAL PARTICULARS OF H.T. GUY INSULATOR (To be filled in by the bidder) Sl.NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 PARAMETER Manufacturers Name & Address Type of insulator Standards to which insulator will conform Dimensions Hole diameter (mm) Color of glaze Dry Power Frequency withstand Voltage (kV) Wet Power Frequency withstand Voltage (kV) Minimum failing load (Newton) Minimum Creepage distance (mm) Weight per piece (Kg) Temperature cycle test (as per ISS) Porosity test (as per ISS) Tolerance, if any (as per ISS) Performance guarantee GUARANTEED VALUE

209

Bid document/ABY-Bijni S-S_________________________________________________________________________________

GUARANTEED TECHNICAL PARTICULARS FOR G.I. WIRE (To be filled in by the bidder) A. 1. 2. 3. 4. 5. 6. B. 1. 2. 3. 4. 5. 6. G.I.Wire (4 mm dia) Size of Wire Tolerance in size of wire Tensile strength Wrapping list Galvanising conforming to IS : 4826 1968 Guarantee G.I.Wire (5 mm dia) Size of Wire Tolerance in size of wire Tensile strength Wrapping list Galvanising conforming to IS : 4826 1968 Performance guarantee : : : : : : : : : : : : : :

GUARANTEED TECHNICAL PARTICULARS FOR C.I. PIPE (EARTH) (To be filled in by the bidder) Sl.No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. G.I.Wire (4 mm dia) Length of Pipe Diameter of Pipe External Dia of Pipe Thickness of Pipe Internal Dia of Socket Thickness of Socket Internal Depth of Socket Internal Radius of Socket Width of Grooves of Socket External Dia of Grooves Socket Weight of Pipe Hydraulic Test Guarantee : : : : : : : : : : : : :

210

Bid document/ABY-Bijni S-S_________________________________________________________________________________

GUARANTEED TECHNICAL PARTICULARS FOR TENSION HARDWARE FITTINGS (To be filled in by the bidder) A. TENSION HARDWARE FITTINGS Size of conductor for which the fitting is designed 1. 2. 3. a) b) 4. a) b) 5. 6. B. Electrical resistance of dead end assembly Slip strength of dead end assembly Total weight of assembly Single Tension Double Tension UTS of Tension string hardware Single Tension Double Tension Purity of zinc used for galvanizing Min. No. of dips in standard Preece test the ferrous parts can withstand MID SPAN COMPRESSION CONDUCTOR JOINT FOR kN kN % No. Kg Kg Ohms kN

Size of conductor for which the fitting is designed 1. 2. a) b) 3. a) b) 4. a) b) 5. a) b) 6. a) i) ii) b) 7. a) b) 8. Suitable for conductor size Material of Aluminum sleeve Aluminum Purity of Aluminum sleeve Outside diameter of sleeve before compression Aluminum Steel Inside diameter of sleeve before compression Aluminum Steel Length of sleeve before compression Aluminum Steel Dimensions of sleeve after compression Aluminum Corner to Corner Face to Face Steel Length of sleeve after compression Aluminum Steel Weight of sleeve 211 mm mm mm mm mm mm mm mm mm mm Mm

Bid document/ABY-Bijni S-S_________________________________________________________________________________

a) b) c) 9. 10.

Aluminum Steel Total Slipping strength Conductivity of the compressed unit expressed, as percentage of the conductivity of equivalent length of bare conductor REPAIR SLEEVE FOR CONDUCTOR Size of conductor for which the fitting is designed

Kg Kg Kg kN %

C.

1. 2. a) b) 3. 4. a) b) i) ii) 5. a) b) 6. D.

Suitable for conductor size Material of Sleeve Aluminum/Aluminum Alloy Purity of Aluminum Inside diameter of sleeve before compression Outside dimensions of sleeve Dia before compression After compression Corner to Corner Face to Face Length of sleeve Before compression After compression Weight of sleeve PARTICULARS OF FOR CONDUCTOR VIBRATION DAMPER

Mm

% mm

mm mm

mm mm Kg

Size of conductor for which the fitting is designed 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. S.NO. 11. 12. Suitable for conductor size Total weight of one damper Diameter of each damper mass Length of each damper mass Weight of each damper masses Material of damper masses Material of the stranded messenger cable Material for clamp Number of strands in stranded messenger cable Lay ratio of stranded messenger cable Description Minimum ultimate tensile strength of stranded messenger cable Slipping strength of stranded messenger cable (mass pull off) Unit Kg/mm kN Particulars mm Kg mm mm Kg Right Left

212

Bid document/ABY-Bijni S-S_________________________________________________________________________________

a) b) 14. 15. a) b) 16. 17. 18.

First frequency Second frequency Designed clamping torque Slipping strength of damper clamp Before fatigue test After fatigue test Magnetic power loss per vibration damper at a conductor Current of 350 Ampere, 50 hz ACPercentage Variation in reactance after fatigue test in comparison with that before fatigue Percentage Variation in power dissipation after fatigue test in comparison with that before fatigue SPAN OF COMPRESSION JOINT GALVANISED STEEL EARTHWIRE FOR

Hz Hz Kg-m

kN kN Watts % %

E.

Size of Earthwire for which the fitting is designed 1. a) b) 2. a) b) c) 3. a) b) c) 4. a) b) c) 5. a) b) 6. a) b) 7. a) b) c) Material of joint Type of Material with Chemical composition Hardnes of steel sleeve (Brinnel Hardness) Inside diameter of sleeve before compression Steel Sleeve Aluminum Sleeve Aluminum Filter Sleeve Outside diameter of sleeve Steel Sleeve Aluminum Sleeve Aluminum Filter Sleeve Outside dimensions of sleeve after compression Steel Sleeve Corner to Corner Surface to Surface Length of Steel Sleeve Before compression After compression Length of Aluminum Sleeve Before compression After compression Weight of Sleeve Steel Aluminum Filler Aluminum Sleeve mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm

213

Bid document/ABY-Bijni S-S_________________________________________________________________________________

8. 9.

Slipping Strength Conductivity of the compressed unit expressed as a percentage of the conductivity of equivalent length of bare earthwire VIBRATION DAMPER FOR GALVANISED STEEL EARTHWIRE (7/3.15mm) Size of Earthwire for which the fitting is designed %

F.

1. 2.

Suitable for earthwire size Total weight of one damper

mm Kh

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

Diameter of each damper mass Length of each damper mass Weight of each damper mass Material of damper mass Material of Clamp Material of Stranded massenger cable Number of Strands in stranded messenger cable Lay ratio stranded messenger cable Minimum ultimate tensile strength of stranded messenger cable Slipping strength of stranded messenger cable (mass pull off) Resonance frequencies First frequency Second frequency FLEXIBLE COPPER BOND Stranding Cross Sectional Area Minimum Copper equivalent area Length of Copper Cable Material of lugs Bolt Size Diameter Length Resistance Total Weight of Flexible Cu bond TENSION CLAMP FOR GALVANIZED STEEL EARTHWIRE Size of earthwire for which the fitting is

mm mm Kg Kg

Kg/Sq.mm kN

Hz Hz

Sq.mm Sq.mm mm

mm mm Ohm Kg

214

Bid document/ABY-Bijni S-S_________________________________________________________________________________

designed 1. i) ii) Material Shackle a) Compression clamp b) Hardness of the material (BHN) 2. 3. 4. a) b) 5. a) b) 6. 7. 8. 9. 10. Inside diameter compression of the of clamp sleeve before before BHN mm

Outside dimensions compression

Outside dimensions of sleeve Corner to Corner Surface to Surface Length of Clamp Before Compression After Compression Weight Slip strength (minimum) Compression Pressure Minimum Breaking (excluding clamp) Strength of assembly mm mm Kg kN T kN mm mm

Performance guarantee

215

Bid document/ABY-Bijni S-S_________________________________________________________________________________

GUARANTEED TECHNICAL PARTICULARS OF 33 kV PIN INSULATOR U (To be filled in by bidder) Sl. No. 1 2 3 4 Description Manufacturers Name & Address Type of insulator offered Drawing Numbers Over all Dimensions (mm) a)Height b)Out Diameter 5 6 7 8 9 10 11 12 Nominal System Voltage(kV) Highest System Voltage (kV) Minimum Failing Load (kN) Particulars

Dry Power Frequency Flashover Voltage (kV) Wet Power Frequency Flashover Voltage (kV) Puncture Withstand Voltage (Power Frequency) (kN) Min. Creepage Distance (mm) Impulse Flashover Voltage : (kV) a)1.2/50 Micro Sec. Wage of Positive Polarity b)1.2/50 Micro Sec. Wage of Negative Polarity

13

Impulse Withstand Voltage : (kV) a)1.2/50 Micro Sec. Wave of Positive Polarity b)1.2/50 Micro Sec. Wave of Negative Polarity

14 15 16 17 18 19 20 21 22

Dry Power Frequency 1 Min. Withstand Voltage (kN) Wet Power Frequency 1 Min. Withstand Voltage (kN) Minimum Visible Discharge Test Voltage Net Weight (Approx.) (Kg) Standard According to which Manufactured and Tested Porcelain Insulators be

Tolerance in Dimensions, if any (as per ISS) Temperature Cycle Test (as per ISS) Porosity Test (as per ISS) Performance guarantee

216

GUARANTEED TECHNICAL PARTICULARS OF GI PIN FOR 33 KV PIN INSULATOR (To be filled in by the bidder) S.NO. 1 2 PARAMETER Name & address of the manufacturer Physical dimensions a. Stalk length in mm b. Shank length in mm c. Thickness of collar in mm d. Diameter of collar in mm e. Diameter of shank in mm f. Threaded length of shank in mm g. Dia of stalk head in mm h. Threaded length of stalk in mm 3 4 5 6 Gross weight in kg. Weight of zinc coating in gms Mechanical failing load in KN Other particulars GUARANTEED VALUE

Performance guarantee

217

GUARANTEED TECHNICAL PARTICULARS OF 33 KV DISC INSULATOR 70 kN (B & S) (To be Filled in by the bidder) Sl.NO. 1 2 3 4 PARAMETER Manufacturers Name & Address Type of insulator offered Drawing Numbers Over all Dimensions (mm) a)Height b)Out Diameter Nominal System Voltage (kV) Highest System Voltage (kV) Minimum Failing Load (kN) Dry Power Frequency Flashover Voltage (kV) Wet Power Frequency Flashover Voltage (kV) Puncture Withstand Voltage (Power Frequency) (kN) Min. Creepage Distance (mm) Impulse Flashover Voltage : (kV) a)1.2/50 Micro Sec. Wage of Positive Polarity b)1.2/50 Micro Sec. Wage of Negative Polarity Impulse Withstand Voltage : (kV) a)1.2/50 Micro Sec. Wave of Positive Polarity b)1.2/50 Micro Sec. Wave of Negative Polarity Dry Power Frequency 1 Min. Withstand Voltage (kN) Wet Power Frequency 1 Min. Withstand Voltage (kN) Minimum Visible Discharge Test Voltage Net Weight (Approx.) (Kg) Standard According to which Porcelain Insulators be Manufactured and Tested Tolerance in Dimensions, if any (as per ISS) Temperature Cycle Test (as per ISS) Porosity Test (as per ISS) Performance guarantee GUARANTEED VALUE

5 6 7 8 9 10 11 12

13

14 15 16 17 18 19 20 21 22

218

GUARANTEED TECHNICAL PARTICULARS FOR XLPE CABLES (To be filled in by the bidder) Sl. No. 1. 2. 3. 4. 5. 6. Description Manufacturer's Name & Address Voltage Grade Core & Cross Section Type & Designation (as per ISS) List of Standards applicable Suitable for system with (a) Service Voltage (b) Neutral Earthing Maximum Conductor temperature (a) Continuous (in Deg. C) (b) Short time (in Deg.C) Conductor (a) Material to IS-8130(Class/Grade) (b) Size (Sq.mm.) (c) No./Nominal diameter of wires in each conductor (No./mm.) (d) Form of Conductor (Circular/shaped) Shielding/screening on Conductor (a) Material (b) Type (c) Whether thermosetting Insulator (a) Material (b) Thickness(mm.) (c) Whether triple co-extrusion with radiant curing process Shielding/screening on insulation (a) Material (b) Type (c) Thickness (mm.) (i) Non-metallic (ii) Metallic Inner-sheath (a) Material (b) Type (c) Thickness (mm.) (d) Extruded/Wrapped (e) Approx. Outside diameter over sheath(mm) Armouring (a) Material (b) Size o (c) D.C. resistance at 20 C(Ohm/Km.) o (d) A.C. resistance at 20 C Overall Sheath: (a) Material (b) Type (c) Thickness (mm.) Approx. Overall dia. of the Cable (mm.) Standard Drum length with tolerance (Mtr.) Net Weight of Cable (approx.) Kg/Km. Continuous current rating for standard condition, laid direct o (a) In ground at temp. 30 C o (b) In duct at temp. C 11 KV

7.

8.

9.

10.

11.

12.

13.

14.

15. 16 17. 18.

219

19. 20.

21.

(c) In air at temp. 40 C Charging current at rated system voltage Short Circuit Current at rated system voltage (a) for 1 sec. (b) for 0.5 sec. Electrical Parameters (a) Maxm. D.C. resistance/Km of o conductor at 20 C (b) AC resistance/kilometer (approx.) (c) Reactance/kilometer (approx.) (d) Capacitance/Kilometer(approx.) losses at rated(Uo/U) system KV, 50 cycles/sec, in watts/KV/Phase) (f) (i) Tan-delta at 0.5 Uo (ii) Tan-Delta at Uo (iii) Tan-Delta at 1.5 Do (iv) Tan-Delta at 2 Uo
o

(e) Di-electric

22. 23. 24.

25.

26.

Vol. Resistively at 27 C (Ohm/Cm) Recommended minimum bending radius Derating factor for following ambient temperature in Air/Ground. o (a) at 30 C o (b) at 35 C o (c) at 45 C o (d) at 50 C Type test results of the similar Cable to be furnished with Tender as specified under Clause-Error! Reference source not found. of the Spec. (a) Tests on Conductor: (i) Tensile test (for aluminum) (ii) Wrapping test (for aluminum) (iii) Resistance test (b) Test for armoring wires/strips. (c) Test for thickness of insulation & sheath (i) Tensile strength & elongation at break (ii) Ageing in air oven (iii) Hot test (iv) Shrinkage test (v) Water absorption (Gravimetric) (d) Physical : (i) Tensile strength & elongation at break (ii) Ageing in air oven (iii) Shrinkage test (iv) Hot deformation (v) Loss of mass in air oven (vi) Heat shock (vii) Thermal stability (e) Partial discharge test (f) Banding test (g) Di-electric power factor test (i) As a function of Voltage (ii) As a function of temperature (h) Insulation Resistance (Volume receptivity)* Test (i) Heating Cycle test (j) Impulse with stand test (i) High Voltage test (j) Flammability test

220

27.

28. 29. 30. 31. 32. 33. 34.

Cable Drums : (a) Length/Drum (Kg) (b) Dimension of Drum (Kg) (c) Shipping weight (Kg) Safe pulling force (Kg.) Partial discharge value. Details of the protective measures against attach by white ante. varnish etc. to be X.L.P.E's outer sheath during manufacture. Type of curing of XLPE insulation Cut ends of the Cable shall be sealed with Cable identification shall b made as per Clause Error! Reference source not found. (Yes/No) Cable Drums shall be marked with the information of Clause Error! Reference source not found. conspicuously (Yes/No) :

SIGNATURE OF THE BIDDER

GUARANTEED TECHNICAL ARTICULARS FOR 1.1 KV GRADE SINGLE CORE [1X185 ,1x300 & 3X120] SQ.MM. XLPE INSULATED & PVC SHEATHED HEAVY DUTY ALUMINIUM CONCUCTOR, UNARMOURED POWER CABLE (To be filled in by the bidder) Sl.No. 1 Particulars 2

3
221

1. 2. 3. 4. 5. 6. 7. 8. 9. 9.1 9.2 9.3 9.4

9.5 10. 10.1 10.2 10.3 10.4 10.5 10.6 10.7 10.8 10.9 10.10 10.11 11.0 11.1

Name & address of manufacturer. Type and make of cable Location of factory. Standard specification to which cable shall conform. Standard specification to which core shall conform. Voltage rating. Permissible variation in voltage, frequency & combined voltage & frequency. Standard specification to which drum shall conform. CONDUCTOR : Material and its composition. Shape of conductor. Total area of conductor.(In Sq. mm) Stranding details :i) No. of nominal strands in a core. ii) Dia of each strand in a core (before stranding) (in mm) Maximum D.C Resistance/Core at 20C (In Ohms/Km.) INSULATION : Type of Insulation Composition of Insulation Nominal thickness of Insulation (in mm). Tolerance on thickness of Insulation. Dia of core over insulation. Minimum volume resistivity at 27C (Ohm.Cm.) Minimum volume resistivity at 70C (Ohm.Cm.) Minimum tensile strength of Insulation material. Minimum Elongation percentage Average di-electric strength (KV/MM) Suitability with regard to Moisture, Ozone, Acid, Oil and Alkaline surroundings. SHEATHING DETAILS OUTER SHEATH : i) Material & composition ii) Type of sheathing by extrusion ST-1 iii) Thickness of sheathing (in mm) iv) Tolerance on thickness of sheathing. v) Calculated diameter under the sheath (in mm). vi) Nominal diameter of cable over outer sheath (in mm) vii) Whether anti termite treatment has been given in the outer sheath. ELECTRICAL PROPERTIES i) Under continuous full load (in DC) ii) Under transient conditions ( in DC) Thermal resistivity of Soil (DC Cm/W) Thermal Resistivity of XLPE (DC Cm/W) Depth of laying (in Cm.) (To the highest point of cable laid direct in the ground or to the top surface of ducts. Current ratings of the cable under basic assumptions : i) Laid in ground (at ground tamp. 30 ii) Laid in duct ( duct temp.30C)Amp. iii) Laid in air (air temp. 40C) Amp. Rating factors under various conditions of installation. Capacitive reactance per Km. of cable at 50 C/S (Ohms per Km.) Inductive reactance per Km. of Cable at 50 C/S (Ohms per KM) MECHANICAL DATA : Approx overall dia of cable (mm)
222

12. 12.1 12.2 12.3 12.4 12.5

12.6 12.7 12.8 13.0 13.1

13.2 13.3

13.4

13.5

Minimum bending radius of cable. Whether identification marking i.e. i) Property of APDCL ii) Name of manufacture iii) Voltage and grade and size iv) Year of manufacture is being provided at the regular intervals of two metres of outer most sheath of cable. v) Whether length of cable at every interval of 1 meter shall be printed over outer sheath. Name of manufacturers of bought out raw materials. i) Aluminium ii) PVC iii) Galvanised Steel strip/ wire for armouring iv) Any other. a) Whether similar cable has been type tested Yes/No b) If yes, when and where was it tested. c) It is expected that you will enclose an electro state copy of type test report of similar cable. Please inform whether or not you have entered the same. d) If yes, how many sheets does it contain. No. of sheets. e) Only a design better than or equal to what type tested and proven shall be accepted, please inform whether you will abide by this condition. Yes/No Whether wood preservative shall be applied to whole drum? Whether all ferrous parts shall be treated with rust preventive finish or coating ? Whether waterproof paper layer shall be applied to the surface of drum & over the outer cable layer. Reference of license to use-ISI certification mark, if any. Do you agree to all the provisions of technical specification. In case of any deviation, state clearly.

13.6 13.7 13.8 13.9 13.10

THE FIRM .. SIGNATURE OF BIDDER .... DESIGNATION & SEAL DATE

223

GUARANTEED TECHNICAL PARTICULARS FOR DISTRIBUTION TRANSFORMERS (To be filled in by the bidder) Sl.No. 1 2 3 Description Make & manufacturer Place of manufacture Rated ratio i) HV (KV) ii) LV (KV) Rated current i) HV (KV) ii) LV (KV) Connection sysmbol Tapping (if applicable) i) Number of steps ii) Range of Tapping Core material used and grade a) Flux density b) Over flushing without saturation (curve to be furnished by the manufacturer in support of his claim) Maximum temperature rise of a) Winding by resistance b) Oil by thermometer Magnetizing (No Load) current at a) Nominal voltage b) Maximum voltage Core loss in watts at 75C a) Nominal voltage b) Maximum voltage Resistance of windings at 20C (with 5% tolerance) a) HV winding (ohm) b) LV winding (ohm) Full load losses (watts) at 75C Current density used for a) HV winding b) LV winding Clearances a) Core & LV b) LV & HV c) HV phase to phase d) End insulation clearance to earth e) Any point of winding to tank Efficiency at 75C a) Unity pf b) 0.8 pf i) 125% load ii) 100% load iii) 75% load iv) 50% load v) 25% load Regulation at a) Unity pf b) 0.8 pf at 75C % impedance at 75C Flash test HV 28 KV/50 Hz for 1 Minute Particulars

5 6

10

11

12 13

14

15

16

17 18 19

224

20 21 22 23 24

25

26 27

LV 3 KV/50 Hz. for 1 Minute Over potential test double Voltage & double frequency for 1 minute Impulse test Weight content of a) Core lamination (min) b) Winding (min) C) Tank & fittings d) Oil e) Oil qty. (min) f) Total weight Oil data a) Qty. for first filing (min) b) Grade of oil used c) Makers name d) BDV at the time of filling Transformer Overall length X breadth X height PERFORMANCE GUARANTEE OF DTR

225

GUARANTEED TECHNICAL SPECIFICATIONS FOR 33 kV DROP OUT FUSE (To be filled in by the bidder) 1. 2. 3. 4. 5. 6. Standard applicable Type Rated Voltage (KV) Rated normal current Amp Rated frequency Hz Rated lightning impulse i) To earth and between poles ii) Across the pole distance Power frequency one minute withstand voltage i) To earth and between pole ii) Across the pole distance Rated short time current Rated breaking current Creepage distance Rated line charging breaking current (A) Total weight Performance guarantee

7.

8. 9. 10. 11. 12. 13.

226

GUARANTEED TECHNICAL PARTICULARS OF 11 KV DISC INSULATOR 45 kN (B & S) (To be filled in by the bidder) S.NO. 1 2 3 4 PARAMETER Manufacturers Name & Address Type of insulator offered Drawing Numbers Over all Dimensions (mm) a) Height b) Out Diameter Nominal System Voltage (kV) Highest System Voltage (kV) Minimum Failing Load (kN) Dry Power Frequency Flashover Voltage (kV) Wet Power Frequency Flashover Voltage (kV) Puncture Withstand Voltage (Power Frequency) (kN) Min. Creepage Distance (mm) Impulse Flashover Voltage : (kV) a) 1.2/50 Micro Sec. Wage of Positive Polarity b) 1.2/50 Micro Sec. Wage of Negative Polarity Impulse Withstand Voltage : (kV) a) 1.2/50 Micro Sec. Wave of Positive Polarity b) 1.2/50 Micro Sec. Wave of Negative Polarity Dry Power Frequency 1 Min. Withstand Voltage (kN) Wet Power Frequency 1 Min. Withstand Voltage (kN) Minimum Visible Discharge Test Voltage Net Weight (Approx.) (Kg) Standard According to which Porcelain Insulators Manufactured and Tested Tolerance in Dimensions, if any (as per ISS) Temperature Cycle Test (as per ISS) Porosity Test (as per ISS) Performance guarantee GUARANTEED VALUE

5 6 7 8 9 10 11 12

13

14 15 16 17 18 19 20 21 22

be

227

GAURANTEED TECHNLCAL PARTICULARS OF COMPOSIT POLYMERIC INSULATOR FOR 11 KV , 45 KN ( T & C ) TYPE (To be Filled in by the bidder) Sl. Description Unit 11KV , 45 KN , T& C type No 1. Type of Insulator 2. Standard according to which the Insulator manufacture and tested 3. Name of material used in manufacture Of the insulator with class/grade (a) Material of core (FRP rod) i) E-glass or ECR- glass ii) Boron content (b) Material of housing &Weather sheds Silicon content by weight (c) ( material of end fitting ) (d) Sealing compound for end fittings 4. Color 5. Electrical characteristics (a) Normal system voltage KV(rms ) (b) Highest system voltage KV(rms) (c) Dry power Frequency withstand voltage KV(rms ) (d) Wet power frequency withstand voltage KV (rms ) (e) Dry flashover voltage KV(rms) (f) Wet flashover voltage KV(rms) (g) Dry lighting impulse withstand voltage KV(peak) a) Positive b)Negative KV(peak) (h) Dry lighting impulse flashover voltage KV(peak) c) positive d) Negative KV(peak) (i) R/V at 1MHz when energized at 10KV/30KV(rms) Microvolt under dry condition (j) Creepage distance (mm) mm 6. Mechanical characteristics (a) Minimum failing load KN 7. Dimension of insulator (i) Weight Kg (ii) Dia of FRP rod mm (iii) Length of FRP rod mm (iv) Die. Of Weather sheds mm (v) Thickness of housing mm (vi) Dry arc distance mm Dimension drawing of insulator including weight with clearances min weight enclosed 8. Method of fixing of sheds to housing (specify single moulder Modular construction moulding ) 9. No. of Weather sheds 10. Types of sheds (i) Aerodynamic (ii) With under ribs 11. Packing details (a) Types of packing (b) No. of insulator each pack (c) Gross weight of package 12. Any other particulars which the bidder may like to give

228

GAURANTEED TECHNLCAL PARTICULARS OF BATTERY BANK (To be Filled in by the bidder) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. Battery Rating Type of battery Battery specification Manufacturers cell designation No of Cells Cycle life of Battery @ 27 C All efficiency WH Efficiency Self discharge/ Week Max, allowable ambient temp at which cell can safely operate Overall dimension of each cell Overall weight of each cell Recommended Max period of storage Material of container Type of separator Type of +ve & -ve plates Material of rack Method of connection between cells

19.

Recommended float charge

20.

Recommended boost charge Time required for boost charge from fully discharged condition at 27 C Voltage ripple allowable Type of connectors

21. 22. 23.

229

GAURANTEED TECHNLCAL PARICULARS OF COMPOSIT POLYMERIC INSULATOR FOR KN PIN INSULATOR TYPE (To be Filled in by the bidder) Sl. No 1. 2. 3. (a) Description Type of Insulator Standard according to which the Insulator manufacture and tested Name of material used in manufacture Of the insulator with class/grade Material of core (FRP rod) i) E-glass or ECR- glass ii) Boron content Material of housing &Weather sheds Silicon content by weight ( material of end fitting ) Sealing compound for end fittings Color Electrical characteristics Normal system voltage Highest system voltage Dry power Frequency withstand voltage Wet power frequency withstand voltage Dry flashover voltage Wet flashover voltage Dry lighting impulse withstand voltage a) Positive b)Negative Dry lighting impulse flashover voltage c) positive d) Negative R/V at 1MHz when energized at 10KV/30KV(rms) under dry condition Creepage distance (mm) Mechanical characteristics Minimum failing load Dimension of insulator Weight Dia of FRP rod Length of FRP rod Die. Of Weather sheds Thickness of housing Dry arc distance Dimension drawing of insulator including weight with clearances min weight enclosed Method of fixing of sheds to housing (specify single moulder Modular construction moulding ) No. of Weather sheds Types of sheds Aerodynamic With under ribs Packing details Types of packing No. of insulator each pack Gross weight of package Any other particulars which the bidder may like to give Unit 11KV , 5 KN , PIN INSULATOR Composite polymeric Insulators IES-61109 with up to date amendments

11 KV , 5

(b) (c) (d) 4. 5. (a) (b) (c) (d) (e) (f) (g)

KV(rms ) KV(rms) KV(rms ) KV (rms ) KV(rms) KV(rms) KV(peak) KV(peak) KV(peak) KV(peak) Microvolt mm KN Kg mm mm mm mm mm

(h)

(i) (j) 6. (a) 7. (i) (ii) (iii) (iv) (v) (vi)

8.

9. 10. (i) (ii) 11. (a) (b) (c) 12.

230

GAURANTEED TECHNLCAL PARICULARS of ACDB (To be Filled in by the bidder)


1 . 2 Manufacturers Name & Co Bus Bars a) Make b) Continuous Current rating in Amps c) Material d) Current Density Incoming Switch Fuse Unit a) Make b) Type c) Rated Voltage d) Continuous Current carrying Capacity in Amps Indication Lamps a) Make b) Type c) Voltage Fuse a) Make b) Type c) Rupturing Capacity Switch (triple/double pole) a) Make b) Type Rated Continuous Current carrying Capacity in c) Amps Current Transformer a) Make b) Type c) Ratio d) VA burden rating e) Accuracy class f) Type of Insulation g) Security factor AC Meters/ Energy Meters (Details for Ammeters Voltmeters, Energy Meters shall be furnished separately) a) Make b) Type c) Range d) Accuracy Internal Wiring a) Make b) Type c) Voltage Grade d) Size e) Material used Cable Glands a) Make b) Type c) Size d) Material used Terminal Block a) Make b) Type d) Material used Switch Board a) Overall Dimension b) Thickness of Steel metal c) Finish d) Approximate Weight 231

1 0

1 1

1 2

GAURANTEED TECHNLCAL PARICULARS of DCDB (To be Filled in by the bidder) 1 2 Manufacturers Name & Co . Bus Bars a . Continuous Current rating in Amps b Material c Current Density DC Double incoming MCCB a . Make b Continuous Current Rating c Making Capacity d Rupturing Capacity DC Double Pole switch Fuse Unit for outgoing feeders a . Make b Continuous Current Rating c Making Capacity d Rupturing Capacity DC Voltmeter a . Make b Type c Range d Accuracy Switch Board a . Overall Dimension b Thickness of Steel metal c Finish d Approximate Weight Fuse a . Make b Type c Rupturing Capacity Indication Lamps a . Make b Type c Voltage Internal Wiring a . Make b Type c Voltage Grade Other Features a 0 Mains fail Alarm Relay with DC Bell b . Earth fault alarm relay with DC Bell AC-DC Changeover contacts for emergency c lighting

232

GUARANTEED TECHNICAL PARTICULARS FOR 33/11 KV SURGE ARRESTORS (To be filled in by the bidder)
Sl. No. 1 Description Name & Address of Supplier & Manufacturer Surge Arrestor Line Disconnector Metal Oxide Block Terminal Clamp Name & address of collaborator, if an Standard to which surge arrestors conforms Surge Arrestor Voltage rating (KV rms) Continuous Operating Voltage (KV rms) a) Continuous Operating Voltage (KV rms) b) Leakage current at continuous operation voltage c) Permitted leakage current of arrestor beyond which arrestor is faulty. Frequency (Hz.) Nominal discharge current (wave shape 8/20 micro second) (KA) Pressure relief rated current (KA rms) Steep current protection level at 10 KA a) Lightning impulse protection level with 40 X 80 mico-sec. Wave at 500/1000 A Long duration current impulse withstand capacity and virtual duration Line discharge class Thermal runway limit arrestor Energy capability (kj/KV) Pressure relief rating Dry arcing distance Reference current and reference voltage Arrestor Housing Power frequency one minute wet withstand voltage (kV rms) Lightning impulse dry withstand voltage (kVP) Creepage distance a) Protected b) Total Short Circuit withstand capacity Bending moment (mm) Dis-connector a) Constructional Details b) Other information as applicable to surge arrestor Surge Monitor a) Constructional Details b) Degree of protection Suitable for hot line washing Dimension and Weight G.A Drawing indicating height of complete unit from base to line, minimum recommended center to center spacing, clearance from ground equipment at various height of Arrestor, earthing arrestor, earthing arrangement on earthed side of arrestor etc. Details of Packing License number and date for using ISI certification mark if any Ammeter for discharge current a) Type & Make b) Accuracy c) Range (mA) Residual voltage Follow Current PERFORMANCE GUARANTEE Particulars

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